Author: Gabija Purkinaite

No business can operate in 2024 without advanced computers and software, but following recent significant technology failures in the global commercial aviation market, software developers are met with increased scrutiny and skepticism. Less than two years after the world-famous failure of IT systems forced U.S. low-cost carrier Southwest Airlines to cancel more than 17,000 flights at a cost of $825 million, airlines and airports across the world were again gripped with massive failures in software systems that brought backlash from news media, political leaders, and civil courts alike. While these IT failures have become more prevalent, Sensus Aero, a next-generation aviation software expert and part of the Avia Solutions Group, is running a complex testing regiment alongside the use of a trusted enterprise backbone with years of experience proving increased operational reliability. These reliable technologies have been combined with cutting edge components to build the software that the company is developing for maintenance, repair, and overhaul (MRO) organizations. Edmundas Sostakas, Chief of Technology Officer at Sensus Aero, shares how the company has leveraged a trusted and modern  technology stack, combined with the next generation innovations to build a robust software solution for MRO and ground-handling companies. After a decade of development, the company is now launching its MRO application ahead of global expansion. “We have engineered reliability as a core design priority in our application, which enables us to guarantee up to a 25% increase in MRO efficiency along with trusted modern technologies and real-time data integration. These combined factors enable our software to provide crystal-clear visibility into process gaps, empowering businesses to make informed decisions with greater agility,” Sostakas said. “Our rigorous testing process and incorporation of proven frameworks have strengthened the trust we’ve built as more customers adopt our modular ERP software.“ While Sensus Aero’s application is new to the industry, the developer has already proven the technology through experience within its parent company Avia Solutions Group.  Sensus Aero’s team of developers worked with Avia Solutions Group to develop an understanding of aviation businesses’ needs and implement software solutions that have enabled the group to expand globally in the last decade. When the company began building competence and different aviation solutions for the group to become the world’s largest provider of aircraft, maintenance crew, and insurance (ACMI) services, the product architects chose to build on technologies with proven dependability to bring this software to the market as a comprehensive, stand-alone enterprise resource planning application covering all business processes. Sostakas added that the experience from Avia Solutions Group made sure that scalability was a part of the applications design. Given the applications original field experience for MROs that are expanding across the world, every subcomponent and feature of the application was selected for the ability to keep pace with industry growth. “Our application is powered by Oracle, the largest and most commonly used database management system (DBMS) in the world, ensuring trusted reliability that users are familiar with in enterprises,” Sostakas said. “To enhance user experience, we also turned to trusted yet modern technologies like Meta’s React framework to create intuitive and easy-to-use interfaces. Originally developed by Facebook and now backed by Meta, React is a reliable framework that will drive product growth while delivering a top-tier user experience.” “We understood that the React framework would continue to become more widespread when we adopted it, and I am happy to incorporate it to give the reassurance of a familiar interface to our customers,” Sostakas said. “The React components in our application have a proven track record, powering some of the largest networks in the world.” Now powered by a robust technology stack, including Oracle and React, Sensus Aero has initiated multiple layers of testing to further prove its reliability. The application is already deployed at MROs across the world such as FL Technics, Sensus Aero is conducting unit, automated integration, functional, performance, and security testing to mitigate the possibility of future disturbance. While these testing practices are common in software development, Sensus Aero leverages its insights into efficiency to accelerate the progress of its testing processes. “Our team is now able to complete regression testing with only one-sixth of the man-hour costs, paving the way for us to test more with less time, this optimization is exactly what we aim to deliver to our customers, helping them reduce man-hours while maintaining quality” Sostakas said. “This is crucial because we have developed a modular system with optional microservices that can be tailored to various customers. Enhanced testing capabilities help prevent the kind of challenges presented during the recent Crowdstrike disruption.” Sostakas added that the Sensus Aero software was designed to be deployed either on a customer’s existing on-premise or cloud infrastructure, or in our maintained cloud as a Software as a Service (SaaS) solution. This flexibility is crucial as it ensures compliance with heightened security standards required for sensitive locations and government facilities. Sensus Aero has already applied its systems for some of the largest MRO groups in Europe and has agreements to expand to additional locations in Asia next year. The company said that it would continue to test and build its system for the MRO and ground-handling industry so the increased efficiency can spread further into the market. In the MRO business, clear communication and transparency are paramount for success. MRO organizations and their customers often face challenges in keeping track of real-time project updates, approvals, and resource allocation. In response to these needs, Sensus Aero has not only developed but is now upgrading its Customer Portal (CP)—a key add-on to its modular MRO ERP system. Built by MROs for MROs, the Customer Portal is designed to enhance transparency, streamline processes, and deliver real-time data that empowers clients to make more informed decisions. Marius Mocevicius, Sensus Aero’s MRO Product Owner, explains the motivation behind these upgrades:
“The Customer Portal was developed with direct input from MRO professionals. With these upgrades, we’re further aligning our features with the evolving needs of the industry. Our goal is to make communication smoother and operations more visible for both MROs and their clients.”
As the portal evolves, feedback from the MRO community has played a crucial role in shaping the improvements and new features that will enhance operational efficiency and customer interactions. Upgrading Project Visibility and Customization A core benefit of the Customer Portal is the ability to provide customers with comprehensive project summaries, offering insights into critical data such as estimated vs. approved man-hours. This gives clients a clear overview of resource allocation and project progress. As part of the ongoing upgrades, the platform will offer more customizable views—allowing certain information, such as routine work lines, to be hidden for clients who have pre-purchased fixed work packages. This feature ensures that only relevant data is displayed, making the interface more user-friendly. The introduction of visual elements, such as pie charts, is also under consideration. These enhancements aim to improve the readability of statistical data, allowing users to grasp key project metrics at a glance. By focusing on data visualization, Sensus Aero hopes to create a more intuitive user experience. Improving Job Card Transparency Another upgrade to the Customer Portal is aimed at enhancing the visibility of Job Cards. Users will have the ability to expand each job card to view detailed information about labor and parts, without needing to approve each item individually. This streamlined approach will allow customers to easily track the status of work being performed on their aircraft, providing full transparency and eliminating unnecessary steps in the review process. This enhanced visibility is expected to foster greater collaboration between MROs and their clients, ensuring smoother communication, reducing delays, and improving overall efficiency. Refining the Labor Approval Process Sensus Aero is also upgrading the labor approval process to provide clients with more transparency around changes in approved hours. One planned feature is the ability to track the history of labor approvals, so clients can see not only the latest approved hours but also previous approvals. For instance, if the initially approved hours were 25 and were later changed to 30, the portal will display both the original approval and the adjustment, ensuring full visibility into the changes. Additionally, a new Reject button will allow clients to reject proposed changes with a reason, which will be communicated directly to the MRO team. This feature aims to enhance communication and ensure that all stakeholders are aligned throughout the project. Driving Innovation in MRO Software Solutions The Sensus Aero Customer Portal provides MROs and their clients with a more streamlined, efficient, and transparent way to manage communication and maintenance projects. By upgrading features in direct response to customer feedback, Sensus Aero continues to demonstrate its commitment to providing solutions that meet real-world needs. The ongoing developments aim to enhance MRO efficiency, communication, and overall customer satisfaction. These upgrades represent the exciting possibilities for how the Customer Portal can further transform MRO operations, elevating the customer experience and positioning Sensus Aero as a leader in next-generation MRO software solutions. In the world of Maintenance, Repair, and Overhaul (MRO) operations, a well-oiled supply chain is essential. Managing parts, warehouses, kits, stock levels, vendors, and procurement processes requires precision and efficiency. Sensus Aero ERP addresses these critical needs with a comprehensive, integrated approach that ensures every aspect of your supply chain is under control. Demand fulfillment: precision in planning At the heart of effective supply chain management is the ability to meet demand without delay. Sensus Aero’s system empowers material managers and planners to fulfill requests seamlessly, whether automatically or manually. The system aggregates all demands, allowing for fulfillment from various stock locations or, when necessary, initiating procurement. This flexibility ensures that the needs of the operation are met efficiently, with minimal disruption. Stock level planning: maintaining balance Managing inventory is a balancing act, where too much or too little stock can have significant consequences. Sensus Aero’s stock level planning features provide the tools necessary to maintain optimal inventory. With the ability to set minimum and maximum stock levels and reorder points, the system can automatically trigger orders—whether for single items or bulk purchases—ensuring that your operation is always prepared without the risk of overstocking or shortages. Advanced inventory tracking Sensus Aero goes beyond simple inventory management by incorporating advanced tracking features that enhance both accuracy and compliance. Shelf life tracking Components with a limited shelf life require careful monitoring. The system’s shelf life tracker automatically monitors expiration dates and issues alerts as items near their end-of-life. This proactive approach allows for timely decisions on whether to scrap, inspect, or extend the life of parts, maintaining high safety standards and minimizing waste. Exchange and serviceable part tracking The system also tracks exchanges, serviceable (SV), and unserviceable (UNSV) parts, providing full visibility of each item’s status and location. This comprehensive tracking ensures that every part is accounted for, reducing the risk of loss and ensuring that the right parts are available when needed. Vendor management and procurement: streamlined processes Vendor relationships and procurement processes are crucial to maintaining a reliable supply chain. Sensus Aero’s procurement module simplifies these tasks by automating purchase orders and tracking the entire procurement process. The system also allows for effective vendor management, ensuring that you receive the best terms and that your supply chain remains resilient. Seamless integration for comprehensive control Understanding the complexities of MRO operations, Sensus Aero ensures seamless integration with other essential systems, such as HRMS, Finance, and CAMO. This integration provides a unified view of operations, enhancing overall efficiency and control. Maximizing efficiency across the supply chain With Sensus Aero ERP, supply chain management is transformed from a challenging necessity into a streamlined, efficient process. From demand fulfillment to inventory tracking and procurement, every step is optimized to reduce waste, improve accuracy, and enhance operational performance. As your MRO operation grows, having a robust and integrated supply chain management system in place is crucial. Sensus Aero ERP ensures that your supply chain is not just managed but optimized for the demands of the industry. Ready to see how Sensus Aero can revolutionize your supply chain management? Let’s explore the possibilities together. In the fast-paced world of aviation, where every second counts, imagine a digital platform that adapts as quickly as your operations. Whether it’s ensuring flawless ground handling services, streamlining hangar maintenance at your MRO, or orchestrating a seamless customer experience through our customer portal, technology is no longer just a tool—it’s the engine powering every movement on the tarmac and in the sky. This is the future we’re shaping with Sensus, where cutting-edge technologies meet the dynamic demands of the aviation industry, delivering real-time, flawless digital experiences to our partners. At the heart of this transformation is React, the backbone of responsive and visually dynamic systems that ensure your operations are managed with precision. Whether it’s optimizing staff scheduling or tracking maintenance workflows, React ensures every click, update, and interaction is as fast and fluid as the aviation world demands. On the mobile front, we rely on React Native to deliver Android and iOS applications that feel custom-built for every device in use, ensuring operational consistency. But what makes it all tick behind the scenes? Enter Node.js—the powerhouse behind Sensus’ real-time data processing, ensuring every piece of critical information flows seamlessly across your systems. And for growing aviation businesses that require scalable, adaptable solutions, Nest.js provides the perfect architecture to expand alongside your needs without losing a beat. Aviation never rests, and neither do we. In an industry where even a slight delay can ripple through the system, every millisecond matters. That’s why we trust RabbitMQ to be the reliable, lightning-fast messenger that ensures your communications—whether between teams, departments, or systems—reach their destination without delay. For those complex, performance-intensive tasks, Golang effortlessly handles the heavy lifting, maintaining efficiency even under the high pressure of peak travel periods. And in an industry where data is king, turning raw numbers into actionable insights is key to staying ahead. With TIBCO Jaspersoft, you can generate detailed reports that help you make informed decisions, from optimizing turnaround times to profit margins. Rest assured that your data is securely managed with Oracle, ensuring your sensitive operational information is safe and always accessible when you need it most. Quality control is non-negotiable in aviation, and we apply the same principle to our technology. With Webdriver.io, our rigorous automated testing guarantees that every part of your digital infrastructure works flawlessly before it goes live. Coupled with GitLab, updates and new deployments are handled seamlessly, minimizing any disruption to your operations. Whether your systems are grounded in local servers or take off into the cloud, flexibility is built into every layer. With Docker, deployments are smooth and rapid, while Kubernetes ensures that even under high demand, your operations run without interruption, keeping up with the fast-paced tempo of modern aviation. But here’s the real story: this isn’t just about technology. It’s about crafting digital experiences that support your aviation business, empower your teams, and delight your customers. It’s about balance—merging the precision of next-generation technologies with the seamless, user-centric experiences that Sensus is built to deliver. In a world where aviation never stops, neither do we. We’re here to ensure your digital platforms grow with you, adapting to the ever-changing landscape and keeping your operations running smoothly every step of the way. Sensus isn’t just a solution—it’s a partner in your success, using the power of technology to turn complex challenges into seamless operations. Whatever your vision for the future of aviation, we’re here to make it a reality. Managing aircraft and components in today’s fast-paced MRO environment is no small feat. The demands of the industry require precision, efficiency, and a robust system that can adapt to ever-changing needs. At Sensus Aero, we’ve built a modular ERP solution that’s designed specifically for these challenges, ensuring that MROs have the tools and speed they need to succeed. Aircraft management & Component handling: The core of your operations Sensus Aero’s M&E module has become the backbone for many in the aviation industry, providing a seamless and efficient way to manage a wide range of aircraft and components. Aircraft management Creating and configuring aircraft and models in the system is straightforward and precise. The system allows for easy management of registrations, serial numbers, and maintenance manuals, integrating these processes to ensure smooth workflow transitions from planning to execution. Advanced production planning Our Gantt Chart view and Hangar Plan Module enables MROs to visualize their entire production plan, making it easier to manage slots and packages based on capacity and demand. This tool is invaluable whether you’re planning for the long term or managing day-to-day operations, ensuring optimal resource allocation. The system’s team and shift planning capabilities also allow for effective management of overcapacity or resource shortages, helping MROs stay ahead of potential bottlenecks. Enhancing efficiency in hangar maintenance Sensus Aero’s prepackage loader is designed to prepare maintenance tasks even before the aircraft arrives, ensuring that everything is ready for execution as soon as the plane hits the hangar. Real-time tracking of each step—from mechanic or engineer clock-ins to material requests—provides full visibility into all hangar activities, ensuring that no detail is overlooked. Tailored solutions for unique needs The flexibility of Sensus Aero’s system is one of its standout features. Whether an MRO requires a full suite or specific modules to manage base, line or component maintenance, the system adapts to meet the unique needs of each operation. Integration with existing systems, such as HRMS, Finance, CAMO, or any other essential software, is seamless, offering complete control over operations and enhancing overall efficiency, fully understanding the current ecosystem of the MRO business. Unlocking the full potential of MROs Sensus Aero’s approach is not just about addressing current challenges but preparing MROs for future growth. As the industry continues to evolve to become paperless, so too does our system, ensuring that our clients are always equipped with the latest tools and technologies. The results speak for themselves. Clients have reported a significant increase in billable hour efficiency, jumping from 50% to 80%, which translates to a 30% increase in revenue. Additionally, the quoting process, which once took a week or two, can now be completed in just less than 2 hours, freeing up valuable time and resources and effective quoting. As we continue to refine and expand our offerings, Sensus Aero remains committed to helping MROs achieve new heights of efficiency and profitability. Let’s explore how Sensus Aero can be the partner you need to unlock your full potential. Book a free consultation or demo now!  In the dynamic world of aviation, efficient management of Ground Support Equipment (GSE) is crucial. The Sensus Aero GSE Management Module integrates advanced features to enhance safety, efficiency, and reliability in airport management, presenting a well-rounded solution to modern aviation challenges. This module allows full control of all equipment, while monitoring its usage and technical health. The GSE Module utilizes mobile devices for various checklists, where the ‘Driver role’ can execute tasks as set by the ‘GSE Manager role’. Sensus Aero GSE Management enables: • Daily Checklists • Technical Checklists • Customized Checklists • Tracking of In-use/Out-of-service status • Repair & Inventory Management Seamless Management of Every Detail Our comprehensive GSE Module digitalizes how you manage all ground support and additional equipment. With a few clicks, you can access a wealth of technical information about each piece of equipment – from the manufacturer, model, and registration details to purchase and retirement dates, asset codes, and more. For organizations operating across multiple stations, you’ll love the ease of sharing information and migrating equipment, complete with all historical data, checklists, and repair records. Intelligent Document Tracking and Compliance Say goodbye to missed deadlines and expired documents. Our system, tailored to your organization’s setup, enables the GSE Manager to effortlessly track and control document expirations and plan for technical inspections. You’ll get daily reminders about expiring documents, and if action isn’t taken, equipment status updates automatically to ‘out-of-service’ to ensure compliance and safety. Collaborative Workflow for Efficiency Our GSE module is designed to foster a smooth flow between different organizational roles. The GSE Manager can set up daily checklists, kickstarting a process where each Driver, using a tablet or mobile device, completes a detailed checklist before operating any equipment. This includes recording motohour counts, taking photos, and checking fuel levels or battery percentages. Any faults? They’re instantly notified to the GSE Manager and relevant roles, then seamlessly transferred to our Repair Management Module. Comprehensive Technical Checklists and Fault Management Customize technical checklists for every piece of equipment with varying frequencies – daily to annually. During checks, any faults detected are immediately sent to the Repair Management Module, where Mechanics plan and resolve issues, keeping your operations smooth and uninterrupted. Beyond the Basics: Specialized Checklists and In-Use Monitoring Our system allows for the creation of specialized checklists, such as pressure checks, ensuring that no detail is overlooked. The status of each equipment piece updates automatically based on checklist findings, keeping Mechanics informed of any non-critical issues while ensuring the equipment remains in use. Efficient Repair Management and On-Demand Reporting All faults from checklists and maintenance tracking are logged into the Repair Register. Mechanics can then manage and execute repairs, tracking progress with a color-coded system for clarity and efficiency. Need data? Our on-demand reports provide historical data, current plans, and status checks at your fingertips. Sensus GSE Management extends its capabilities beyond traditional management with the potential incorporation of IoT and Telematic devices. This enhancement allows for real-time monitoring and smarter management of ground support equipment, leading to increased operational efficiency and more informed decision-making. We also specialize in the development of Virtual Reality (VR) Training modules, offering a modern approach to staff training. This method provides a practical and interactive learning experience, ensuring that your team is thoroughly prepared for their roles in aviation ground handling. Furthermore, our system is designed for seamless integration with the Sensus Aero Ground Handling Resource Management Solution. This integration ensures cohesive management of ground operations, harmonizing various aspects of ground handling and equipment management into a streamlined workflow. In summary, our GSE Management system is not merely a tool for day-to-day operations but a step towards creating a more connected, efficient, and expertly trained ground handling team. Technological innovations today impact all business sectors. The aviation industry is no exception; companies are turning to more advanced software. However, they usually face resistance to change. Why is it worthwhile for businesses to invest in innovative solutions and be determined to step into a future that guarantees more efficient management of processes and resources? Renata Sumskaite, CEO of Sensus Aero, a company that develops software for aviation and is part of the globally operating aviation holding Avia Solutions Group, shares her insights on the subject The Aviation Industry Lacks Challenges Sumskaite points out that one of the main reasons why the aviation industry is not embracing changes quickly and investing in new technological solutions is the lack of challenges. According to her, compared to other business sectors, no one questions the work of aviation companies or creates more advanced, better-performing alternatives as a challenge. The exclusivity and privacy of the industry limit opportunities and development. “Aviation is extremely comfortable; everything here happens very slowly. No one challenges us – no one is even able to challenge us. For example, banking, the payment sector has an infinite number of ideas. Startups emerge every day. And aviation is highly private. As a result, there are no challenges. Only those currently working in aviation, those who have worked before, or those who will work in the future can bring something new. Do these people do it? I think it’s quite difficult for them. After all, nothing has changed in the last four decades,” Sumskaite assures. Start Point of Change is Analysis According to the CEO of Sensus Aero, the change should begin with the analysis of existing processes, “Every company’s leader occasionally looks at their business risks – which ones are the biggest, most likely to happen, and causing the most damage. Changes should start with what happens most frequently and costs the most. In the Avia Solutions Group, we all feel a duty to contribute to the improvement of the aviation industry through technology – we constantly invest in new, innovative technological solutions, striving to be at the forefront. After all, the beginning of any change starts with a leader’s perspective on the business and the issues it faces”, Sumskaite assures. “The business must decide the level of the system it needs. If you decide to implement all the latest functions here and now, the project will take 3-5 years and cost way too much. Do we really want to invest that much? For example, in the ground handling sector, we don’t issue invoices for services provided, we lose money, we don’t hire the necessary number of employees because we don’t plan their work based on existing flight information, and we can’t react in real-time when it changes. There is no one-size-fits-all starting point for every business’s journey into innovation. I do not recommend changing everything at once. Start at the point where the greatest financial and personnel losses happen.,” says Sumskaite. The Role of External Specialists R. Sumskaite emphasizes that implementing change within an organization is impossible without an external specialist responsible for planning and executing the entire process from A to Z: ” The involvement of an external expert, in my opinion, is necessary for the effective adoption of innovation. If these duties are performed by an internal employee, there will always be some kind of manipulation because it leads to a conflict of interests.” She also notes that one of the essential responsibilities of this specialist is to find a middle ground between what employees and managers want and what is genuinely needed for a specific business, “Those involved in the change always want a miraculous system. Then it costs an extraordinary amount of money, deadlines extend to infinity, and people become disillusioned with the change because it takes too long, and the results are not visible. An external specialist must manage communication, prepare processes, initiate change, and ultimately facilitate the transition. They find solutions that generate value and return for the specific company.” Human Resources – Key for Innovation The CEO of Sensus Aero points out that organizations often tend to overlook the role of employees and expect extraordinary results solely from technology, “Everyone thinks that technological solutions will perform miracles, in truth, it’s the human behind the technology who plays the key role. We must understand that the human mind is an integral part of innovation; it must be involved in ongoing processes, even within the system itself.” According to her, this is why the external specialist involved in change management should also be responsible for training middle managers”. “Managers need to learn how to manage changes, and they often lack these skills. As we know, significant changes in aviation occur very rarely. Training in human resource management during changes is essential: what their role is at each stage, what needs to be done, what to pay attention to, how to manage themselves and their team. Dealing with people, especially during changes, requires talent, hard work, and patience,” says Sumskaite. Sensus Aero, a developer of new-gen software solutions for the aviation industry and a member of Avia Solutions Group, has announced the appointment of Renata Sumskaite as the company’s CEO. With an extensive background in finance and technology, Sumskaite brings over 23 years of diverse management experience to her new role, having led both in-house and remote global teams. “I am delighted to join Sensus Aero and develop a pioneering IT platform that would become the premier choice for ground handling and MRO (Maintenance, Repair, and Overhaul) organisations. In addition to integrating the latest technology into our software solutions, my vision for the company includes ambitious team development and business growth. The aviation sector needs to ramp up its digitization efforts, and Sensus Aero can help the industry streamline complex processes that still require too much manual input,” Ms Sumskaite says. Emphasising the importance of collaboration with researchers, Sumskaite cites optimising the algorithm for Sensus Aero’s ground handling ERP system among the company’s primary goals. Plans are also underway for integrating advanced technologies such as Artificial Intelligence (AI), Machine Learning (ML), and blockchain into Sensus Aero’s software offering, as well as expanding the company’s virtual reality training package by adding modules for pushback and other business needs. Sensus Aero is a digital technology provider for the aviation industry. The company is developing and providing an integrated Enterprise Resource Planning (ERP) optimisation platform, designed to increase and streamline every aspect of the MRO, Ground Handling, and Fuelling processes. Sensus Aero is part of the Avia Solutions Group family, the world’s largest ACMI provider (Aircraft, Crew, Maintenance, and Insurance), operating a fleet of 192 aircraft.