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Streamlining MRO processes to minimise aircraft downtime

Aircraft maintenance, repair, and overhaul (MRO) is an essential component of aviation that ensures higher revenues, customer safety, and better flying experience. Modern MRO technologies leverage artificial intelligence, data analytics, 3D printing, blockchain, and robotics to streamline processes and minimise downtime. Regular MRO assures the fleet’s performance and longevity.

This article explains the importance of MRO services and the technologies that assist in optimising and minimising aircraft downtime.


Importance of MRO in the aviation industry

MRO services include routine inspections, intricate repairs, and predictive maintenance to ensure the safety and efficiency of flight operations. It encompasses:

  1. Routine inspection and maintenance – From airframes to engines and electronics, MRO processes inspect the entire airplane to highlight and address potential problems.
  2. Component repairs – From hydraulic systems to engines, any fault could jeopardise the airworthiness of the aircraft and put the passengers at risk. Proactive or reactive component repair requires MRO teams to act quickly and reduce downtime.
  3. Inventory management – For seamless repair and maintenance, MRO teams must have ready access to spare parts. Optimal inventory management ensures that the correct parts are available in the right quantity without tying up the capital.
  4. Supply chain management – Successful MRO operations rely on smooth collaboration between the flight operator and its suppliers. MRO process optimisation ensures a steady flow of parts for timely maintenance and repair.
  5. Downtime optimisation – Efficient MRO services ensure that the aircraft spends minimum time in the hangar under repairs and returns to the skies swiftly.
  6. Documentation and compliance – MRO ensure that all documentation relating to repair and maintenance is complete and up-to-date, easily accessible, and complies with the applicable regulations. This streamlines audits, ensures adherence to rules, and enhances passenger safety.

Technology solutions for MRO optimisation

Advanced MRO optimisation technologies offer a reliable solution for minimising aircraft downtime and increasing revenues. Some examples are –


Predictive maintenance

Predictive maintenance uses Internet of Things (IoT) sensors, machine learning, and data analytics to proactively detect problems in the airplane and its components before they escalate into failure. This helps avoid costly downtime, expensive parts replacement, and a higher service life.
Data analytics collects and analyses data from aircraft components, electronics, airframes, and hydraulics and detects abnormalities. This real-time data is based on a pre-defined schedule and as per the aircraft’s usage. It eliminates the need for programming skills or specialised data science.

The predictive aviation maintenance system of a leading aircraft engine and avionics manufacturer has witnessed 30-50% fewer operational disruptions, 10-15% fewer premature parts replacements, and 99% predictive accuracy.


Augmented reality

Maximise fleet performance with Infosys BPM

Maximise fleet performance with Infosys BPM

AR uses computer-generated video, sound, coordinates, and graphics to provide maintenance and repair technicians with real-time data and accurate instructions, thus elevating their efficiency and accuracy while doing a job. By using AR technology, technicians can also provide remote support even for highly intricate and complex inspections and repairs.

Augmented reality enhances technician safety with high-quality aviation maintenance and repair. The world’s leading aircraft manufacturer in the US has actively used AR for aircraft inspections and maintenance. Technicians can note and review defects by comparing the current status of the aeroplane with its recorded history using AR glasses and a handheld tablet.


3D printing

Additive manufacturing uses digital designs to quickly and efficiently create complex aircraft parts on demand and at a lower cost. It can also produce components that are difficult or expensive to manufacture using traditional methods, thus promoting innovation in the aviation industry.

A leading defence engineering giant and aircraft engine manufacturer actively uses 3D-printed components in commercial jet engines. It reduces the total number of parts required and potential failures due to fewer joints.


Big data analytics

According to an estimate, newer aircraft engines would generate up to 1 TB of data per cycle, which is significantly more than their older counterparts. To manage this data and derive valuable insights for repair and maintenance, MRO processes are adopting big data technologies that leverage artificial intelligence (AI) and machine learning (ML).

Leading global commercial jet and defence aircraft engine manufacturers are using big-data analytics to monitor the performance of new engines during flight. The Basing & Logistics Analytics Data Environment (BLADE) data system of the US Air Force uses analytics and AI for efficient repair and maintenance.


How can Infosys BPM help in aviation maintenance?

Infosys BPM transforms aviation maintenance and repair by using cutting-edge tech interventions focused on MRO process optimisation and automation. Its solutions include a digital control tower, master data enrichment, process automation, customer self-service, Gen AI, robotic process automation (RPA), and proactive order status updates.

Know more about the MRO services at Infosys BPM.


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