A major U.S. defense contractor faced a critical juncture in its $2.1 billion naval combat system modernization program, designated to serve allied nations with enhanced defense capabilities. The project, comprising over 800 engineers and spanning suppliers across four countries, encountered significant setbacks: spiraling costs, missed milestones, and documentation chaos threatened program viability.
Requirements management and system design processes relied heavily on siloed Word documents, spreadsheets, and disconnected CAD files stored on multiple servers. Change notifications lagged, with a single specification update requiring weeks to cascade across the program. Compliance documentation and verification were maintained manually, often leaving audit trails incomplete or out of sync with the latest engineering work. In one case, outdated radar specifications given to suppliers caused expensive component mismatches that were only found during late-stage integration.
Analysis revealed root causes common in large-scale defense projects: fragmented document management, poor version control, and limited traceability, resulting in rework, integration delays, and escalating costs. In previous operational reviews, up to 70% of systems engineering staff time was consumed by managing documentation rather than driving technical solutions. The lack of a unified systems engineering approach threatened not only schedule and budget but also regulatory compliance and customer trust.
The Critical Need for Transformation
Facing intensifying oversight and the risk of project cancellation, the contractor initiated a strategic shift to model-based systems engineering (MBSE), selecting ENOVIA on the 3DEXPERIENCE platform as the central backbone. The prime objectives: eliminate document fragmentation, enhance real-time collaboration among multinational teams, automate traceability, and strengthen compliance management to meet rigorous defense standards.
Implementing Model-Based Systems Engineering with ENOVIA on the 3DEXPERIENCE platform
ENOVIA on the 3DEXPERIENCE platform delivered a highly configurable MBSE environment that centralized requirements, system architecture, and verification data. The transition was phased:
Unified Requirements and Architecture Modeling: ENOVIA replaced static, document-centric requirements processes with dynamic, model-driven views. Leveraging 3DEXPERIENCE’s interoperability, all data and changes were propagated system-wide in real time, eliminating manual cross-referencing. Engineers were able to visualize system impacts instantly on a cohesive digital platform. Change impact analysis, previously requiring weeks of coordination, could now be completed in hours—directly reducing the potential for downstream integration issues.
Seamless, Secure Collaboration: ENOVIA’s integration with the cloud-enabled 3DEXPERIENCE platform (configured for ITAR and defense data compliance) empowered secure, distributed collaboration at scale. Suppliers in Europe and Asia accessed live requirements and participated in virtual design reviews, while sophisticated encryption and granular permission controls preserved data integrity.
Automated Traceability and Compliance: The combined ENOVIA and 3DEXPERIENCE solution tracked the lifecycle of every requirement, linking design, simulation, and verification activities on a single digital thread. Compliance reports—once compiled manually—were generated instantaneously, supporting both internal audits and external regulatory reviews. Automated workflows dramatically reduced human error and audit exposure, establishing a continuous state of readiness.
AI-Enabled Risk Mitigation: With AI-powered analytics built into the platform, the program proactively identified potential interface risks before integration, applying data-driven recommendations to the verification strategy. Historical design and testing data enabled predictive planning—optimizing resources and minimizing late-stage issues.
Measurable Results
Eighteen months after ENOVIA implementation, the defense program reported:
- 38% reduction in development cycle time compared to pre-transition baselines, enabling realignment with contractual milestones.
- 67% decrease in integration-related rework, attributed to improved visibility of dependencies and automated impact assessment.
- 52% increase in first-time test success rates during formal verification.
- $47 million in documented cost avoidance, spanning rework, late change orders, and compliance penalties.
- The program closed $23 million under budget by reducing documentation overhead and streamlining supplier integration.
In post-implementation surveys, engineering teams cited increased efficiency and job satisfaction, directly correlating to the shift from administrative documentation tasks to higher-value technical analysis and problem-solving.
Why MBSE Adoption Is Accelerating Across Defense
Defense contractors are turning to model-based platforms like ENOVIA in response to:
- Rapidly evolving landscapes, requiring adaptable system architectures and accelerated timelines.
- Demanding multinational partnerships, which necessitate real-time, role-based collaboration without compromising security standards.
- Rising regulatory complexities, where automated compliance tracking and reporting offer clear advantages over manual processes.
- Building the workforce of the Future as next-generation engineers gravitate to organizations using state-of-the-art digital engineering environments.
Ultimately, programs that persist with traditional document-driven engineering methods face compounding disadvantages in efficiency, bid competitiveness, and overall program execution quality.
Strategic Recommendations for Defense Program Transformation
The experience from this real-world defense initiative highlights several best practices for organizations considering MBSE adoption:
- Establish Security and Compliance Foundations Early: Ensure digital engineering solutions meet industry and governmental security standards from the outset.
- Phase Supplier Integration: Transition collaboration workflows incrementally, with clear onboarding programs for key suppliers.
- Invest in Organizational Change Management: Budget sufficient resources for training, process redesign, and cultural alignment to sustain adoption.
- Design for Scalability Across Programs: Configure MBSE platforms to accommodate diverse, concurrent program requirements with flexible access and compliance controls.
- Define Success Metrics Upfront: Baseline measurable KPIs including cycle time, rework rates, and audit findings to track and report ROI.
Conclusion
ENOVIA, powered by the 3DEXPERIENCE platform, has demonstrated its impact in revitalizing complex defense programs burdened by legacy systems engineering practices. But its benefits extend far beyond the defense sector. Today, organizations across industries—from aerospace and automotive to high-tech manufacturing and life sciences—are leveraging ENOVIA and the 3DEXPERIENCE platform to harmonize product development, accelerate innovation, and ensure regulatory compliance on a global scale. The platform’s scalability, security, and industry adaptability position ENOVIA as an essential tool for any enterprise committed to operational excellence in a rapidly evolving business landscape.
Learn how ENOVIA’s next-gen PLM can safeguard your programs.
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