January 7, 2025
The Complete Guide to Aviation MRO
Tips, best practices, and mistakes to avoid
Safety in the aviation industry has steadily evolved since the first air-powered flight in Kitty Hawk, North Carolina 120 years ago (NASA). Eight years later, the first aircraft safety belt was introduced, an important step for increasing the reliability of air travel.
Many more advancements have since followed to make air travel safer for passengers, planes, and cargo. (FAA).
Today, the aviation industry relies heavily on specialized Maintenance, Repair, and Overhaul (MRO) processes to keep their aircraft running safely and efficiently.
MRO manages the processes needed for compliance and operational efficiency, even ones like commercial passenger flights, cargo freight planes, or unmanned aerial vehicles (UAVs).
In this guide, we’ll take a closer look at MRO so you have a thorough understanding of the topic, including benefits, considerations, and best practices for using MRO operations.
We’ll also examine the impact of artificial intelligence (AI) on future industry developments.
What is MRO?
MRO stands for maintenance, repair, and overhaul. Within the aviation industry, MRO services cover numerous processes, including:
- Routine inspections
- Upgrades to aircraft interiors
- Component replacements
- Major overhauls
- Emergency repairs
- Engine maintenance and testing
- Avionics upgrades and calibration
- Structural modifications and retrofitting
- Landing gear servicing and inspections
- Software and firmware updates
The aviation industry relies heavily on MRO to ensure fleet readiness and manage operational costs.
History of MRO
In terms of aircraft safety, the history of MRO dates back to the earliest days of aviation in the 1910s. Then, MRO was more reactive than proactive. MRO processes consisted of pilots and mechanics performing manual inspections to repair obvious signs of damage.
Over time, with the emergence of jet engines and sophisticated computer systems, the need arose for dedicated aviation MRO providers.
Today, these providers serve many different sectors. Skilled technicians perform MRO operations for numerous aircraft types and facility settings, including:
- Hubs for major commercial and regional airlines
- Airfields and hangars for private aircraft fleets
- Dedicated cargo and freight centers
- Military and defense aviation bases
- Helicopter and rotorcraft maintenance facilities
- Specialized service and test centers for UAS (Unmanned Aerial Systems) and UAV aircraft.
Artificial intelligence (AI) is increasingly being integrated into MRO services across all types of aircraft and aviation facilities for predictive maintenance and optimized repair schedules.
Common MRO challenges in aviation
While MRO has a straightforward mission—ensuring flight craft are safe and operationally sound—executing on MRO is not. Aviation MRO is a complex industry that faces many headwinds, no pun intended.
- Prolonged turnaround times: MRO processes like in-depth inspections, major overhauls, and component replacements can take days, weeks, or even months. These processes can disrupt fleet operations and ultimately, harm business reputation.
- High operational costs: Labor accounts for around 60-70% of all MRO costs. FAA-certified technicians are essential, but are becoming increasingly scarce, which drives up labor expenses.
- Parts management: Stocking and ordering spare parts, especially for rare or older aircraft models, can be time-consuming and costly. Smaller fleets or operators in remote locations face further challenges that can lead to prolonged groundings or paying a premium for the emergency sourcing of a part.
AI-driven tools, like those developed by ePlaneAI, offer practical solutions to everyday MRO hurdles. AI-powered technology predicts maintenance needs, schedules repairs to minimize disruption, and manages parts inventory efficiently, so you have what you need on hand and aren’t left scrambling for a costly spare.
Leveraging the predictive power of machine learning gives you the ability to better manage costs and prevent coverage gaps.
What is the difference between MRO and FBO?
An FBO, or fixed base operator, provides ground services for private and general aviation, like fueling, parking, and basic cleaning for aircraft. MRO, or maintenance, repair, and overhaul, is focused on in-depth maintenance and repairs, such as engine overhauls and structural fixes. In short, FBOs keep planes ready for travel, while MROs keep them safe and fully operational (NATA).
What is the difference between OEM and MRO in aviation?
In aviation, OEMs (original equipment manufacturers) design and build aircraft and their parts, while MRO (maintenance, repair, and overhaul) providers focus on maintaining, repairing, and overhauling those parts to keep aircraft operational. OEMs create the original products, and MROs handle ongoing upkeep, repairs, and replacements to ensure safety and performance (Aviation Business News).
How many types of MROs are there?
There are four main types of MRO for aviation, each with a distinct focus:
- Aircraft infrastructure maintenance: Involves upkeep of the aircraft structure and hangar facilities, including tasks like airframe repairs, hangar upkeep, and necessary modifications for aircraft safety and longevity.
- Production equipment maintenance: Focuses on the maintenance and repair of specialized aviation equipment, such as ground support equipment (GSE) and diagnostic tools.
- Material handling and logistics: Covers the systems and logistics needed to handle materials, such as parts inventory, equipment transport, and materials management for optimized maintenance schedules that minimize downtime.
- Tooling and consumables: Manages the supply and upkeep of tools, fasteners, lubricants, and safety gear essential for daily maintenance activities.
AI-driven best practices for MRO operations
Now that we’ve covered MRO fundamentals, let’s dive into some best practices for optimizing MRO operations, especially with AI tools:
1. Predict problems before they happen
Using predictive maintenance means staying ahead of issues rather than reacting to them. When AI analyzes data from Internet of Things (IoT) sensors and equipment, it can forecast when aircraft components might wear out or fail. MRO teams are then notified when to replace parts or schedule repairs before problems escalate, minimizing unplanned downtime and avoiding costly disruptions.
Using AI predictive analytics, businesses can see:
- 10–20% increase in equipment uptime
- 25% increase in productivity
- 70% reduction in equipment breakdowns
- 5–10% reduction in maintenance costs
- 20–50% reduction in maintenance planning time
(Source: Deloitte Predictive Maintenance study)
2. Keep inventory lean and ready
Inventory management in aviation can be a balancing act—stocking too much ties up capital, while too little risks delays. AI-driven demand forecasting helps MRO providers predict the need for specific parts, allowing them to maintain just-in-time inventory. This ensures that critical components are on hand when needed, reducing wait times and the financial burden of holding excess stock.
Some key benefits of AI-driven inventory planning include:
- Sharper forecasting: Cut forecasting errors by 20–50%, slashing lost sales and product shortages by up to 65%.
- Lower costs: Reduce warehousing expenses by 5–10% and administrative costs by 25-40% with AI forecasting.
- Efficient workforce management: Automate up to 50% of workforce tasks with AI, saving 10-15% in labor costs and improving hiring and flexibility.
- Rising external data sources: The external data market is booming, growing 58% annually, offering more tools for precise, data-rich forecasting.
(Source: McKinsey & Company)
3. Match technicians to tasks
Not every job requires the same level of expertise. AI-based scheduling tools can analyze the skills required and match technicians accordingly. This approach not only reduces overtime and prevents burnout but also ensures that your FAA-certified Aviation Maintenance Technicians (AMTs) are deployed most effectively.
4. Maintain high standards, easily
Quality and compliance are essential in aviation. AI tools make it easier to track FAA standards and other regulations, ensuring quality benchmarks are met. By automating compliance checks and enabling real-time tracking, AI lowers the risk of missed steps, costly fines, and rework, keeping operations safe and on track.
Common mistakes to avoid in MRO operations
Even the most established MRO facilities can make a misstep. Here are a few of the most common ones to avoid:
1. Missing data
Using AI, MRO providers can capture more data points than ever before, leading to near limitless opportunities for optimization. Similarly, siloed data or delays in getting data can also lead to easily avoidable errors and bottlenecks.
2. Reliance on legacy (manual) processes
If you’re not updating, your competitors are. Manual processes slow down MRO operations and increase the risk of data errors. When you are leveraging AI, you can automate manual processes for increased speed, accuracy, and employee satisfaction as your workers focus on more complex issues.
With ePlaneAI, data from every part of your operation flows into one dashboard. Everyone sees the same up-to-date numbers—no waiting for BI to pull reports or dealing with siloed information.
3. Not upskilling your workers
With AI and automation transforming MRO, training your team is crucial. Upskilling improves productivity and reassures employees that technology isn’t here to replace them but to make their work more meaningful.
Giving your team the skills to handle advanced tools keeps everyone engaged and ready for the future. When you invest in their growth, you’re not just future-proofing your operation—you’re helping build a stronger workforce for the industry.
The future of MRO aviation
The future of MRO is all about smarter, faster aircraft maintenance. AI-driven predictive tools are already helping teams stay ahead of breakdowns, meaning fewer grounded planes and lower repair costs.
As we move forward, other hands-on tech like augmented reality could help technicians troubleshoot issues in real-time, guiding them step-by-step. Digital twins—virtual models of actual aircraft—may let teams run tests before making a single adjustment on the plane.
Why choose ePlaneAI for AI-powered MRO?
ePlaneAI offers a distinct approach to MRO by transforming data into actionable insights. This allows aviation teams to proactively manage complex maintenance operations. Unlike traditional MRO providers, ePlaneAI doesn’t just optimize routine schedules—it uses AI to reveal precisely when and where interventions are needed, reducing operational surprises and costly downtime.
Recent implementations showcase the impact: one ePlaneAI client reduced AOG incidents by 43%, thanks to automated procurement and inventory optimization that provided 95% forecasting accuracy. This led to a 65% increase in labor efficiency and freed up cash flow by identifying 37% of inventory as stale.
With ePlaneAI, you benefit from:
- Real-time maintenance insights: Integrated with SAP, AMOS, or other ERP systems for predictive insights without the need for a full technology overhaul.
- Preview of any operational changes: With What-If Analysis tools, you can measure the impact for different scenarios, such as extending A-check intervals by 10% or reallocating technicians.
- Cost-efficient inventory management: Prevents overstocking, yielding a 10% reduction in warehousing costs and 40% savings in administrative tasks by automating reordering and inventory decisions.
- Scalable AI solution: Customizable to meet the demands of growing fleets with evolving MRO needs, helping your operations stay agile and cost-effective.
Adding ePlaneAI helps with creating a comprehensive, forward-looking solution that optimizes for efficiency. ePlaneAI works with MRO teams to make aircraft safer, arming them with the tools needed to tackle problems before they impact flights.
Use AI to augment MRO and increase efficiency
As 21st-century industries adapt to new AI technologies, smart MRO providers aren’t waiting in the wings. They’re adopting powerful, AI-driven solutions for predictive maintenance, real-time data integration, smart decision-tree modeling, and more, making every stage of their maintenance operations smarter and leaner.
FAQs
1. Does ePlaneAI provide aircraft parts?
ePlaneAI helps air fleets manage and optimize the replacement of aircraft parts, but they are not a parts supplier. Their technology helps aviation companies accurately forecast demand, streamline maintenance, repairs, and inventory levels, and efficiently schedule replacements.
2. How does ePlaneAI integrate with existing MRO systems?
ePlaneAI’s platform works as an AI analytics layer on top of existing ERP systems, such as SAP, AMOS, and Oracle. It can process real-time data from these systems without needing a complete overhaul of your current technology stack.
3. What types of data does ePlaneAI use for predictive analytics?
ePlaneAI uses a variety of data to make accurate maintenance and parts predictions:
- Historical maintenance records: Past data on repairs and part replacements.
- Real-time sensor data: Live information from aircraft sensors and IoT devices.
- Event-based triggers: Factors like weather or flight schedules.
ePlaneAI analyzes these data sources so you can:
- Spot wear patterns: Identify when parts are likely to fail.
- Predict maintenance needs: Schedule repairs before issues become critical.
- Optimize inventory: Keep parts stocked at ideal levels.
As AI models continually learn and improve, their forecasts will become even sharper.
4. What sets ePlaneAI apart from other MRO providers?
Unlike traditional MRO providers that focus on manual repairs and part replacements, ePlaneAI takes a proactive approach using AI. Integrated directly with ERP systems like SAP and AMOS, ePlaneAI helps teams spot maintenance needs before they become issues, cutting AOG incidents by up to 43%.
This means fewer last-minute scrambles, smarter inventory levels, and lower costs—all while cutting unnecessary downtime.
