With a highly regulated aerospace industry, upgrades and improvements in aircraft engineering are an ongoing process – a natural progression, and in tandem, the same goes for the MRO sector MRO companies authorised or certified to service newer aircraft variants must remain aligned in letter and spirit with OEM manuals and with the necessary frequency. That is the real challenge, how often. How agile and nimble can an MRO can remain, their ability to make smart investments in infrastructure, re-training, and upskilling staff in working with advanced materials, the latest in software for the aviation industry, and adopt digitalisation with alacrity- will all truly test their mettle.
Advanced Materials and Newer Aircraft and Engine Variants
Airlines and OEMs are fast moving towards the adoption of assets made of advanced materials like composite material for aircraft surfaces which make lighter, agile aircraft and yet far more durable when compared with aluminium. Graphene is atom-thick, lightweight, and durable, with which batteries are applicable in energy harvesting, storage, and structural health monitoring, amongst others.
For an MRO, this would mean learning how to apply and work with this new material, learning about the characteristics and how they react to certain external environments, and importantly how to repair aircraft surfaces/parts, with this new material. It does not end there. Storage of the material in ideal condition, and resources to stock the material are equally critical.
For instance, in the 787’s ‘more-electric system’ from Boeing, there are electric motors, and electric brakes replacing the hydraulic system. This requires the MRO team to unlearn and reskill, as a ‘more-electric system’ again aligns with the Net Zero objectives.
Boeing’s flexible twin-aisle offerings allow an airline to have airplane families with the same speed, range, and economics in three distinct sizes.
Again, the 787 advanced, single-barrel composite fuselage requires less scheduled maintenance. Here too, an MRO provider is impacted as this means less hospital time, resulting in less revenue earned.
Some of the tools that an MRO unit needs to equip itself with are turbo graphs – (a fast parallel graph engine handling billion-scale graphs in a single PC), Ramp Testers, Non-Destructive Testing units, and probe sensors for correcting of each location—calibrating, tools for correct reading, and interpretation, testers for fibre composite materials.
At every stage, MRO service providers must upgrade their tools and offerings with each improvement or advancement in say Avionics, Ground Proximity Warning Systems (GPWS) to Advanced GPWS.
Software, which is a manufacturer’s intellectual property is provided by manufacturers, as well as Automatic Testing Computers. However, it is not always that an OEM will pass on software to the MRO unless there is a closer tie in existence.
Established firms like Safran, the engine maker, and SAEI (Saudia Aerospace Engineering Industries) are using smart hangars, applying Predictive Maintenance by bringing in digitization. A single digital thread can run through disconnected data, and turn that into connected processes. The threads make up the neural network of a digital twin – a virtual version of a part that mirrors its physical version.
MROs are constantly gearing up for testing, maintenance, and repair of newer aircraft variants, like CFM’s RISE Engines (Revolutionary Innovation for Sustainable Engines), and its new propulsion technologies with the open fan concept is an example of this.
Engines with 100% SAF hydrogen capability, aiming to reduce CO2 emissions by 80%. Hybrid electric technologies allowing optimization of the engine performance, are all newer concepts and technologies an MRO crew must grasp.
Airbus A350’s innovative design offers spaciousness, wide seats, high ceilings, and ambient lighting. This then becomes another new space, the MRO crew will need to adjust to, where three-class configurations, can carry up to 480 passengers in a single-class layout. That apart, high-quality air delivery, renewal every 2-3 minutes, and precise temperature, and humidity controls all must be assured while handing over an MRO-serviced aircraft. Smart galleys and integrated connectivity are passenger-side enhancements that the MROs must take into their maintenance plan.
Newer additions like Bluetooth Connectivity Onboard, and the use of wireless headphones to connect to the seatback entertainment system via Bluetooth; or the High-Speed Inflight Connectivity – Inmarsat’s Ka-Band satellite communication system, for high bandwidth and reliable connectivity.
AREAS OF INVESTMENTS THAT MROs NEED TO CONSIDER
Use of 3D printed parts
Additive Manufacturing (3D Printing) -Novel technologies adapted for aviation like 3D printing, that enable additive manufacturing, and for fabricating components and aircraft parts. Parts manufacturers are looking at additive manufacturing to create a range of products right from seat frameworks to air ducts. For an MRO entity, this is another new element in the supply chain. Stocking of 3D manufactured components and parts and tracking their use is another additional activity.
Digitization
Blockchain ensures data transparency while sharing of records auditable, traceable, and shareable, across stakeholder realms, safely and securely. A shared blockchain leaves an indelible record, traceable right up to the end customer.
Internet of Things (IoT) to Predictive Maintenance – Aircraft MROs have adopted Internet of Things technology (IoT) to predict potential damage to aircraft parts and equipment. Data analysis from ultrasonic and vibration sensors attached to a machine, aids in planning maintenance schedules, procuring parts, and assigning personnel judiciously.
Artificial intelligence (AI) –The aerospace industry is making use of the power of Artificial Intelligence and use of Machine Learning (ML) in research and education. Users of AI and ML can gain insights from collected data of materials, to discover new patterns and their correlations. AI can handle far more complex problems than humans and can crunch thousands of volumes of data outcomes within seconds, unlike the time taken by the human brain to process the same volume of information.
Change towards an agile MRO
Reliable A&D Supply Chain is a must fortheaviation MRO sector. It is crucial and must be reliable, for the viability of the MRO business. MROs must incorporate on-shoring, vertical integration, and increased cyber defence to strengthen supply chains.
Structural Health Monitoring (SHM) –can be applied to gauge changes to the material and geometric properties of aircraft structures. These are done by embedded or attached Non-destructive Evaluation (NDE) sensors. This data then is used to assess accurately, the health of the structure, metal fatigue, and avoidance of accidents thereof. All these are investments for the MRO sector and financial planning must budget for these elements.
Augmented Reality
Through Professor Lori Brown’s HoloLens work, Western Michigan University was the first university aviation program to use augmented reality in the classroom to train technicians on aircraft maintenance. Seen here are Students immersed inside a jet turbofan engine or get to interact with 3D cockpits.
Crunching Big Data
By 2025, more than 38,000 new aircraft and their variants are expected to be operating worldwide. Imagine the volumes of Data generated, many times more than previous-generation aircraft. Sensors on modern aircraft combined with better data routers have resulted in a 60-fold jump in the number of data parameters collected from each flight, according to Mr. Serge Panabiere – Airbus Head of Services Business Development. The newest engines can generate up to one terabyte of data each cycle. Now, for MROs, this adds to the complexity of their businesses.
To better manage this deluge of data, MROs are compelled to turn to machine learning, deep learning, neural networks, artificial intelligence, blockchain, and other developing information management technologies. MROs’ financial outlays must be such that they budget in current and futuristic technologies and stay ahead of the curve. Paring costs, flighting inflation, managing supply chains, and dealing with raw material shortages… are the real challenges the MRO sector must circumvent with great efficiency.
According to Grand View Research, the MRO market was valued at $79 billion in 2022 and is projected to grow at a rate of 5% through 2030, to reach a revenue forecast of $119 billion.
Smart Hangars: The Future Of MRO?
Making MROs business hardy and resilient may be the ‘smart hangar’ concept. One such smart hangar can facilitate finding the right tools at the right time, as wasted time would result in useless expenditure. Detecting Foreign Object Debris (FOD) becomes easier, and quicker. This saves time and costly repairs are avoided. Overall, a safer environment is achieved. Smart Hangars comes with a real-time location solution (RTLS) that tracks and locates assets and people in complex environments.
The system also tracks worker movements to ensure they follow safety protocol and are also alerted if they enter a dangerous area. MRO providers can become more efficient, work in safer environments, and are better optimized. A tighter operation will ensure better TAT (Turnaround Time), and better customer satisfaction. Maintenance is a major contributor to aircraft operating costs, flight delays, and cancellations. Despite improved aircraft design and streamlined operations, airlines now spend more on maintenance than on fuel or crew. There is a constant see-saw between airlines and MROs where the former keeps MRO costs down while demanding quicker inspection and repairs, and streamlined parts management. On the other hand, MROs want to run a tight ship and remain profitable. Well, solutions lie in incorporating newer technologies as mentioned herein.
