Predictive Spare Parts Planning Deployed at Volotea to Enhance Long-Term Maintenance Forecasting
We are excited to announce that EXSYN has deployed its Predictive Spare Parts Planning capability at Volotea, enhancing the airline’s ability to forecast material demand months and even years ahead. Built on EXSYN’s modular aviation data platform, the solution transforms how Volotea plans, procures, and positions spare parts across its maintenance network.
Developed in close collaboration between EXSYN and Volotea, the new capability leverages EXSYN’s Long-Term Forecasting capability to merge data from Volotea’s maintenance program with historical unscheduled maintenance events. This integration further allows the airline to strategically allocate materials, optimise procurement cycles, and reduce unplanned AOG exposure across multiple bases.
“Predictive spare parts planning is a natural next step in our digital maintenance journey,” said Matías Datino, Technical Senior Director Volotea and the logistics team. “By combining our operational experience with EXSYN’s data expertise, we can anticipate material needs earlier and ensure our maintenance network is better prepared to support our growing operations.”
“Data-driven material planning is a key enabler for efficient and resilient maintenance operations,” said Sander de Bree, CEO of EXSYN Aviation Solutions. “Working together with Volotea, we’ve connected forecasting intelligence directly to logistics workflows, turning trusted operational data into tangible cost and reliability gains.”
This new capability enables long-term, data-driven material forecasting, transforming how airlines plan and manage spare parts across their maintenance networks. The initiative is expected to improve forecasting accuracy and reduce annual spare parts purchasing costs significantly through fewer AOG-related surcharges and more efficient material allocation.
From Forecast to Fulfilment: Connecting Data to Action
Volotea will use the Long-Term Forecasting capability to anticipate material needs based on maintenance patterns and fleet utilisation. These insights feed directly into EXSYN’s Logistics & Supply Chain app, which manages stock positions and part movements between maintenance locations, ensuring critical items are available ahead of need.
About Volotea
Founded in 2011 by Carlos Muñoz and Lázaro Ros, who previously founded Vueling, Volotea has become one of the fastest-growing airlines in Europe. In December 2025, the airline reached the milestone of transporting 80 million passengers across its network.
Volotea serves 110 airports and operates bases in 21 small and medium-sized European cities, including Asturias, Bari, Bilbao, Bordeaux, Brest, Florence, Lille, Lourdes, Lyon, Marseille, Montpellier (from November 2026), Nantes, Naples, Olbia, Palermo, Rodez, Strasbourg, Toulouse, Venice, and Verona.
In 2026, Volotea will offer more than 430 routes—over half of them exclusive—operate more than 80,000 flights, and provide approximately 14 million seats, supported by a fleet of 45–46 Airbus A319 and A320 aircraft.
Through its sustainability programme Voloterra, Volotea reduced its direct CO₂ emissions per passenger-kilometre by 51% by the end of 2024, six years ahead of schedule, and has now set a new target of 55–60% reduction by 2030.
With more than 2,250 employees, Volotea strengthens regional connectivity, supports local economic development, and contributes to the cultural landscape through impactful sponsorship projects. The airline holds a four-star Skytrax rating and was named “Best Low-Cost Airline in Europe” at the 2023 and 2024 World Airline Awards, alongside multiple wins at the World Travel Awards.
About EXSYN Aviation Solutions
EXSYN helps airlines, operators, and MROs keep aircraft data clean, connected, and predictive. Its modular, aviation-native apps support every stage of the aircraft data lifecycle, from compliance and reliability to logistics and long-term forecasting.
With over a decade of experience in aviation data management, EXSYN has supported aircraft operators worldwide through fleet migrations, system transitions, and daily operational challenges. This deep operational background ensures that EXSYN’s solutions align with real-world maintenance and airworthiness workflows.
EXSYN’s modular approach allows organisations to start with specific use cases and expand at their own pace. Each app integrates seamlessly with existing M&E and MRO systems, delivering immediate value without disrupting safety-critical processes. Together, the apps form an aviation data continuity layer that keeps aircraft data consistent and trusted across systems—enabling confident, data-driven decision-making.