Category: News

By Jevgenijus Petronis, Head of MRO Product, Sensus Aero  Effective planning remains one of the greatest challenges in MRO operations. The industry still relies heavily on manual processes and legacy workflows, often depending on years of accumulated expertise to navigate complex tasks. This approach frequently results in inefficiencies, extended aircraft downtime, and operational bottlenecks, making the need for streamlined and innovative solutions more urgent than ever.  At Sensus Aero, we are committed to transforming MRO operations by developing and testing next-generation management capabilities. Unlike general-purpose platforms, our software is specifically designed for MRO management and maintenance, backed by years of focused research and development. By streamlining workflows, improving resource utilization, and delivering integrated solutions, we aim to tackle the challenges faced by modern MRO organizations and support both short-term and long-term planning. 

The Core Challenges of MRO Planning 

1. Inventory and Supply Chain Volatility 

Managing inventory and ensuring the availability of critical parts and tools remains a pressing issue in MRO operations. Supply chain disruptions, uncalibrated tools, and delays in part availability can lead to extended aircraft downtime and increased costs.  Striking the right balance between overstocking parts, which ties up valuable resources, and understocking, which risks operational delays, is critical. Proper forecasting, automating pre-orders, integrated inventory systems, and enhanced supply chain visibility are essential to mitigate these risks effectively. 

2. Workforce Planning, Skill & Qualification Allocation 

Aligning workforce capabilities with operational demands is a complex task. Technicians often possess varying certifications and skill levels, such as A-, B-, or C-level qualifications, which must be matched to specific job requirements while meeting compliance standards.  Effective planning must address not only current workforce capabilities but also workload fluctuations and unforeseen absences. Ensuring the right personnel are scheduled efficiently reduces bottlenecks, enhances reliability, and maximizes labor utilization. 

3. Managing Repairs and Non-Routine Maintenance 

Non-routine maintenance tasks can significantly disrupt pre-planned workflows. Whether it’s an unexpected system malfunction or an issue discovered during routine inspections, these events require dynamic planning tools capable of reallocating resources and adjusting schedules in real-time to minimize downtime.  Systems that adapt quickly to changing circumstances are essential to maintaining operational stability and readiness. 

Financial Efficiency and Cash Cycles 

Delayed invoicing, fragmented billing processes, and misaligned cash cycles often create financial bottlenecks in MRO operations. Efficient cash flow management is essential not only for maintaining financial health but also for ensuring timely payments in an industry where delays can cascade across multiple areas of operations.  Profitability margins in MRO projects are often strained by unforeseen bottlenecks, such as NRC orders, which can disrupt planned workflows and significantly impact overall project profitability. These disruptions risk escalating costs and eroding revenue, making it imperative for MROs to monitor financial performance closely.  Streamlined billing systems, integrated into planning workflows, can mitigate these risks by ensuring prompt invoicing and quicker turnaround times for payments. Additionally, incorporating profitability tracking tools into the process allows MROs to monitor projects in real time, ensuring they stay aligned with financial projections. This proactive approach not only safeguards profitability but also supports operational sustainability by identifying potential risks before they escalate. 

Planning for the Future with Integrated Solutions 

Modern MRO planning requires a holistic approach that integrates all aspects of operations—from labor and inventory management to billing and execution.  At Sensus Aero, we are dedicated to addressing these interconnected challenges through our cloud-based MRO management platform, which delivers: 

The Role of Technology in Transforming MRO Planning 

Technology continues to reshape how MRO organizations approach planning and execution. Advanced analytics, AI, Machine Learning, integrated software platforms, and data-driven insights offer significant opportunities to enhance planning efficiency.  At Sensus Aero, we are exploring how predictive algorithms and scenario modeling can help MROs analyze multiple variables—such as workload spikes, part shortages, or resource constraints—to provide actionable recommendations for optimal planning.  By aligning these advanced tools with industry best practices, MRO organizations can overcome long-standing inefficiencies and position themselves for future success. 

A Call to Action for the Industry 

The journey toward operational excellence for MRO organizations begins with addressing key challenges in planning. Inventory management, workforce allocation, and financial workflows are interconnected systems that demand innovative and integrated solutions to achieve seamless efficiency.  At Sensus Aero, we are dedicated to helping MROs overcome these challenges by continuously developing and testing new features and improvements. Our focus is on enabling greater automation, adaptability, and precision, ensuring MRO operations are ready to meet both current demands and future complexities.  As the industry evolves, the question remains: How can MRO organizations continue to innovate and adapt to ever-growing operational challenges? At Sensus Aero, we are committed to leading this evolution, driving advancements in MRO planning and management to support the next generation of maintenance operations.  Jevgenijus Petronis  Head of MRO Product, Sensus Aero  By Furkan Ozgunaydin , Director of Sales and Marketing, Sensus Aero As we step into 2025, I’ve had the privilege of engaging with MRO leaders across the globe – through conferences, meetings with potential customers, and visits to diverse maintenance facilities. These interactions provided a clear picture of the challenges the industry faces and, more importantly, the opportunities to drive meaningful change. MROs are the backbone of aviation, yet many still grapple with outdated, inefficient systems and processes that hinder their ability to adapt to modern demands. Here are the key findings and reflections from last year’s journey.

Legacy Systems: A Sunk Cost Holding Back Progress

One recurring theme was the overwhelming reliance on legacy, highly customized on-premises software. These systems, while once innovative, have become a costly burden to maintain and nearly impossible to migrate without significant disruption. The challenge extends beyond the technical aspects. Many MROs struggle with historical and operational data that is fragmented or misleading, leading to poor decision-making and compounding sunk costs. For component MROs managing complex parts like auxiliary power units (APUs), landing gear, and engines, the lack of comprehensive software to address their unique needs pushes them toward expensive, heavily customized solutions. The industry is crying out for scalable, adaptable systems that can replace these legacy solutions without the operational headaches and financial strain.

Mobility and IoT: Bridging the Gap to Paperless Operations

Another critical takeaway from the field is the growing demand for mobility in hangar maintenance. With technicians working across vast spaces and handling complex jobs, integrating mobile tools, IoT devices, and real-time inventory, tooling, and job card management has become non-negotiable. MROs want to transition incrementally to a paperless environment, but this requires solutions that prioritize usability and connectivity. A mobile-first approach, combined with seamless IoT integration, will enable technicians to access, update, and complete tasks without the inefficiencies of traditional processes.

The Challenges of Implementation and Migration

One of the most persistent pain points in adopting new software is the time and cost of implementation. MROs are cautious, as migrating from legacy systems often involves significant downtime and operational disruption. At Sensus Aero, we’ve addressed this by building solutions rooted in Lean and Agile principles, enabling shorter implementation timelines and smoother migrations. By offering scalable, lightweight systems, we empower MROs to make the transition without compromising their operations.

The Importance of Seamless Integrations

MROs increasingly require software that integrates with OEM databases, supplier portals, quality assurance systems, and financial tools. However, these integrations are often fraught with technical challenges that delay projects and inflate costs. Having robust APIs and a partner who prioritizes seamless integrations can eliminate these headaches. Smooth data flow between systems is critical for optimizing workflows and ensuring compliance, all while reducing the manual effort required to keep systems in sync.

Financial Sensitivity: The Margins That Matter

MROs operate on razor-thin margins, where even a single delayed job card or an AOG order can jeopardize project profitability. A key takeaway from my discussions is the critical need for a technology partner who truly understands these financial realities. Flexible pricing models, such as OPEX-CAPEX hybrids or SaaS options, are increasingly preferred over rigid, high-cost vendor solutions. MROs require adaptable cost structures that align with their operational needs—whether during peak seasons, when part-time or contracted staff are brought on, or during expansion phases that demand additional licenses.

Scalability and Centralized Control

As MROs expand their global reach, the need for centralized solutions becomes critical. Managing operations across multiple locations requires a system that scales effortlessly while maintaining visibility and control. By offering solutions that adapt to fluctuating staffing and stock levels, MROs can avoid unnecessary costs and streamline operations during peak activity. Scalability isn’t just about growth—it’s about providing flexibility to meet the demands of a dynamic industry.

Key Takeaways and a Path Forward

The insights gathered over the past year paint a clear picture: the MRO industry must modernize to keep pace with the demands of a rapidly evolving aviation ecosystem. However, modernization does not mean disruption. By embracing flexible, scalable, and integrated solutions, MROs can overcome legacy challenges without sacrificing operational continuity.

The focus should be on:

The journey to modernization is not without its challenges, but the rewards—greater efficiency, reduced costs, and enhanced operational agility—are well worth the effort. The question is: how quickly can the industry adapt to this new reality? By Matas Stumbrys, Head of Development, Sensus Aero In the fast-paced world of aviation maintenance, keeping aircraft operational isn’t just a technical challenge – it’s a logistical and regulatory battle. MROs today face a perfect storm of obstacles: evolving Aircraft Maintenance Manuals (AMMs) and Maintenance Planning Documents (MPDs), supply chain disruptions, a shortage of skilled labor, constant regulatory demands, and the increasing complexity of customized workflows. Add to this the unique challenges of newer aircraft with their sophisticated systems and older aircraft requiring tailored maintenance processes to meet airline-specific needs, and the pressure on MROs becomes immense. Outdated manual processes, legacy technologies, and organizational silos only exacerbate these issues, costing millions in lost productivity and resources. It’s clear: the industry needs a better way forward.

Agile and Lean: A Powerful Combination for MROs

At Sensus Aero, we’ve witnessed firsthand how the combination of Agile methodologies and Lean principles transforms MRO software development and operations. Both Agile and Lean share foundational principles such as customer-centricity and continuous improvement. While Agile emphasizes adaptability, collaboration, and delivering value incrementally, Lean focuses on eliminating waste, maximizing customer value, and fostering a culture of continuous improvement. Together, these approaches align around the core principle of delivering value with efficiency and precision.

Here’s how Agile and Lean tackle the industry’s biggest challenges:

Breaking Down Silos and Standardizing Workflows: Agile fosters collaboration across traditionally disconnected teams, while Lean emphasizes standardizing processes to reduce variability and waste. Together, these approaches ensure that software development aligns with real-world operational needs and eliminates inefficiencies caused by siloed operations. Adapting to AMMs, MPDs, and Regulatory Changes: Agile’s iterative and incremental approach ensures that software updates prioritize customer needs, enabling quick adaptation to changes in AMMs and MPDs while maintaining compliance and minimizing delays. Combined with Lean principles, workflows are optimized through Value Stream Mapping (VSM), identifying and removing inefficiencies to minimize resource waste and enhance customer value. Modern MRO software further enhances this process by integrating with OEM databases to provide live updates. This ensures maintenance teams always have access to the latest data, boosting compliance and operational efficiency. Creating Adaptable Software for Diverse Needs: From General Aviation to Heavy Airframe Maintenance, MROs require tailored solutions that reflect their unique operational demands. Lean principles guide the creation of adaptable workflows that minimize unnecessary steps, while Agile ensures flexibility, enabling the software to evolve seamlessly with tailored customizations for diverse operational needs. Replacing Manual Processes with Automation: Agile-driven development empowers teams to focus on delivering value by leveraging automation for repetitive tasks like inventory tracking, task scheduling, and maintenance recordkeeping, reducing errors and improving efficiency. Lean principles enhance this by systematically identifying and eliminating waste, inconsistencies, and overburden, ensuring that automation maximizes efficiency while aligning with customer value. Providing Real-Time Transparency and Risk Mitigation: Agile methodologies offer continuous visibility into project progress, allowing MRO managers to identify bottlenecks early and adjust workflows proactively through tools like Sprint Boards in Scrum or Kanban Boards for continuous flow. These visual aids, combined with practices like regular sprint reviews, enable MRO managers to identify bottlenecks early, adapt workflows proactively, and ensure steady delivery of value. Lean complements this by emphasizing flow efficiency and actionable metrics, ensuring workflows are streamlined, disruptions are minimized, and throughput is maximized through continuous feedback loops. Future-Proofing with Scalability and Lean Flexibility: Agile’s adaptability supports the evolution of systems, whether scaling operations to new regions or integrating predictive maintenance tools, ensuring responsiveness to changing demands.

The Power of Agile and Lean in Action

A recent project at Sensus Aero exemplifies how Agile and Lean methodologies are driving real-world impact. We partnered with FL Technics Lithuania, an MRO previously struggling with inefficiencies caused by siloed operations, outdated systems, and complex workflows. Through Agile and Lean principles, we are iteratively replacing legacy systems with a customized ERP solution, continuously delivering value while adapting to evolving needs. Results to date: As the project progresses, we are expanding and scaling the MRO management software to support FL Technic’s new hangars in the fast-growing Asia-Pacific market. This ongoing transformation not only continues to optimize their existing operations but also equips them to manage future growth and regional expansion with confidence and adaptability.

A Call to Action for the Industry

The aviation industry can no longer rely on outdated systems and rigid processes. Agile and Lean methodologies provide MROs with the flexibility, collaboration, and efficiency needed to meet today’s challenges and tomorrow’s opportunities. If your organization is ready to embrace Agile and Lean-driven solutions and unlock the full potential of your operations, let’s start the conversation. Together, we can break down silos, streamline processes, and build a future-ready MRO. Matas Stumbrys Head of Development, Sensus Aero In the dynamic landscape of Maintenance, Repair, and Overhaul (MRO) operations, efficiency and precision are paramount. However, many MRO organizations grapple with entrenched organizational silos, fragmented legacy systems, and manual, paper-based processes. These challenges disrupt smooth operations and hold back the industry’s progress toward modernization. The Challenge of Organizational Silos Organizational silos emerge when departments operate in isolation, each with its own processes and objectives. In MRO settings, this often results in disjointed workflows between maintenance, engineering, procurement, and quality assurance teams. Such fragmentation can lead to miscommunication, redundant tasks, and delays, ultimately affecting aircraft turnaround times and operational efficiency. Fragmented Legacy Systems: A Barrier to Integration Many MROs rely on legacy systems that were implemented decades ago. These systems, while once state-of-the-art, now struggle to keep pace with the demands of modern aviation maintenance. The lack of integration between these systems means that data is often siloed, making it challenging to obtain a holistic view of operations. This fragmentation can lead to errors, inefficiencies, and increased operational costs. The Burden of Manual Processes Despite advancements in technology, manual, paper-based processes remain prevalent in many MRO organizations. Reliance on physical documents for work orders, maintenance logs, and compliance records not only consumes time but also increases the risk of errors and data loss. Moreover, manual processes make it difficult to track real-time progress and generate actionable insights, limiting an organization’s ability to respond swiftly to emerging issues. The Path Forward: Embracing Digital Transformation To overcome these challenges, MROs must embark on a journey of digital transformation. This involves adopting integrated, modular ERP systems designed specifically for the aviation industry. Such systems unify various functions—maintenance planning, inventory management, labor tracking, and compliance—into a cohesive platform. By doing so, organizations can break down silos, streamline workflows, and enhance data visibility across all departments. For instance, implementing a comprehensive MRO software solution can automate routine tasks, reduce human error, and provide real-time insights into operations. This not only improves efficiency but also enables better decision-making and resource allocation. Furthermore, digital tools can facilitate compliance with industry regulations by maintaining accurate, up-to-date records and generating necessary reports with ease. Case in Point: Sensus Aero’s Approach Sensus Aero was built by MRO professionals, directly from the day-to-day demands of the hangar. With years of hands-on testing and industry expertise, this platform addresses the core needs of maintenance teams by covering every step of the MRO process—from quoting and planning to inventory management and billing. Unlike rigid, outdated systems, Sensus Aero’s flexible, modular design allows MROs to adapt quickly, reduce errors, and keep operations running smoothly with clear oversight. Conclusion The aviation maintenance industry stands at a crossroads. To remain competitive and meet the evolving demands of the market, MRO organizations must address the challenges posed by organizational silos, fragmented legacy systems, and manual processes. Embracing digital transformation through integrated ERP solutions offers a viable path forward, leading to streamlined operations, improved efficiency, and a stronger position in the global aviation landscape. In the complex and highly regulated world of MRO operations, managing employee records and administration with precision is essential. From maintaining comprehensive employee records to ensuring compliance, Sensus Aero ERP is designed to streamline these critical functions, allowing your MRO to operate smoothly and efficiently.  Comprehensive Employee Records Management  Managing employee information goes beyond just storing basic details. Sensus Aero’s Employee Records module ensures that every aspect of an employee’s profile is meticulously tracked and easily accessible.  User & Employer Information The system captures all essential employee details, including certificates, signed documents, addresses, emails, and more. This data is securely stored with full traceability, ensuring that every change is logged and can be audited when necessary. With Single Sign-On (SSO) or Active Directory integration managing user identities becomes seamless, with any changes in employee information automatically reflected in the system.  Role Segregation The system enforces strict role segregation based on our customers needs, ensuring that no single user can create, modify, authorize, and approve a financial transaction or vendor-related document. If a user is mapped to roles that might conflict, such as both buyer and approver, the system will issue an alert, ensuring that proper segregation is implemented. This feature helps prevent fraud and ensures that your operations remain compliant.  Overtime Tracking and Release Management  Managing employee time, particularly overtime, is crucial in maintaining operational efficiency and controlling costs. Sensus Aero’s Overtime Tracker allows you to monitor and manage overtime hours effectively, ensuring that all work is properly recorded and compensated.  Release Management Deploying updates and maintaining the system is a critical part of keeping your operations running smoothly. Sensus Aero provides a robust deployment process that allows for controlled release management. We offer training for your IT team to manage deployments in a live environment, ensuring that updates are carried out seamlessly without risking system integrity.  HRMS Integration and Reporting  Integration with your existing HRMS is vital for comprehensive employee management. Sensus Aero can integrate with your HRMS to manage employee records, training, skill assignments, and expiration tracking.  Reporting and Data Integration Sensus Aero offers a variety of standard reports, including Purchase Orders, Quotations, and Invoices, as well as more detailed Management Information System (MIS) reports. For deeper insights, the system integrates with data lakes and other platforms, allowing for comprehensive data analysis and reporting across all modules.  Integration with 3rd Party Software At Sensus Aero, our tech stack is our biggest advantage. Built with the latest and most advanced generation of code, our solution delivers minimal latency and maximum speed, ensuring optimal performance whether on-premise or in the cloud. We understand that MROs rely heavily on a variety of tools and systems, which is why Sensus Aero is open to evaluating and integrating with 3rd party tools, providing a seamless, high-performance experience across your entire operation  Elevating Employee and Operational Management  Effective management of employee records and administrative tasks is vital for the success of any MRO. Sensus Aero ERP offers a comprehensive, compliant, and integrated solution that enhances your ability to manage these critical functions, ensuring that your operations run smoothly and efficiently.  Are you ready to take your employee management and administrative processes to the next level? Let’s explore how Sensus Aero can help you achieve greater compliance, efficiency, and operational excellence.  In the fast-paced world of MRO operations, managing contracts, service level agreements (SLAs), and financial transactions is the backbone of profitability. As MROs face unprecedented challenges—from labor shortages and supply chain disruptions to surging demand—the need for a robust, flexible system to handle these complexities is more critical than ever. Sensus Aero’s Commerce and Finance suite is designed to meet these demands, providing MROs with the tools they need to stay ahead on the books!  Contract Management: Flexibility at Its Core  Contracts are the lifeblood of any MRO operation, and the ability to manage them effectively can make or break your margins. Sensus Aero’s contract management module offers unparalleled flexibility, allowing you to tailor contracts to fit the unique needs of each customer—even within the same organization. Whether you’re dealing with general terms or specific agreements for long-term maintenance cycles like 6-year or 12-year checks, the system adapts to your requirements, ensuring that every detail is captured and managed efficiently.  Cost Management: Accurate and Transparent  In an industry where margins are tight, accurate cost management is essential. Sensus Aero allows you to track labor hours, materials, and non-routine estimates with precision. From detailed maintenance department cost breakdowns to corrective action tracking, every element is accounted for. This transparency helps MROs avoid unexpected costs and ensures that all expenses are clearly documented and easily accessible.  Billing & Invoicing: Precision in Every Transaction  Billing and invoicing are where the rubber meets the road in terms of revenue generation. Sensus Aero supports both quote-based and actual-based billing, allowing for flexibility depending on the contract terms. The system covers all customer requirements, including overheads, non-routine’s , additional charges and handles multi-currency management seamlessly, with live rates pulled from the European Central Bank. This ensures that all conversions are accurate, and any discrepancies are managed effectively, reducing the risk of revenue leakage.  Profit Margin Tracer: Monitoring Profitability in Real-Time  Maintaining healthy profit margins is a constant challenge, especially as work progresses on a complex project. Sensus Aero’s Profit Margin Tracer is designed to help MROs track margins on a per-job, per-customer, or per-region basis. As parts are issued and labor is recorded, the system tracks whether the projected margin will be met, allowing you to make adjustments on the fly. This proactive approach helps safeguard profitability and ensures that potential threats to margins are identified and addressed early.  Customer Portal: Enhancing Client Interaction  In today’s digital age, providing customers with easy access to their accounts and ongoing projects is no longer just a nice-to-have—it’s essential. Sensus Aero offers a customer portal where clients can log in to view project statuses, interact with your team, approve or reject non routine cards or additional parts and labor. This transparency and ease of access build trust and improve customer satisfaction.  Finance Integration: A Seamless Workflow  Sensus Aero is built to integrate seamlessly with financial systems, whether for time and material tracking, procurement management, or aircraft data. With a range of touchpoints and API capabilities, the system ensures that all financial data flows smoothly between departments, reducing the risk of errors and enhancing overall efficiency.  Driving Profitability and Efficiency in MRO Operations  In a challenging market, the ability to manage contracts, costs, and finances effectively is crucial. Sensus Aero’s Commerce and Finance suite equips MROs with the tools needed to navigate these complexities, ensuring that every project is profitable and every transaction is precise.  Are you ready to take control of your MRO’s commercial and financial operations? Let’s explore how Sensus Aero can help you achieve sustainable profitability and operational excellence.  We are excited to announce a key leadership transition at Sensus Aero. Effective October 4th, 2024, Paulius Cegis will officially assume the role of Chief Executive Officer (CEO). Paulius brings a wealth of experience, passion, and a clear vision to position Sensus Aero as a customer-centric leader, delivering scalable and reliable technology solutions that meet the evolving needs of the aviation industry. We also extend our heartfelt gratitude to Renata Sumskaite, whose contributions have been pivotal to Sensus Aero’s growth and success. Her passion, energy, and unwavering commitment to going above and beyond for our customers and stakeholders have played a key role in shaping the company. Fondly referred to as the ‘godmother’ of Sensus Aero—much like a ship has its guiding godmother—Renata has been a driving force in leading the company through critical milestones since she joined. Although she is stepping down as CEO, we are thrilled that Renata will remain part of the Sensus Aero as a member of the Advisory Board for some time, where she will continue to provide invaluable insights and guidance during this transition period. We are confident that Paulius, alongside our talented team, will lead Sensus Aero into a new chapter of growth and success, delivering exceptional value to our clients and stakeholders. 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.