Case Studies

Aircraft maintenance planning for a US Airline

A US-based airline sought to improve aircraft maintenance productivity by efficiently disseminating work to optimize the available resources. The airline wanted to develop variable standards to provide a customized workload plan that met the needs of the airplane and managed time efficiently.

Infosys incorporated changes in the business practice and process for the aircraft maintenance planning system. We implemented the project using J2EE technologies and frameworks. Our approach resulted in an efficient and cost-effective method to assign and control work at line maintenance stations.

Business need

The existing aircraft maintenance procedures were inefficient, resulting in wastage of manpower and material, and provided unrealistic workload. The Field Maintenance Reliability (FMR) results were not measurable, as all FMRs were assumed to be addressed. Work was being routed to ‘maintenance opportunity’, ignoring station capability.

In addition, aircraft maintenance parts were being ordered based on an unrealistic Bill of Material (BOM) process. A large number of parts shipped from other stations were unused. Manual ordering of parts was inefficient, since GDS commands and transactions had to be keyed in sequentially for each part.

The role of Infosys

Infosys produced an automated manpower and resource-based overnight workload for line maintenance stations. The Bill of Work (BOW) was driven by a sophisticated operations research algorithm.

We consolidated FMR parts and Aircraft on Ground (AOG) information for stores and created the Bill of Material. We generated a close-to-real Bill of Material early in the day. Since Bill of Material is driven by Bill of Work,the incidence of unused, ordered parts reduced significantly.


Infosys used operations research algorithms for effective work scheduling and aircraft parking. We executed the project in a co-development mode with the customer and followed an iterative model.

In addition, we automated processes such as Bill of Material to check package and non-routine work, parts ordering, and AOG processing.


Our approach realized several benefits:

  • Optimized Bill of Work – to do the right or required maintenance on time
  • Optimized workload – provides credit for all manpower activities, exposes inadequacies of staffing
  • Management can derive useful metrics to measure station performance, work deferral patterns and manpower distribution
  • Effective inventory management
  • Reduced expenditure on inter-station shipping tickets
  • Unified graphical user interface (GUI) eliminated manual systems, ensuring faster operations
  • Seamless integration with other systems such as aircraft routing, flight operations, and work-card management
  • High satisfaction among users at stores in maintenance stations
Cookie Settings