Drone-based logistics cuts material delivery times from around 15 minutes to 30 seconds, supporting faster and more flexible maintenance operations
LATAM Airlines has introduced a drone-based internal logistics system at its MRO facility in São Carlos, São Paulo, Brazil, using the technology to transport small maintenance materials between its warehouse and aircraft maintenance workshops.
The initiative is designed to accelerate the movement of components and consumables required by maintenance teams, with LATAM reporting that delivery times have been reduced from approximately 15 minutes to just 30 seconds, a reduction of more than 96%.
The São Carlos facility is the airline’s major maintenance hub and is described as the largest aircraft maintenance center in South America. The approximately 95,000-square-metre facility features nine hangars and 22 workshops, supporting maintenance activities across a broad range of aircraft components and systems.
Under the new system, drones transport small items required for maintenance and component repair, including screws, seals, gaskets, connectors and other materials. The system is currently completing approximately 160 transport operations per day, covering both deliveries and returns.
The drone service currently supports the Electrical, Electronics, Pneumatics, Pressure Vessels, Emergency, Hydraulics, ATEC, IDG and Battery workshops within the São Carlos MRO complex.
Moving from scheduled collections to on-demand delivery
Before the drone system was introduced, small materials were transported between the warehouse and workshops using ethanol-powered utility vehicles. These vehicles operated according to three scheduled collection windows each day, meaning maintenance teams could face waiting times when materials were not immediately available at the point of use.
The new drone-based model enables materials to be delivered on demand, allowing workshops to request and receive smaller items without waiting for the next scheduled logistics run. According to LATAM, the change is helping to reduce internal logistics bottlenecks while providing greater flexibility to maintenance teams and supporting a more responsive workflow.
The system also reduces the need for ground vehicles to circulate within the maintenance complex, contributing to lower internal vehicle movements.
Autonomous warehouse-to-workshop operations
The new process allows warehouse employees to prepare the required materials and autonomously launch the drone, without requiring a separate internal logistics employee to make each delivery.
Each flight takes approximately 30 seconds between the relevant locations. LATAM says the drone operations follow established safety protocols, including defined speed and altitude limits, as well as the use of designated and isolated areas for take-off and landing.
The technology has also enabled LATAM to reorganise its internal logistics workforce. Employees who previously focused on transporting small packages between the warehouse and workshops can now concentrate on the movement of larger materials, which require specialised handling and dedicated equipment.
This allows the airline to make more effective use of its logistics resources while maintaining support for the maintenance operation.
Potential for wider MRO applications
LATAM has identified opportunities to expand the drone-based logistics model beyond its current routes at São Carlos. The airline is evaluating the possibility of establishing additional transport routes within the MRO complex, potentially extending the system to more workshops and warehouse locations.
In the longer term, the technology could also be considered for transporting materials to advanced warehouses and workshops located in external areas of the facility. LATAM has previous experience with drone technology in its operations, having used drones for aircraft inspection since 2019. The latest initiative represents a move into another potential application for unmanned technology within the airline’s maintenance ecosystem, internal movement of materials and parts.
“Innovation is part of LATAM’s strategy to make our operations increasingly efficient, safe, and sustainable,” said Alexandre Peronti, Maintenance Director, LATAM Brazil. “This project demonstrates how technology can transform day-to-day processes, support our technical teams and contribute to more agile aircraft maintenance.”
Peronti added that the results achieved during the initial phase provide an opportunity for LATAM to assess new applications of the technology across other company operations.
For the MRO sector, the project highlights how drone technology can extend beyond aircraft inspection and maintenance activities to address a less visible but critical part of the operation: the movement of materials within an MRO facility. By reducing a 15-minute ground logistics process to a roughly 30-second drone flight, LATAM is using automation to bring parts closer to technicians when they are needed, while freeing logistics personnel to focus on more complex material movements.
