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MROs are the backbone of aviation, yet many still grapple with outdated, inefficient systems and processes that hinder their ability to adapt to modern demands.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:
- Transitioning from legacy systems to lightweight, adaptable platforms.
- Digitizing workflows to enable mobility and IoT-driven efficiencies.
- Prioritizing seamless integrations to streamline operations.
- Adopting financial models that align with the sensitive margins of MRO projects.
- Ensuring scalability to support seasonal fluctuations and geographic expansions.
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?
January 9, 2025
