Case Study
Accelerating a Mission-critical MRO Process
A leading aerospace manufacturer needed to accelerate Technical Variance processing across its global maintenance, repair and overhaul network. With hundreds of requests handled each week, engineers spent significant time manually preparing technical responses. Infosys developed an AI-assisted solution that uses MRO request context and previous cases to generate initial drafts, helping improve engineering efficiency and response quality while maintaining human review and safety controls.
Key Challenges
Rising Technical Variance Volumes
Increasing maintenance demand created a need to scale Technical Variance processing from approximately 300 to 450 cases per week.
Lengthy Engineering Turnaround
Technical Variance requests averaged about three weeks from initiation to final response, with substantial engineering effort required for manual drafting.
Inconsistent First-Time-Right Quality
Technical responses had first-time-right rates of 40–50%, with quality gaps leading to additional review and revision cycles.
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Talk To ExpertsThe Solution
Augmenting Engineering Decisions with Governed AI
AI-assisted Technical Response Drafting
- Generates initial Technical Variance response drafts using MRO request context and a repository of previous cases.
- Reduces the manual effort involved in preparing complex engineering documentation.
- Improves consistency while allowing engineers to focus their expertise on review and decision-making.
Human-in-the-Loop Engineering
- Maintains structured human review alongside AI-generated initial drafts.
- Uses built-in safeguards to support a safety-first, regulated engineering process.
- Keeps engineering oversight central while introducing AI into a business-critical workflow.
Trusted AI for Regulated Operations
- Cleared the customer Safety Board review and European Union Aviation Safety Agency audit.
- Achieved EASA (European Union Aviation Safety Agency) approval for production deployment in the aerospace aftermarket environment.
- Creates a trusted basis for extending AI-assisted engineering into additional processes.
From Manual Drafting to AI-assisted Engineering
- AI-generated drafts reduce the effort required to prepare Technical Variance responses while preserving expert oversight.
- Improved consistency helps engineering teams raise first-time-right performance and reduce avoidable revision cycles.
- Regulatory approval provides a trusted foundation for applying AI within other safety-critical aerospace engineering workflows.
Business Outcomes
80%
reduction in engineering draft preparation effort
83–95%
first-time-right quality for AI-generated sections
EASA-approved
for production deployment
Building a Trusted Foundation for AI in Aerospace Engineering
The AI-assisted solution transforms a labor-intensive engineering workflow while preserving the controls required in a highly regulated environment. By combining contextual AI-generated drafts with structured human review and built-in safeguards, the manufacturer can accelerate response preparation and improve consistency without compromising engineering oversight. EASA approval also establishes a trusted foundation for exploring how similar AI-assisted approaches could support additional business-critical aerospace processes.
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