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:
- Workforce Scheduling Aligned with Operational Needs: Dynamic task assignments and workforce forecasting to ensure the right resources are deployed efficiently.
- Seamless Supply Chain and Inventory Management: Real-time insights into inventory levels and calibration schedules to prevent delays caused by unprepared tools or missing parts.
- Adaptive Management of Non-Routine Tasks: Workflows designed to integrate unplanned repairs smoothly into existing schedules without disrupting operations.
- Streamlined Billing and Cash Cycles: Automated billing processes integrated with finance and accounting systems ensure prompt invoicing, accurate tracking of customer agreements, and support for multiple-currency invoicing. A dedicated customer portal enhances transparency, enabling clients to monitor milestones, progress, and billing statuses, improving financial flows and customer satisfaction.
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
February 4, 2025
