Robotic Process Automation: How RPA can be used to perform a full record check during aircraft returns and deliveries / re-deliveries

Robotic Process Automation (RPA), became part of the EXSYN's platform around September last year, when EXSYN launched the first RPA driven process of creating maintenance work packages with Vueling Airlines in Spain. (Check the case study here). Soon after this first skill was mastered by the software robot, a new requirement arouses where RPA skills were deemed necessary:

The task

Performing the aircraft technical records checks to ensure timely return delivery of 5 aircraft within 8 weeks.

Typically, any aircraft return delivery project within an airline could easily see anything between 100K to 200K USD budgeted for aircraft technical records inspections and can easily amount to weeks of work to complete. Under these circumstances returning 5 aircraft within 8 weeks would accumulate to an expensive and resource heavy undertaking with high margins for error and potentials for overshooting return delivery deadlines and accumulating late return penalty fees for the airline.

The software robot skills

In order to reduce the overall risk for airlines within this return delivery process, EXSYN decided to embed the skill of aircraft technical records verification within the RPA solution. Part of these learned skills included:

  • Automatically retrieving the required aircraft airworthiness reports from source MRO software’s
  • Digital recognition of physical aircraft records such as EASA form one’s, FAA form 8130, Certificate of Compliances, removal / installation labels, workorders, task cards and release statements
  • Automated verification of airworthiness reports with the digital recognized physical aircraft records
  • Provide outputs on records completion and gap lists (such as missing certificates for parts installed or missing compliance statements for AD’s)


With the aid of this newly developed RPA skill, the engineers tasked with returning the aircraft could focus on resolving the gaps that were identified by the software robot. Thereby considerably reducing the required manhours and costs for record verification as part of the aircraft return delivery project. Finally, all 5 aircraft where returned in-time and according return conditions to the lessor and were directly transferred further to new operators.

aircraft redelivery rpa

Do you would like to know how your airline can benefit from RPA? Speak to one of our consultants and discuss your airline's situation in person - call us on +31 20 760 8200 or send an email to

You can also download the case study: