2025 - 03 - 00 MRO 360 AvTrader
2025 - 03 - 00 MRO 360 AvTrader
MRO360
March 2025
Talk about working under pressure and yes, it can come right down to the very smallest screw. There
is nothing more frustrating than when an aircraft cannot be returned to service because of a missing
expendable part. In this month’s issue we talk to experts about the basics of effective management of
expendables and consumables.
We have also had the good fortune to be able to talk to Tommy Hughes, CEO of VAS Aero Services. Tommy
very kindly gave us some fascinating insights into the company together with an idea of its future plans.
What are your thoughts on aircraft safety and the human factor where MRO is concerned? We’ve shared
some of our own on the matter and summarised most of the key points that every MRO
operation may well want to consider.
And finally, we have an article on how automation, artificial intelligence and robots
could well change the future of aircraft maintenance. We are looking towards the
future of MRO operations.
Happy reading!
Peter Jorssen
Publisher
MRO360 .
Editorial
Peter Jorssen
Publisher
[email protected]
Heike Tamm
Editor-in-Chief
[email protected] 23
Expendables and Consumables
David Dundas
Content Writer
[email protected]
5 News in Brief
ADVERTISING &
CONTRIBUTION ENQUiRIES 5
Tamar Jorssen
Central, North & South America
20 Industry Interview
Malte Tamm
Europe, Middle East & Asia 23 Expendables and Consumables
20
[email protected]
Phone: +49 (0)162 8263049 A Look Behind the Curtain
Become a CONTRIBUTOR
28 32
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Big changes ahead
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AviTrader MRO 360° - March 2025
NEWS IN BRIEF 5
Fiji Airways appoints Heston MRO for line maintenance support in Cairns
Fiji Airways, the national carrier of Fiji, has appointed
Heston MRO to provide line maintenance support
in Cairns, Australia, marking another addition to the
airline’s expanding international network. Heston MRO
will deliver transit and daily checks for Fiji Airways’
fleet of B737 MAX 8 and B737-800 aircraft, along with
unscheduled inspections, maintenance and aircraft
on ground (AOG) services. As Australia’s largest
independent MRO organisation, Heston MRO services
over 40% of all international flights at Australian
airports. The Cairns operation, set to be fully operational
by mid-April, will join Heston MRO’s extensive network
of line stations across major Australian airports. The
partnership between Fiji Airways and Heston MRO
began over seven years ago with limited services at a
single station. Since then, it has evolved into exclusive
Australia-wide support for all Fiji Airways flights, © Heston MRO
GE Aerospace and Lufthansa Technik open XEOS engine MRO facility in Poland
XEOS, the joint venture between GE Aerospace and Lufthansa Technik, has been inaugurated in Poland © GE Aerospace
GE Aerospace and Lufthansa Technik have officially inaugurated advanced test cell. The facility is designed and operated using
XEOS, a cutting-edge engine MRO facility located in Środa GE Aerospace’s lean operating system, FLIGHT DECK, ensuring
Śląska near Wrocław, Poland. The joint venture focuses on efficiency and precision. The opening of XEOS coincides with
servicing CFM International LEAP engines, which power two Lufthansa Technik’s recent agreement to maintain LOT Polish
of the world’s most popular narrow-body aircraft types — the Airlines’ fleet of LEAP-1B engines. LOT operates 18 Boeing
Airbus A320neo family and the Boeing 737 MAX. Specifically, 737 MAX 8 aircraft, with a further 13 on order, making for a
XEOS handles the LEAP-1A and LEAP-1B engines, supporting total of 62 engines plus spares. The first engine from LOT’s
growing demand for maintenance as global fleets expand. fleet has already been inducted at XEOS, marking a significant
Currently, the facility is performing LEAP-1B shop visits and milestone for Poland’s growing aerospace sector. GE Aerospace,
supporting module work and engine testing for LEAP-1A celebrating 30 years in Poland, employs over 2,000 staff across
engines. Plans are in place to introduce LEAP-1B test cell six facilities and works closely with eight local universities
capability in the coming months, alongside an increase in and more than 1,000 suppliers. Through projects like XEOS
overhaul capacity and repair services. Covering 35,000 m², XEOS and investment in training programmes, including the Next
is equipped with an engine preparation hall, a main assembly Engineers initiative, GE is committed to developing Poland’s
and disassembly area, a clean-and-inspect line, multiple skilled aerospace workforce and expanding its MRO capabilities
repair stations, a dedicated engine training centre, and an in the region.
a319-100
MSN 2554
Thales signs avionics support deal for Malaysia Airlines' new A330neos
Thales and Malaysia Airlines have entered into a long-term
services agreement covering the Thales avionics systems
onboard the airline’s new A330neo fleet. This strategic
partnership ensures dedicated support for the airline’s
operations, enhancing fleet reliability and optimising
maintenance efficiency. Under the agreement, Thales
will oversee all repairs of its avionics products, while
also providing guaranteed spares availability and timely
replenishment. Stock will be held both at Malaysia Airlines’
main hub and Thales’ Asia-Pacific repair centre in Singapore.
This dual-location approach will enable Malaysia Airlines to
maintain optimal aircraft performance while streamlining
maintenance processes and minimising operational
disruptions. The MRO contract capitalises on Thales’s role Thales and Malaysia Airlines have signed a long-term avionics service agreement © Thales
as the original equipment manufacturer (OEM) of the flight
management and surveillance systems installed on the A330neo aircraft in 2024. As the OEM, Thales is uniquely positioned to
offer premium repair services tailored to the specific needs of Malaysia Airlines, ensuring high-quality support that maximises
operational efficiency and helps control maintenance costs. This agreement is supported by Thales’s Aviation Global Services
(AGS), a comprehensive one-stop shop for airline customers worldwide. AGS provides round-the-clock aircraft on ground (AOG)
support, maintenance, repairs, technical assistance, training, parts trading, and line maintenance services. Thales also offers
flexible programmes such as repair by the hour (RBTH) and asset availability initiatives, designed to deliver cost-effective, reliable
support for its airline partners. The new contract further strengthens the longstanding relationship between Thales and Malaysia
Airlines. Earlier this year, Malaysia Airlines selected Thales’s Flight Management and Surveillance systems for its A330neo fleet,
reflecting the airline’s commitment to high standards of safety, performance and passenger experience. Thales remains dedicated
to supporting Malaysia Airlines’ focus on hospitality and quality as the carrier continues to expand and modernise its fleet.
Breaking new ground: West Star Aviation sets course for growth
our focus on customer needs, service
excellence, and operational efficiency.”
Angela Padalecki, Executive Director of
Airport Operations at Grand Junction,
highlighted the significance of the
collaboration, stating that West Star
Aviation has played a crucial role in the
development of the airport and local
economy. She described the project as
a testament to the strong partnership
between the airport and the company.
Curtis Englehart, Executive Director
of the Grand Junction Economic
Official ground-breaking ceremony at Grand Junction MRO facility © West Star Aviation Partnership (GJEP), also emphasised the
importance of the expansion, noting
West Star Aviation has officially broken includes 38,000 square feet of office that it will bring continued investment
ground on a major expansion at its and back shop space, along with an and economic benefits to the region.
Grand Junction (GJT) MRO facility. additional 31,000 square feet of ramp The expansion is being designed and
The ceremony, held on March 11, space. “As we officially break ground, we constructed in partnership with Tectonic
marked the beginning of construction look forward to the opportunities this Management Group, with completion
on a state-of-the-art hangar, adding expansion will create for our customers, expected in the second quarter of 2026.
40,000 square feet to accommodate employees, and the local community,” Once operational, the new facility will
increasing demand for maintenance said Allen McReynolds, President enhance West Star Aviation’s capabilities,
services, avionics installations, and and COO of West Star Aviation. “The supporting its workforce, customers, and
interior refurbishments. The project also expansion at Grand Junction reflects long-term growth strategy.
BOOTH 2530
ATLANTA, GA
April 8-10
Jet Parts Engineering acquires Percival Aviation to strengthen aircraft interiors capability
Jet Parts Engineering (JPE), a specialist in PMA parts, DER to become a leading supplier in the aircraft interiors sector.
repairs and MRO services for commercial aircraft, has acquired The acquisition supports JPE’s mission to reduce airline
Percival Aviation, a UK-based company renowned for its aftermarket costs while maintaining a strong emphasis on
design, production and maintenance of aircraft interiors and service quality and product availability. Both companies
associated equipment. This strategic acquisition strengthens share similar values, with a commitment to delivering reliable
JPE’s service offering, enabling the company to provide more solutions and maintaining ready inventory to meet customer
comprehensive solutions to meet the evolving needs of the demands efficiently. The deal was facilitated by Vance
global aviation market. By integrating Percival’s expertise, JPE Street Capital, a private equity firm focused on investing in
expands its product range, combining interior components engineered solutions businesses across aerospace, defence,
with its established aftermarket services to deliver cost- industrial, and medical markets. JPE forms part of Vance Street
effective, high-quality solutions. Percival Aviation, based in Capital’s portfolio, and this latest move marks a significant
Fareham, Hampshire, has built a strong reputation within step in its growth strategy. With combined regulatory
the industry for its specialist work in aircraft interiors. The approvals and complementary strengths, JPE and Percival
company has also been pursuing an ambitious growth plan, Aviation are well-positioned to drive innovation and deliver
with a particular focus on expanding its international presence greater value to airlines and aviation stakeholders worldwide.
Liebherr-Aerospace Saline, based in Michigan, U.S.A., has signed Dew, Managing Director Commercial at Liebherr-Aerospace Saline,
a definitive agreement with SkyWest Airlines, headquartered in stated: “We initiated induction lines for the first Americas region
St. George, Utah, to provide landing gear overhaul and systems overhauls in 2012 and have continuously operated active lines
maintenance for a defined portion of SkyWest’s Embraer 175-E1 for the complete Embraer E170/175/190/195-E1 family since that
fleet. The programme is set to commence in 2025 and will include time. Over the course of the prior three years, we have undertaken
complete landing gear restoration in compliance with Embraer’s a structural transformation of our MRO activities to establish
specifications, performed at intervals of 30,000 flight hours or additional capacity, mature efficiencies, and anchor supply chain
12 calendar years. Since entering service in 2004, the Embraer resilience within the landing gear product line. In this upcoming
170/175-E1 family has been highly successful, with over 950 phase of overhauls, we welcome SkyWest Airlines as a lead
aircraft delivered and a current production backlog. Liebherr- customer that will benefit from this achievement”. The Embraer E1-
Aerospace Saline has supported landing gear maintenance for generation landing gear system was designed and is manufactured
this aircraft family since 2012, operating continuous overhaul lines by Liebherr-Aerospace Lindenberg GmbH, Germany, Liebherr’s
for the full range of Embraer E170/175/190/195-E1 models. Will centre of competence for flight control and landing gear systems.
Jordan Airmotive, an independent engine MRO provider, has solutions, ensuring our partners receive high-performance, cost-
successfully delivered a CFM56-5B engine to BOC Aviation, one of effective, and reliable engine services. Our growing presence in
the world’s largest aircraft leasing companies and a major player in the Asia-Pacific region reflects our commitment to serving aviation
the Asia-Pacific aviation market. This milestone reinforces Jordan leaders worldwide with tailored maintenance and support.”
Airmotive’s growing influence in the global leasing sector and Jordan Airmotive, certified by both EASA and the FAA, continues
underscores its capability to provide high-quality, reliable MRO to expand its global presence, offering comprehensive repair and
solutions to leading aviation companies. Mahmoud Bashir, CEO of overhaul services for CF6-80C2, CFM56-7B, CFM56-5B, CFM56-3,
Jordan Airmotive, expressed his pride in the partnership, stating, and the latest LEAP-1A/1B engines. With a forward-thinking
“BOC Aviation is a key player in the global aircraft leasing industry, approach, the company remains dedicated to strengthening its
and we are honoured to support their engine requirements. This partnerships and delivering innovative MRO solutions to meet the
delivery highlights our dedication to delivering world-class MRO evolving needs of the aviation industry.
ametekmro.com
Let’s connect:
MRO Americas,
Specialist component MRO. Underwriting OEM quality.
April 8-10, 2025
#1741
Actuation | Aviation Safety | Avionics | Landing Systems | Power Generation | Thermal Management
Lufthansa Technik Malta expands with new hangar for 787 Dreamliner maintenance
representatives from Malta’s political
and business sectors. Harald Gloy, Chief
Operating Officer at Lufthansa Technik,
emphasised the significance of the
development, stating that it strengthens
the company’s global network. He
noted that, in addition to the recent
construction of new facilities in Portugal
and Canada, this project marks another
milestone in Lufthansa Technik’s
corporate strategy. Gloy highlighted
that Lufthansa Technik Malta will be the
first location worldwide to carry out
787 Dreamliner cabin modifications as a
Boeing-licensed service centre, creating
new opportunities for customers and
Rendering of the new hangar in Malta © Lufthansa Technik
skilled employment in Malta. Once
Lufthansa Technik Malta, the European MRO provider worldwide authorised completed, the new hangar will be
Centre of Excellence for wide-body to both engineer and implement 787 integrated with existing facilities, giving
base maintenance within the Lufthansa cabin modifications. The modern facility Lufthansa Technik Malta a total of four
Technik network, is set to expand its will accommodate one wide-body hangars capable of servicing nearly
facilities and increase capacity. From aircraft, while three additional parking all commercial Airbus aircraft, except
autumn 2026, a new 6,400 metre² spots will be created for narrow-body the A380, as well as the Boeing 787
hangar will be dedicated to base aircraft. This expansion will generate Dreamliner. Construction is expected to
maintenance services, particularly approximately 70 new jobs. The signing take approximately 18 months, with the
cabin modifications for the Boeing 787 of the expansion agreement was officially facility becoming operational in autumn
Dreamliner. As a Boeing-licensed service recognised by Lufthansa Technik on 2026.
centre, Lufthansa Technik is the only Wednesday, March 12, alongside
Vista, the private aviation group, has announced a definitive Thomas Flohr, founder and Chairman of Vista, described the deal
agreement for a US$600 million equity investment from a as a significant endorsement of the company’s strategy and future
consortium of investors led by RRJ Capital, a prominent Asian plans. He welcomed RRJ Capital and the consortium, expressing his
investment firm. This investment marks a major milestone in enthusiasm for the partnership and the opportunities it will bring.
Vista’s continued growth and reflects strong confidence in the Flohr also highlighted the value of adding these new investors
group’s strategic vision and business model. The new capital to Vista’s carefully curated shareholder base. Alongside RRJ
injection is set to optimise Vista’s capital structure, improve free Capital, Andalusian Private Capital and other partners will join the
cash flow generation and reduce overall debt. This aligns with consortium, bringing a wealth of expertise and an expanded global
Vista’s commitment to accelerating its deleveraging efforts, network. They join existing shareholders such as Rhône Group LLC,
diversifying its investor base and further strengthening its who have been long-standing investors in Vista. The transaction
financial standing. The investment will also position the group is expected to close by the end of March 2025. Jefferies served as
for sustainable long-term growth in the private aviation sector. financial adviser to Vista, while UBS advised RRJ Capital on the deal.
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V
AS Aero Services is a wholly Airlines, OEMs, and MROs. VAS maintains state-of-the-art
owned subsidiary of Satair, an Tommy Hughes has been the warehouses as well as a global sourcing
Airbus company. The company company CEO since 2015 and is a and sales network. Our business and
is a leading provider of aviation parts seasoned professional with over 30 operations footprint covers North
and services, and in an industry marked years in aviation and aerospace. He America, the UK, Europe, Southeast
by constant change, VAS stands out for leads the company's strategic direction Asia, Australia and China (through
its stability and reliability as a global and operations, and in 2022, facilitated the expansion of Satair Chengdu, a
resource for innovative, tailor-made VAS' acquisition by Satair, a wholly powered-by-VAS USM end-of-life
solutions. The company provides owned subsidiary of Airbus. facility).
a portfolio of services that address We were recently fortunate to With over 45 years of experience, VAS
the industry's logistics, warehousing, catch up with Tommy and he was kind has one of the largest portfolios of
programme management, and sourcing enough to spare us some time to help any provider of quality aviation assets
needs, and as a leading provider in us get to know a little more about the in the aftermarket. The company
the aftermarket, delivers unmatched company and the state of the MRO became part of the Airbus Group of
inventory distribution services to major environment. companies in 2022 when VAS was
acquired by Airbus’s Satair subsidiary.
AviTrader MRO 3600: Can you tell us We now operate as a wholly owned,
about your company’s core business? independent subsidiary of Satair.
Tommy Hughes: VAS Aero Services How do you see the aviation parts
(VAS) is a leading provider of market evolving over the next five
aftermarket services in the aviation years?
industry and a highly experienced
provider of nose-to-tail Used I see a larger role for Used Serviceable
Serviceable Material, with more than Materials (USM) over the next several
US$4bn in engine/airframe/component years. OEMs have signed big multi-year
assets currently under management. deals to supply new aircraft. This likely
We source, warehouse, and market will limit resources for manufacturing
aftermarket components across a new replacement parts. That leaves
broad range of aircraft and engine an opening for third-party USM parts
platforms and provide related logistics suppliers such as VAS. Deliveries on
and programme management services the new aircraft in the sales pipeline
to airlines, MROs and OEMs around the are years away, so keeping current
Tommy Hughes, CEO VAS Aero Services world. aircraft flying and producing revenue
AviTrader MRO 360° - March 2025
Industry Interview 21
will be the key to profitability for meet those demands. Todays CRM the maintenance needs of A320s,
many operators near term. And that and ERP systems grant us that critical A330s and A380s that continue in
plays to VAS’ strengths in lifecycle view and allow us to exceed customer service.
management, aircraft transition and expectations. Harvesting and redistributing the used
teardown, and USM parts sourcing and serviceable material from these aircraft
distribution. As we look ahead, we like What role does technology play means that those parts will have a
what we see. in your operations, and are there continuing, useful life as replacement
any innovations you're particularly parts. By reclaiming and recycling
What are the biggest challenges excited about? those parts, we’re saving the energy
currently facing the aircraft parts needed to produce new parts and the
supply chain? VAS has invested over US$30 million subsequent carbon emissions created
in dedicated IT infrastructure and in the process.
Global supply chain disruption enhanced capability for aftermarket
continues to be a challenge. It often business solutions. Our customised Where do you see your company in
leads to shortages and delays in SAP system seamlessly integrates five to ten years, and what are the
obtaining critical parts, which plays out with customers’ systems for key priorities to get there?
as maintenance delays and increased aftermarket programmes, automated
downtime for aircraft. I expect this quotations, inventory management With forecasts for continued growth of
issue to continue to plague the and programme management. both passenger and cargo air transport,
industry for the near term. That’s why, Customers are able, at a glance, to the industry’s future looks bright,
from the airline and MRO perspective, see inventory availability and order indeed. It will impact all aspects of the
it’s critical to have a close relationship needed parts and material. All parts aviation business, including aftermarket
with your parts and materials supplier. are certified air-worthy and include the parts supply, repair and logistics. How
Parts shortages bring on another proper documentation, provenance can we as a company participate in
challenge: visibility into parts and history so clients know they are and benefit from that growth? That’s a
availability. Researching the receiving verified, flight-ready material. question we continually ask ourselves.
marketplace for needed parts can be With warehousing strategically located A few years ago, VAS undertook a
slow and painful, especially for those in the US and Europe, and through our long-term strategy development
airlines or MROs that may not have the alliance with Satair, we can deliver parts program. It required a bold look in
capabilities or resources to thoroughly rapidly, increasing TAT and reducing the mirror and asking some tough
and continually monitor and assess AOG… all thanks to our investment in questions to determine where we want
industry-wide inventories. Again, this IT infrastructure and automated order to be as a company. As a result of that
underscores why partnerships with processing. process, we realised that to succeed we
third-party suppliers are so important. needed to invest more in our business
With our overarching view of the What are the key trends shaping infrastructure and in our people. And
aftermarket, suppliers such as VAS demand for used aircraft parts? that’s just what we did. We expanded
know what is available, where, when, opportunities for our associates,
in what condition, in what quantities Supply-chain-disruption induced provided mentorships and beefed-up
and in what price range. Our market parts shortages, the growing backlog training. And we sourced state-of-
intelligence helps ensure that our of orders for new aircraft and the the-art IT systems that would allow
customers have access to the parts increasing emphasis on sustainability us to operate more efficiently, more
and materials they need, at a properly are all driving the increasing demand proactively, more productively.
valued price. for USM parts. Doing so propelled us to where we
We’re certainly seeing greater need for are today, among the leading USM
How does your company manage replacement parts as lessors and airline parts suppliers in the world. Surviving
inventory and logistics to ensure operators are keeping aircraft in service and thriving for the next five to ten
timely delivery? longer due to the large backlog of new years will require more of the same.
aircraft deliveries. That insight led us to There’s no standing still, so you’ll find
We are firm believers in investing acquire twenty-six A320 aircraft, seven VAS investing in facilities, people and
in IT infrastructure. With over one Airbus A330 ex-China Southern Airlines the latest technology – deploying
million parts in stock, automated aircraft and increase our teardown innovative logistics systems, recruiting
inventory tracking has become an business with the Dr. Peters Group to and rewarding top-quality employees,
essential element of our business. Our now include eight A380 aircraft. harnessing the power of AI, enhancing
ability to know the precise condition, These aircraft acquisitions mean, of our aircraft transition management
location and availability of parts is key course, that for some years to come capabilities and doing whatever it
to delivering parts on time and on VAS will have access to a greater takes to be the leader in aftermarket
budget. In the aftermarket, you cannot supply of quality, certified used parts trading, re-distribution of assets, and
know enough about your customers’ for distribution across our global programme management reporting.
needs or your own capabilities to aftermarket customer base to support
AviTrader MRO 360° - March 2025
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23
© Shutterstock
I
n the world of MRO, it can be easy to supply chain volatility, fleet modernization, As a result, customers are seeking
take certain elements for granted owing along with the need for more cost- dependable distributors who can offer
to their lack of ‘presence’. By that, we effective maintenance strategies and needed parts at competitive prices, and
mean those smaller items that tend to be increasing demand for efficiency. As VAS Aero Services has emerged as a key
overshadowed by the focus of attention Daniel Tautges, Executive Vice President, player in this evolution. We are proud
being more on major (and costlier) Component Control explains, “In recent to be a trusted alternative source for
components. However, expendables and years, we’ve seen supply chain disruptions, expendables and consumables. With
consumables are as vital an element of material shortages, and inflationary over 400,000 square feet of warehouse
MRO operations as without them, aircraft pressures impacting the availability and space and a large expendables inventory,
would simply be unable to fly safely. While cost of these items. At the same time, we are equipped to fulfil both routine
the terms expendables and consumables airlines and MROs are prioritising just- and urgent material needs worldwide.
tend to be interchangeable, for the in-time inventory strategies and digital We stock and redistribute parts from
purposes of this article, we consider the procurement solutions to streamline our U.S. locations in Boca Raton, FL, and
likes of nuts and bolts, fasteners, gaskets, operations. The demand for predictive Kent, WA. Our strong relationships with
seals, filters, etc., to be expendables, and maintenance solutions has also increased, OEMs and airlines allow us to offer a wide
hydraulic fluids, greases, oils and cleaning requiring better data integration between range of parts sourced through long-
chemicals, etc., to be consumables. suppliers, operators, and MROs to ensure term consignment and resale agreements,
stock levels are optimised without ensuring consistent availability and quality
We wanted to know more about just how overcapitalisation.” at more competitive prices. This approach
critical a role expendables and consumables Marina Vivas-Birkeland, Director Asset aligns with the industry's growing demand
played in MRO operations, and so we asked & Price Management BVAS, VAS Aero for efficiency, affordability, and reliability,”
three leading operators for their opinions on Services has seen a major change in a she comments.
a series of related topics. sector traditionally dominated by OEMs Meanwhile, Scott Butler, Chief
but which is now witnessing a shift as Commercial Officer, Ascent Aviation
airlines and MROs increasingly turn to Services identifies unpredictability as a
How has the market for
third-party suppliers for both efficiency key factor since the COVID-19 pandemic,
aircraft maintenance
and flexibility. “The adoption of digital stating that “Ascent had to pivot very
expendables and consumables
inventory planning and management quickly from a Heavy Maintenance
evolved in recent years?
tools is also driving this change, as these environment to Preservation & Storage.
The market for expendables and help streamline procurement and move This put a huge strain on the supply
consumables in aircraft maintenance has from a reactive purchasing model to chain.”
experienced significant shifts driven by a more proactive, planned approach.
AviTrader MRO 360° - March 2025
Supply Chain 24
“
With improved access to sensor data and advanced
analytics, airlines can now predict maintenance needs,
”
plan ahead, and avoid unexpected downtime.
Marina Vivas-Birkeland, Director Asset & Price Management
BVAS, VAS Aero Services
reduce waste and lower costs. Third- ongoing disruption in global supply
party suppliers are instrumental in this chains and unfortunately, this issue is
sustainability shift, helping to minimize likely to persist in the foreseeable future.
waste, energy consumption, and carbon These disruptions result in shortages
emissions while maintaining a reliable and delays in obtaining critical parts,
supply of quality parts.” causing increased aircraft downtime and
While Daniel Tautges also identifies higher costs, where the lack of a few
sustainability as an influencing factor, he bolts can disrupt and delay operations.
Marina Vivas-Birkeland, Director Asset & Price
Management BVAS, VAS Aero Services comes up with several additional trends As Marina Vivas-Birkeland advises:
that are shaping demand. To begin with, he “Another challenge is getting accurate
What are the key trends discusses fleet transition and sustainability: information on the availability of these
shaping the demand for “As airlines retire older aircraft and types of materials,” adding that “Searching
expendables and consumables introduce next-generation fleets, the the market for expendables can be
in the aviation industry? expendable and consumable mix is shifting. time consuming, and many airlines and
Newer aircraft often require different MROs lack the resources to thoroughly
The demand for expendables and
maintenance approaches, affecting demand check all available sources. This is where
consumables is being shaped by several
patterns. Additionally, sustainability aftermarket suppliers like VAS Aero
key trends, all focused on improving
initiatives are prompting interest in eco- Services offer a key advantage, providing
availability and lowering operating
friendly alternatives.” He then discusses real-time information on availability,
costs across the industry. Two main
global supply chain diversification: condition, traceability and price to ensure
trends that are driving this change
“Airlines and MROs are diversifying their customers get the right materials at the
are the use of predictive maintenance
supplier base to mitigate risks. There’s right price.”
technologies, and a growing focus on
a growing push for localized stockpiling Daniel Tautges has identified four of
sustainability. Marina Vivas-Birkeland
and partnerships to reduce reliance on the greatest challenges, also including
makes the consequences clear as she
single-source vendors.” Finally, he talks supply chain disruptions and lead times,
tells us that: “With improved access to
about digital procurement and predictive while ongoing geopolitical tensions,
sensor data and advanced analytics,
maintenance: “The adoption of AI-driven manufacturing slowdowns, and logistics
airlines can now predict maintenance
procurement tools is improving forecasting constraints have also extended lead
needs, plan ahead, and avoid unexpected
accuracy, reducing excess inventory while times for critical consumables. He adds
downtime. This enables customers to
ensuring critical parts availability. Predictive that price volatility - the cost of raw
manage expendables and consumables
maintenance is also driving demand for materials, particularly specialty metals and
more efficiently by replacing parts only
condition-based replenishment rather than composites, has fluctuated significantly,
when necessary. As a result, inventory
traditional time-based stocking.” impacting procurement budgets, while
management is streamlined, leading to
Interestingly, Scott Butler identifies regulatory and compliance Constraints,
cost savings and improved operations.
three further areas of influence – big such as compliance with evolving
Consequently, there is an increasing
data, usage forecasting and AI, as he tells regulatory standards (PMA approvals and
demand for affordable expendables and
us that: “Big data and usage forecasting traceability requirements etc.,) can create
consumables. Aftermarket suppliers like
are allowing the industry to strategically bottlenecks in sourcing and stocking. He
VAS Aero Services are meeting this demand
purchase long-term and stock according also points out that where data Integration
by offering competitive pricing and quick
to the MRO demand. AI is adding and visibility are concerned, many MROs
delivery. This provides airlines and MROs
another tool to the bag and allowing very and operators still struggle with real-time
with more options without compromising
sophisticated models to be generated and visibility into inventory levels, leading to
quality. Sustainability has become another
utilized accordingly.” inefficiencies in procurement planning.
focal point in the aviation industry, leading
A further challenge identified by Scott
to a stronger emphasis on re-distributing
Butler is the changes in aircraft mix. He
expendables and consumables rather What are the biggest
states: “As the OEMs have had issues
than scrapping them, especially when challenges in sourcing
ramping up to demand, we have had to
these parts still have a viable market expendables and consumables
keep older aircraft flying which has not
demand. This approach not only makes for aircraft maintenance?
been part of the larger forecast, leading to
environmental sense but also helps airlines One of the biggest challenges is the supply chain disruptions.”
© Shutterstock
How do airlines and MROs parts are always available when needed. As vendors who can help manage the supply
manage supply chain previously mentioned, airlines and MROs chain forecast is a solution we at Ascent
disruptions for these are increasingly utilizing forecasting tools find valuable, allowing the disruption to be
materials? and inventory management software to managed further upstream where it won’t
optimize stock levels. These predictive impact our projects,” he comments.
Supply chain problems have plagued the
analytics enable them to accurately forecast
MRO sector since late 2020, coinciding with
demand, preventing both overstocking
the outbreak of the COVID-19 pandemic. What strategies can suppliers
and shortage of critical parts, even during
The question is, how do you mitigate for adopt to ensure a steady
supply chain disruptions.”
such an ongoing challenge? supply of critical consumables?
Daniel Tautges at Component Control
At VAS Aero Services, Marina Vivas- Inventory management is a significant
adopts a slightly different approach,
Birkeland has identified three areas that challenge for many airlines and MROs.
though based on similar principles.
can help the situation: “Airlines and MROs Maintaining an adequate supply of
Put succinctly, he has focuses on four
are increasingly focusing on working with consumables without overstocking
principal areas: “Strategic Stockpiling:
a group of trusted suppliers, including requires precise forecasting, which can
Maintaining higher safety stock levels for
third-party options like VAS Aero Services. be difficult due to variable demand
critical consumables, particularly at major
By diversifying their supplier base and and long lead times for some parts. To
maintenance hubs. Supplier Diversification:
establishing strong partnerships, they address this challenge, suppliers can
Establishing multiple supplier relationships
reduce the risks associated with relying implement strategies to ensure a steady
to avoid dependency on a single source,
on a single source. This approach helps supply of critical consumables. Marina
especially for high-turnover items. Digital
create a more flexible and dependable Vivas-Birkeland’s advice? “Investment
Inventory Management: Leveraging
supply chain, one that can better withstand in advanced forecasting and inventory
cloud-based ERP systems like Quantum
unforeseen disruptions. Building strong, management systems is essential. By
Control to enable real-time visibility into
long-term relationships with suppliers is leveraging predictive models, maintenance
stock levels, supplier performance, and
essential for success in this strategy. By organizations can anticipate demand
automated reordering. Predictive Analytics:
securing long-term contracts, engaging in fluctuations, plan production schedules,
Using AI-driven forecasting to anticipate
collaborative planning, and maintaining and maintain appropriate stock levels.
demand fluctuations and proactively adjust
open and transparent communication about This helps avoid shortages during peak
procurement strategies.
challenges, better coordination during demand periods and ensures timely
At Ascent Aviation Services, Scott
disruptions can be achieved. Safety stock delivery of critical consumables. For
Butler identifies long-term planning and
agreements for high demand or hard to example, VAS Aero Services customers
forecasting to secure material is the best
find parts are also essential, ensuring that can integrate their information
solution for disruptions. “Bringing on
AviTrader MRO 360° - March 2025
Supply Chain 26
“
We employ several different solutions at various stages,
VMI / kanbans as well as AI predictive forecasting to
”
help give us the best visibility to our needs.
Scott Butler, Chief Commercial Officer,
Ascent Aviation Services
management systems with our online mile delivery capabilities, and alternative
parts platform for constant visibility into shipping routes to counter logistical
availability, trace documentation and delays,” adding, “Enhancing Transparency
pricing. This transparency enables real- & Communication: Providing real-time
time tracking, reducing lead times and order tracking and proactive notifications
enhances responsiveness. Additionally, to customers to ensure expectations are
collaborating with airlines and MROs to aligned.
share demand forecasts and maintenance Meanwhile, Scott Butler takes a slightly
Scott Butler, Chief Commercial Officer,
schedules allows suppliers to adjust different approach, advising that: “We Ascent Aviation Services
“
AI and machine learning are enhancing predictive
maintenance and demand forecasting, allowing
MROs and operators to optimise stock levels while
”
reducing waste.
Daniel Tautges, Executive Vice President, Component Control
Daniel Tautges, Executive Vice President,
Component Control
AVAILABLE NOW
UK CAA, 2-Reg and Cayman approvals on
A320 family and B737NG aircraft at our facility
2025 Maintenance Slots! at Teesside International Airport in the UK.
For additional information on how we can assist with your base maintenance needs contact us at
[email protected] | +44 (0) 1656 508 270 | www.wlfc.global
28
© Shutterstock
Minimising Errors
Human Factors in Aircraft Maintenance
By David Dundas
R
egular, effective and error-free (used in place of an optional emergency day-to-day operations. By this we
maintenance is essential for the safe door that was not required), and nor was refer to cognitive, physical and also
operation of all aircraft, whether it be there anything structurally wrong with the social influences that can affect overall
small training aircraft like the Cessna 172 four bolts what should have held the door performance in the workplace. We want
or a commercial passenger jet capable of plug in place, but owing to human error, to see how effectively technicians and
carrying over 150 people, like the Airbus the bolts were never used to secure the the likes carry out their tasks, how they
A320. There is one element of aircraft plug and maintenance and safety checks utilise tools and understand and follow
maintenance however that is perhaps more thereafter failed to notice the mistake. procedures, and how they respond to
critical when it comes to safety than any Despite technological advancements, pressures and time constraints, especially
other element, and that is human input maintenance errors still contribute when fatigued. Even small human errors
– mechanics, engineers, etc. While every significantly to aviation incidents and, as can have significant consequences,
effort can be made to ensure that all the a consequence, understanding human affecting aircraft reliability, passenger
parts and materials, consumables and factors and implementing strategies to safety, and operational efficiency. However,
expendables used in aircraft maintenance minimise human error is vital for ensuring we also need to examine the types of
meet all the necessary safety standards, the very highest safety standards, which mistakes made.
such exacting standards become somewhat this industry demands. The intention with
irrelevant in the face of human error where the following is to explore the human
What Are the Common Types
aircraft maintenance is concerned. element in aircraft maintenance safety
of Human Error in Aircraft
and to examine methods to help mitigate
Maintenance?
As a perfect example of human error, human error.
we have the incident on January 5, 2024, Omission errors are often the result of
involving a door plug on an Alaska Airlines complex and long-winded maintenance
The Importance of Human
737 MAX jet which blew out at an altitude procedures. It is not so much a case of
Factors in Maintenance
of approximately 16,000 feet on a flight technicians omitting a step to lighten the
between Portland in Oregon and Ontario First, we have to look at how engineers, workload but simply getting distracted,
in California. In reality, there was nothing technicians and other members of an perhaps by tight time constraints or simply
structurally wrong with the door plug MRO team physically function in their misunderstanding the instructions given.
© Shutterstock
We also have the improper installation work-induced though long shifts, working Management (CRM) training tailored
of aircraft components such as missing nights, and tight deadlines, but can also for maintenance personnel to improve
bolts as we have mentioned above, or result from off-site activities, making it teamwork and decision-making.
incorrectly connected systems, which can harder for supervisors to look out for. The next two points are closely related,
lead to mechanical failures. These errors Finally, we have organisational and and those are fatigue management and
often result from miscommunication, cultural influences. For example, a improving the work environment. For
lack of training, or once again, fatigue. workplace culture that prioritises speed some MRO operators, the workload can
Miscommunication is one of the over safety may encourage shortcuts and vary dependent on orders. However,
hardest challenges to eradicate from non-compliance with standard procedures, when shiftwork is required to either clear
maintenance teams as sometimes the while poor and ineffective leadership and a backlog or there is simply a number
ensuing misunderstanding will not become lack of safety reporting mechanisms will of urgent tasks, it is difficult for staff to
immediately obvious. Beyond this, you likely discourage technicians from speaking adapt to working night shifts some weeks,
also have highly technical manuals that up about potential risks or seeking to then only day shifts the majority of the
require considerable knowledge in order to implement better working practices. time. Where possible, it is always best
follow specific instructions. Add inaccurate to have regulated shift patterns. Beyond
maintenance records and a failure to log this, encouraging breaks and providing
Strategies to Minimise Human
all completed work and the problems with fatigue-awareness training to help workers
Errors in Aircraft Maintenance
human error can mount. recognise when they are too tired to
Another challenge is keeping up to date Reducing human error in aircraft operate both efficiently and safely is also a
with all the latest technology, new tools maintenance requires a multi-pronged sound proposition.
and new materials. For many mechanics approach, one which involves integrating When it comes to communication
and technicians, it is very much a constant training, work environment improvements, and documentation, to begin with,
learning curve as using the wrong tools and safety culture improvements. While it implementing standardised reporting
or incorrect handling of equipment can may seem a little like stating the obvious, procedures will help to improve
damage aircraft components, but that but simply educating engineers and documentation accuracy, while using
damage may not always be immediately technicians about the causes of human digital maintenance logs and automated
obvious. And then we have fatigue, which error and introducing better prevention checklists can lead to a reduction
can destroy concentration levels and strategies can make a huge difference. in paperwork errors. As for better
impair cognitive functions, such as making Beyond that, you also have the opportunity communication, this is often a ‘work
the right decisions. Fatigue isn’t always to implement implementing Crew Resource culture’ aspect and the easiest way to
© Shutterstock
improve communication is to simply and audits to identify procedural weaknesses maintenance, allowing maintenance to be
openly encourage it, especially as it is a and enhance compliance, and finally scheduled before a failure occurs, reducing
great means for knowledge sharing. there is a need to promote leadership reliance on reactive repairs. Then there
commitment to safety, ensuring that is wearable technology, such as smart
efficiency pressures do not compromise glasses, to provide technicians with hands-
Advances in Today’s
maintenance standards. free digital checklists and real-time expert
Technology and Automation
assistance. Third we have blockchain-based
In today’s other article on aircraft record-keeping, ensuring maintenance
The Role of Regulatory Bodies
maintenance, we have specifically drilled documentation is tamper-proof and easily
down on automation and the human Aviation authorities such as the FAA accessible, and finally we have Virtual
factor. It is clear that with advances in (Federal Aviation Administration) and EASA Reality (VR) training, offering immersive
robotics and automation, when combined (European Union Aviation Safety Agency) simulations to enhance technician learning
with new materials, there is a sea change set guidelines to ensure high safety and decision-making skills.
in place intent on reducing the human standards in maintenance operations. As
input into aircraft maintenance and a result, these regulations require airlines
Conclusion
therefore reducing the chances of human and maintenance providers to conduct
error. We have reached the stage where human-factor training, implement fatigue Human factors play a pivotal role
using augmented reality (AR) systems can management programmes, maintain in aircraft maintenance, influencing
provide real-time maintenance guidance thorough documentation and audit safety, efficiency, and overall operational
and reduce errors, while implementing systems, and finally, continuously improve reliability. While human error is virtually
error-proofing tools such as torque sensors safety protocols based on industry best unavoidable, proactive measures such
and barcode scanning for component practices. as human-factor training, fatigue
verification can also help reduce the management, improved communication,
opportunity for human error. and technological advancements have the
Looking Further Into the
potential to significantly reduce instances.
Future
Airlines, maintenance providers, and
Fostering a Safety Culture
As technology advances, new strategies regulatory authorities should continue
There are three main ways to improve are emerging to further reduce human working together to bolster a culture of
a safety culture in a business, and in the error in aircraft maintenance. We have safety and precision in aircraft maintenance
MRO environment, the first step would be earmarked four specific areas where we operations and through understanding and
to encourage technicians to report errors feel future developments will have a major addressing human limitations, the aviation
without fear of punishment, fostering a influence in reducing the opportunity for industry can achieve even greater safety
learning-based approach to safety. We human error in aircraft maintenance. standards in the years to come.
then have the need for regular safety First, we have AI-powered predictive
AviTrader MRO 360° - March 2025
•
•
•
•
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© Shutterstock
I
t goes without saying that aircraft The Need for Advanced to detect structural issues. What is also
maintenance is essential for not just Maintenance Solutions important to mention here is that these
safety, but also efficiency, as well as technologies are all capable of identifying
Traditionally, aircraft maintenance has
being part of a set of aircraft records that structural issues that may not be easily
always been a labour-intensive exercise,
detail its history. Complete records of spotted by the naked eye. However, the
and over time new maintenance techniques
aircraft maintenance enhance the value cost-effective benefit is hard to ignore as,
and equipment have been geared towards
of an aircraft, and reduce the risk of any for example, drones fitted with specialist
reducing the labour element. In addition
end-of-lease penalties when returning an cameras scan an aircraft’s exterior for
to the cost element, the longer a plane is
aircraft to its lessor. surface damage, corrosion, and other
on the ground, the greater the true cost
defects in a matter of minutes, reducing
of maintenance and repairs to the carrier.
While aircraft technology has the time required for manual inspections.
With the need to develop more efficient,
continually changed, maintenance Next, we have automated painting and
accurate, and cost-effective maintenance
technology has tended to be reactive as coating systems. While saving considerable
solutions, so the arrival of robotics and
opposed to proactive. That now seems time on the labour front, there are multiple
automation has been widely embraced.
set to change with the introduction of other benefits that make this new spraying
automation and robotics in the MRO technology such a boon to aircraft
environment. The advantages? More maintenance. With automation comes
Robotics in Aircraft
precise maintenance, reduced risk of smoother applications of paint, fewer
Maintenance
human error, and for the MRO itself, inconsistencies, reduced material waste
reduced operational costs after investing in While robotics has been around and the opportunity to eliminate exposure
the new technology. for decades, it is the advancements in of maintenance staff to hazardous
In the following, it is our intention technologies that robotics incorporates chemicals.
to take a closer look not just at today’s that has been the game changer where Automated composite repair systems
enhancements to the maintenance sector, aircraft maintenance is concerned. So, what is next on our list. With the extensive use
but to see what the future may hold, with are we referring to? of composite materials in today’s jetliners,
specific attention being paid to the role of To begin with, we have automated new repair methods are also required,
automation, robotics, artificial intelligence inspection systems which use advanced and these new materials lend themselves
(AI), as well as other cutting-edge imaging technologies such as infrared well to robotic systems. As an example,
technologies. cameras, ultrasonic sensors, and LIDAR a robotic system can cover all aspects
AviTrader MRO 360° - March 2025
Trends 33