Predictive Maintenance & Engineering Process Data Automation Apps - Webinar Recap

Last week, we at EXSYN performed an insightful webinar with Aircraft IT on continuous improvement in aircraft maintenance efficiency through predictive analytics and automation. The session discussed key industry challenges, innovative solutions, and live demonstrations of EXSYN Apps that address these core issues.

Watch the On-Demand version here

Key Challenges in Aviation Maintenance

We began by highlighting some of the main challenges facing the aviation industry:

• Unplanned downtime and AOG events. These can cost airlines up to $150,000 per day.
• Shortage of skilled engineers and mechanics. Projected to reach 48,000 by 2027, impacting maintenance efficiency.
• Cost pressures in maintenance operations. Maintenance constitutes around 20% of an airline’s operating costs.
• Ensuring compliance and reliability. Operators must maintain high standards to meet safety regulations.

EXSYN Apps

1. AOG Risk Monitor: Predicting Failures Before They Happen

The AOG Risk Monitor is a predictive analytics tool that helps airlines prevent unplanned maintenance by identifying high-risk components before they fail. Analyzes failure patterns and aircraft health data to assess AOG risk in real-time. Using statistical modeling and reliability analytics, it identifies high-risk aircraft, enabling proactive maintenance decisions that reduce downtime and improve fleet availability.

Q&A

• How does the AOG Risk Monitor predict failures?

It continuously analyzes component performance and historical failure patterns, identifying high-risk components before failure occurs.

• Can the AOG app integrate with my current MRO system?

Yes, it seamlessly integrates with AMOS, TRAX, Veryon, IFS, and airline-specific maintenance systems.

• What type of data does the system use?

ACARS, FDM, HUMS data (if available), maintenance history, and component reliability trends.

Explore the AOG Risk Monitor Demo

2. Base Maintenance Ground Time Prediction App: Optimizing Maintenance Planning

The Base Maintenance Ground Time Prediction App is designed to improve maintenance efficiency by forecasting the expected duration of heavy maintenance checks. Uses historical maintenance records, reliability trends, and operational data to forecast maintenance durations. This enables operators to align maintenance slots, allocate resources efficiently, and reduce unnecessary downtime.

Q&A

• How does the suite help reduce base maintenance costs?

By optimizing check intervals, slot allocation, and resource planning, it helps reduce last-minute changes, minimize AOG risks, and optimize workforce deployment.

• Can the tool assist in lease return planning?

Yes, it forecasts maintenance needs before lease expiration, ensuring compliance and reducing penalties.

• Can this tool help with planning heavy maintenance checks?

Yes, it provides insights into potential findings during upcoming maintenance visits, helping operators plan for additional inspections, repairs, and parts sourcing before the aircraft enters the hangar.

Explore the Base Maintenance Prediction App

3. Data Management & OEM Library Apps: Ensuring Compliance and Data Accuracy

The Data Management & OEM Library Apps ensure data accuracy and regulatory compliance by automating validation processes and integrating OEM updates. These solutions detect missing or inconsistent records, streamline AD/SB compliance tracking, and provide real-time monitoring for improved fleet efficiency. By eliminating manual processes, they reduce operational disruptions and enhance maintenance planning reliability.

Q&A

• How does the Data Health Check improve maintenance efficiency?

It identifies missing, duplicate, or incorrect records, preventing compliance risks and operational disruptions.

• How does AD/SB Automation ensure regulatory compliance?

It automatically scans and categorizes new ADs/SBs, linking them to relevant aircraft and components.

• What impact do these tools have on reducing aircraft downtime?

By ensuring accurate, up-to-date data and automated compliance tracking, these solutions help prevent delays caused by missing documents, outdated AD/SB compliance, or incorrect maintenance records.

Explore the Data Management & OEM Library Apps

Next Steps: Get Started with EXSYN’s Predictive Maintenance Solutions

Interested in exploring how EXSYN can enhance your maintenance strategy? Schedule a consultation or access the full webinar recording below.

Schedule a 1-on-1 Session to Discuss Your Fleet’s Needs

Watch the Full Webinar On-Demand