Data-Driven Aircraft Maintenance: How to get there?
Data is more than just numbers and figures; it is the backbone of operational efficiency, safety, and reliability. The aircraft maintenance field is rich with data, encompassing a broad spectrum from basic operational details like flight speed and altitude to complex streams such as real-time component health monitoring and extensive maintenance histories. Data has become a key player in enhancing aircraft maintenance practices with the increased usage of more advanced technologies and new aircraft. Our recent collaboration with Norse Atlantic Airways shows how harnessing data is integral to achieving digital excellence. Thus, today we share with you some more details of the steps to take to become data-driven.
Meaning data-driven
First of all, what is the meaning of "data-driven"? It is a term used to describe a decision-making process that is guided by data analysis rather than intuition or personal experience. In a data-driven approach, decisions are made based on the systematic examination of collected data, which can be quantitative or qualitative. This methodology emphasises the importance of empirical evidence and often involves the use of various tools and techniques for data collection, processing, analysis, and interpretation.
Having defined this, let’s have a look at the specific situation for aircraft maintenance. In 2018, EXSYN charted a 3-step success model for airlines and aircraft operators to be able to use predictive maintenance and become data-driven: from the reporting airline to the monitoring airline to the data-driven airline.
The Reporting Airline
This stage involves producing monthly reliability reports from manually collected data like aircraft utilization, pilot reports, maintenance findings, and component removals, typically consolidated in Excel. This labor-intensive process limits the airline to monthly reporting without the capacity for immediate action.
The Monitoring Airline
Progressing from Excel, this stage uses analytical tools and dashboards for data visualization. This allows quicker responses to emerging issues and active fleet monitoring, although it still relies on limited data sets, hindering full adoption of predictive maintenance.
The Data-Driven Airline
This advanced stage accesses broader data sets beyond airline-specific information, including industry reliability data, Flight Data Recorder info, weather data, and ADS-B transponder data. Implementing a data-driven platform enables informed decision-making on the day of operation itself.
Benefits of a data-driven approach
Reducing Unplanned Maintenance
Traditionally, the aviation industry has relied heavily on scheduled maintenance and reactive measures. However, by analyzing vast amounts of data from aircraft sensors and systems, it is possible to predict potential failures before they occur. This predictive capability allows for more strategic planning and scheduling of maintenance activities. The result is a drastic reduction in unplanned maintenance events, which traditionally cause significant disruptions and costs. This proactive approach not only enhances the efficiency and effectiveness of maintenance operations but also increases the reliability of the aircraft.
Maximizing Aircraft Utilization
For airlines and aircraft operators, utilization is a critical factor. A data-driven approach facilitates efficient maintenance planning, ensuring that aircraft spend more time in the air and less time in hangars. Accurate and timely data leads to better-informed decisions about when and how maintenance should be carried out, thus maximizing aircraft availability. This increase in operational efficiency is a direct contributor to profitability, as higher aircraft utilization rates are intrinsically linked to an airline's financial performance.
Strengthening Safety Protocols
Safety is paramount in aviation, and by using a data-driven approach, it is possible to proactively identify and address maintenance issues. This means the likelihood of in-flight failures and safety incidents is significantly reduced. The ability to anticipate and prevent issues contributes to a safer flying experience for passengers and crew alike.
Achieving Significant Cost Savings
A data-driven approach goes beyond just preventing major repairs; it optimizes maintenance schedules through strategic data analysis, leading to substantial cost reductions. These savings are not limited to direct maintenance expenses. They also include reduced costs associated with operational disruptions, delays, and cancellations, which can be significant. By minimizing the need for emergency repairs and reducing downtime, airlines can achieve better financial performance and resource utilization.
Enhancing Decision-Making Processes
With comprehensive, data-backed insights, maintenance decisions are no longer based on guesswork or intuition but on solid, actionable information. This shift leads to more effective, efficient, and reliable maintenance operations. The data-driven approach empowers maintenance teams to make informed decisions that enhance the performance and longevity of aircraft, ultimately contributing to the airline's operational and financial goals.
Self-Assessment for Airlines and Aircraft Operators
You can gauge your progress towards being data-driven by answering the following YES/NO to specific questions regarding your MRO/M&E systems, data integration, data audits, data quality, and more.
Has your airline an integrated MRO/M&E software system?
Is your MRO/M&E software system less than 8 years old?
Is the MRO/M&E software system updated at least once a year?
Does your airline have interfaces built between various sources of information within your IT setup? (i.e., records, Engineering, Inventory, inventory, finance and resources, and flight operations data)
Does your airline conduct data audits to ensure that the data is up-to-date?
Does your airline have high data integrity and quality?
Do you cross-reference and update data against sources and revisions?
Does your airline use a software solution (not Excel) to perform reliability analysis?
Does your airline need to manipulate or correct data every time the airline reliability report is published?
Does your airline have access to weather data?
Does your fleet use onboard data systems such as AHM or ACARS?
Is your airline's flight department willing to share flight data recorder information with other departments?
Is your airline willing to share technical and operational data with other airlines that operate the same aircraft type(s)?
The ultimate goal is to answer all questions with ‘yes', but we all know that, especially the last two questions, generate a lot of discussion within the industry. In contrast to 2018, the barrier to sharing FDR data decreased due to new techniques to anonymize data. This is a huge advantage as FDR data provides detailed insights into the performance and condition of aircraft systems during flights, adding an important layer to the data models used and making predictions more reliable, thus being a huge step forward to being a data-driven airline.
The step of adding industry data, which includes information from a wide range of airlines and aircraft types, is still a huge one, but with technology evolving and the option of sharing data anonymously, we might also tackle this hurdle.
Even when not utilising industry data, being able to answer the other 12 questions with a ‘YES’ is a huge step forward for many airlines and aircraft operators, something we still do not see often.
Three widely known data challenges
However, why can it be seen as a huge advancement? Based on years of experience and talking to airlines and aircraft operators, many face a few major challenges at an earlier stage:
4. Does your airline have interfaces built between various sources of information within your IT setup? (i.e., records, Engineering, Inventory, inventory, finance and resources, and flight operations data)
Why is this important?
Without interfaces between various systems in aircraft maintenance and engineering, data becomes siloed within each department. This isolation leads to inefficiencies, as information has to be manually transferred between teams, increasing the likelihood of errors and delays in maintenance processes. It also means that gathering and analysing information becomes time-consuming. It can also lead to discrepancies in maintenance records and tracking, ensuring compliance becomes more complex and error-prone, increasing the risk of non-compliance with aviation standards and regulations.
5. Does your airline conduct data audits to ensure that the data is up-to-date?
Why is this important?
Given the large volume of data that is entered into the MRO/M&E system daily, especially for airlines with a large fleet, it is easy to miss minor errors or inconsistencies that can accumulate over time and lead to airworthiness problems and aircraft on ground (AOG) situations. Thus, automated data health checks and audits take away the final risk that any flowed or inaccurate data in the system might affect airworthiness compliance.
Ultimately, the above two will impact the third: data quality and integrity.
6. Does your airline have high data integrity and quality?
Why is it important?
Garbage in means garbage out; you cannot drive value from data and make the right decisions on flawed data. Having your data organised, cleansed, labelled, identified, and filled with gaps is needed to drive value from data, your digitization strategy, and airworthiness compliance. For example, if the data used for predictive maintenance is incorrect or unreliable, the maintenance activities scheduled based on that data may be ineffective or even harmful to the aircraft. Similarly, if the data used for root cause analysis is of poor quality, the root cause of the problem may not be accurately identified, leading to inefficient and ineffective solutions. Ensuring the quality of the data collected during aircraft maintenance is critical for the success of any data-driven approach.
To overcome these three challenges, start with the following steps:
Data integration
Ensure that all systems use standardised data formats and protocols to facilitate seamless data exchange. Automate the data transfer between different systems to reduce manual handling and the associated errors. This means it is necessary to invest in robust IT infrastructure to support these integrations, along with strong cybersecurity measures to protect sensitive data.
Conducting Data Audits
Use software tools that can automatically conduct regular data audits, identifying and correcting discrepancies in real time. Periodically review and update the audit processes to adapt to new data types and sources. Conduct training sessions for staff to ensure accurate data entry and to raise awareness about the importance of data accuracy.
Ensuring High Data Integrity and Quality
It is necessary to establish consistent data collection and validation processes, enforce standardised formats and robust security measures, and regularly maintain and monitor data accuracy and integrity. As this is quite an important and extensive topic, we recommend reading our blog post:
In addition to these foundational elements, we also need to consider further actions to achieve a data-driven approach.
Other Vital Aspects to Address
Let’s have a look at the importance of questions 7 to 9:
7. Do you cross-reference and update data against sources and revisions?
Why is this important?
Continuously updating and cross-referencing data should be a cornerstone. It supports accuracy, compliance, risk management, operational efficiency, and informed decision-making, all of which are essential for safe and efficient airline operations.
8. Does your airline use a software solution (not Excel) to perform reliability analysis?
Why is this important?
With software solutions, you move away from manual data gathering and presentation to providing real-time analysis and taking action. These are usually integrated with all the major systems you need to perform your reliability analysis. Can handle large data sets, ultimately reducing time spent and human error. This leads to long-term cost savings and safer aviation practices.
9. Does your airline need to manipulate or correct data every time the airline reliability report is published?
Why does this happen?
It is the result of all the above: Data quality problems, such as inaccuracies or inconsistencies, might be a primary cause, necessitating corrections for report accuracy. Integration challenges with multiple data systems could lead to discrepancies, while errors in data processing and analysis algorithms might produce incorrect outputs. Changes in regulatory requirements or operational shifts, like new aircraft types or altered routes, could also affect data accuracy. Human factors, including inadequate training or errors in data collection and entry, are potential contributors to these inaccuracies. As we can see, this should be avoided in all terms.
By addressing these additional questions, airlines and aircraft operators can further refine their path towards becoming data-driven.
Embracing a data-driven approach in aircraft maintenance isn't just about adopting new technologies; it's also about a fundamental shift in mindset, processes, and decision-making. The journey from a reporting airline to a data-driven one is challenging but critical for the future of aviation maintenance, where safety, efficiency, and profitability are intertwined with the intelligent use of data.
