{"id":184450,"date":"2025-06-18T10:42:36","date_gmt":"2025-06-18T09:42:36","guid":{"rendered":"https:\/\/www.aviationbusinessnews.com\/?p=184450"},"modified":"2025-07-15T11:45:48","modified_gmt":"2025-07-15T10:45:48","slug":"digital-twins-delivering-value-in-mro-activity","status":"publish","type":"post","link":"https:\/\/www.aviationbusinessnews.com\/in-depth\/digital-twins-delivering-value-in-mro-activity\/","title":{"rendered":"Digital twins: Delivering value in MRO activity"},"content":{"rendered":"

Digital twins \u2013 virtual replicas of aircraft or components \u2013 are predicted to transform MRO in a variety of ways.<\/h4>\n

“Be prepared!\u201d \u201cFailing to prepare is preparing to fail!\u201d There are many common phrases and sayings which involve preparing or being prepared, and they usually have a good dollop of wisdom behind them. The ability to anticipate events in aircraft operations can be the differentiating factor between success and struggle. It often begins with the design of an aircraft, which nowadays is created with maintainability in mind. Here, virtual reality (VR) has been used for many years, ensuring accessibility for maintenance technicians throughout the aircraft and engines.<\/p>\n

Gaining deeper insights<\/h5>\n

The latest advance in this area is the digital twin, which is a facsimile of a real aircraft or engine. Pete Boeskov, director of commercial training, digital and analytics at Boeing Global Services, explains how a digital twin differs from VR designs. \u201cWe should differentiate between physical objects and virtual or digital tools,\u201d he begins. \u201cVirtual reality can be an effective tool to interact with under-design digital models\/concepts. Whether a designer builds a physical mock-up or prototype, or uses a digital tool like VR, the goal is to gain a deeper understanding of the model or system.<\/p>\n

\u201cA digital twin, however, is a digital representation of a physical object. Only after we create a physical item can we then create a digital representation of it,\u201d Boeskov emphasises.<\/p>\n

\u201cIn the operational space, a digital twin collects all the life experiences and data of the represented object or system. We are working on digital twins of components, systems, aircraft and airports. A digital twin can include information as extensive as what material was used, where it was mined, who machined it, what machine it was created on, and more. This allows analysts to interrogate the twin to deliver more accurate insights,\u201d he adds.<\/p>\n

\u201cDigital twins offer the possibility of superior data-driven decision-making and the desire for enhanced operational understanding and optimisation, accurate simulations and future predictions to enable levels of integrated vehicle health management that exceed existing capabilities,\u201d Boeskov remarks.<\/p>\n

Airbus takes a similar view, noting that VR is utilised in the industry \u201cto mimic costly and\/ or dangerous situations, or to simulate a specific experience\u201d, according to a company spokesperson. \u201cFor example, designing assembly stations for part installations in tight spaces, we use VR to ensure that there is enough space for the necessary equipment and that the technician can manoeuvre and perform the required action.<\/p>\n

\u201cThe digital twin of an aircraft is used to represent an often complex element (aircraft, engine, part, process and so on) in order to test scenarios and the impact of each of these scenarios. This then enables data-driven decision-making,\u201d the spokesperson adds.<\/p>\n

\"Digital<\/a>
Credit: Lufthansa Technik<\/figcaption><\/figure>\n

Dinakar Deshmukh, vice president of data science at GE Aerospace, notes that the company has been developing and applying digital twins for well over a decade to help build and scale predictive maintenance capabilities. \u201cUsing artificial intelligence (AI)\/machine learning (ML)- driven digital twin engine models, we\u2019ve been able to expand the number of conditions that can be monitored with greater accuracy and identify needed maintenance measures well ahead of time,\u201d he explains. \u201cThese models have enabled us to achieve a 60% earlier lead time identifying preventive maintenance measures, a 45% increase in detection rates, and cut the number of false alerts in half over the past decade.\u201d<\/p>\n

Deshmukh continues: \u201cThe key difference with a digital twin is that it is a living, learning digital model that reflects the current state or condition of the physical engine it is modelling. It is a virtual replica of its physical counterpart at any given point in time. We do this by continuously updating our digital twin models with the latest data from sensors (virtual and physical) that monitor the condition of critical components and processes with the engine, from fleet data of what other similar engines are experiencing across the fleet, and from the insights of our engineers who design and monitor these engines.\u201d<\/p>\n

Observing this technology from an MRO provider vantage point is Dr Jean- Philippe Kremer, senior engineer performance and product owner engine health management at Lufthansa Technik (LHT). \u201cAs an MRO, we are not really involved in the design of entire aircraft,\u201d he says. \u201cHowever, certain fields of our overall business can also entail the application of VR or AR technology.<\/p>\n

\u201cJet engines are not typical consumer goods where it\u2019s all about design and looks \u2013 it\u2019s about efficiency, durability, maintainability and so on,\u201d Kremer adds. \u201cA digital twin from a propulsion engineering perspective thus goes way beyond the pure visualisation aspect as it is a lot more sophisticated and can be seen as a multitude of sub-models, each one being focused on\/catering to a specific use case.\u201d Multiple MRO disciplines Potential users are now looking at the advantages of digital twins across the different MRO disciplines such as predictive maintenance, optimisation of repair schedules and reducing downtime. Kremer picks up the theme. \u201cWell-designed models based on physical fundamentals help understand cause-and-effect pathways. Downstream fine tuning or improvement by ML models is facilitated if all known influences have been correctly modelled,\u201d he remarks. \u201cThese algorithms are then able to find previously unknown correlations and further improve accuracy.<\/p>\n

\u201cFor engine health management, a digital twin allows quicker detection and diagnosis of small initial faults and failures, before they become issues impacting flight operations. Raw sensor data from the engine or aircraft shows high scatter and does not always directly point to the root cause of the failure, so our digital twin can be seen as a \u2018decoding device\u2019, transforming data into information and knowledge,\u201d Kremer continues. \u201cAdditionally, they allow us to integrate our own know-how from an MRO perspective so we do not have to rely solely on black-box systems designed by the OEM.\u201d<\/p>\n

For GE Aerospace\u2019s Deshmukh, the big advantage of digital twins is the earlier lead times they provide for understanding the maintenance needs of critical parts. \u201cDigital twins give us the ability to forecast maintenance well before the need has even materialised, which then allows us to plan ahead with our repair schedules. That, in turn, helps reduce the downtime for how long an engine needs to be in a shop,\u201d he explains. \u201cIt can even inform adjustments to our longer-term material forecast to the new-make supply chain if our physics-based models indicate the component will not be repairable at the upcoming maintenance event.\u201d<\/p>\n

Boeing\u2019s Boeskov hones in on digital twins in the world of predictive maintenance. \u201cHere, digital twins are used to increase maintenance efficiency and reduce aircraft downtime by analysing the data to anticipate maintenance needs, while also ensuring the right components are available when and where they are needed,\u201d he elaborates. \u201cFor example, general processor modules (GPM) are prone to overheating for a variety of reasons. This results in early failures for parts of the GPM and scheduled interruptions for the aircraft while the GPM is replaced.\u201d<\/p>\n

Boeskov continues: \u201cWe can track the configuration of GPMs across the fleet, in addition to tracking which parts have been installed and for how long. We can also measure the temperature on the internal boards and aggregate them across the life of the part. This allows us to develop an understanding of which parts are at risk of failure, plan for replacements of those parts and work with the supply chain to get the parts ordered and on-hand.\u201d<\/p>\n

According to Airbus, MRO activities can be mapped in a digital twin so that the company can always have a clear view of what\u2019s happening in the maintenance chain \u2013 mapping all the chain and the link between each action or actor \u2013 and even simulate scenarios and find the most optimal slot allocation for an urgent task, with respect to its required skills, equipment and parts. \u201cThis can enable the company to see the impact of a problem throughout the whole chain and also to easily define and implement possible solutions,\u201d the spokesperson notes.<\/p>\n

Making business sense<\/h5>\n

Utilising digital twins has to make sense for a business. There needs to be a positive effect for the customers of MRO organisations \u2013 the airlines \u2013 in areas such as aircraft availability, cost savings and enhanced safety.<\/p>\n

For an MRO, according to Airbus, the creation and optimum use of a digital twin should make it possible to improve processes and therefore save time and money through more effective decision-making and better prevention of problems. \u201cThis has a direct impact on aircraft availability and therefore on the airline\u2019s profits,\u201d the spokesperson emphasises.<\/p>\n

\"Digital<\/a>
Credit: Airbus<\/figcaption><\/figure>\n

The LHT<\/a> view of the business case from Kremer centres on digital twins being all about understanding a system and its sensitivities. \u201cThis improved insight can then be made available to the customer \u2013 in the case of engine health management, through timely fault detection and customised maintenance recommendations, possibly even pointing out several courses of action, allowing the airline\/customer to integrate them into their maintenance schedule at their convenience,\u201d he explains.<\/p>\n

Kremer adds: \u201cPunctual interventions help maintain or improve engine performance and thus aircraft availability, while information improving the scheduled engine removal process leads to cost savings by preventing impact on operations and expensive secondary engine damages. Our goal is to support our customers in their journey to an improved operational excellence.\u201d<\/p>\n

According to Boeskov, when describing the value of a digital twin, the twin does not necessarily deliver value or savings. \u201cThey come from the insights that are derived from a digital twin that truly make an impact in the highlighted areas of increased aircraft availability, cost savings and enhanced safety,\u201d he says.<\/p>\n

Boeskov adds: \u201cWhen we can find ways to increase the efficiency of MROs, that leads to reduced costs for operators, and increased profits for the MRO. When we detect a component failure early and recommend replacement, that reduces surprises and enables an early aircraft delivery from a maintenance check, enabling a faster return to revenue service and improved aircraft reliability.<\/p>\n

\u201cDigital twins deliver value when their insights are implemented well, saving operators cost, reducing repair times and putting aircraft back into service faster. Additionally, they enhance safety by reducing the risk factors that are involved in inspections and repairs,\u201d Boeskov emphasises.<\/p>\n

GE\u2019s Deshmukh is another who believes that digital twins help deliver better outcomes. \u201cFor us, that\u2019s principally with aircraft availability and fleet management, by helping us see and identify issues earlier, and by expanding the number of conditions that we monitor 24\/7,\u201d he comments.<\/p>\n

\u201cWith MRO shops, it\u2019s not unusual for them to experience an escalation in workscopes for engines coming for service. The insights from our AI\/MLenabled digital twins are helping us predict part needs ahead of time so that we can be ready with the right materials and personnel to make any needed repairs,\u201d Deshmukh explains. \u201cWe can also avoid any undue delays and find alternative, more cost-effective solutions for replacement parts for our customers in the form of used serviceable material (USM).\u201d<\/p>\n

With many undoubted attributes, one would expect enthusiastic adoption by the MRO industry. \u201cOn an engineering level, the enthusiasm is definitely there, but turning use cases into business cases remains a challenge,\u201d says LHT\u2019s Kremer.<\/p>\n

Boeing\u2019s Boeskov points out that seeing the value of digital twins requires a big picture view. \u201cMROs don\u2019t exist in isolation, but are part of a larger ecosystem including operators, the supply chain and OEMs. The ability and willingness to share data across the lifecycle is foundational to maintaining a digital twin,\u201d he concludes. And that means being prepared!<\/p>\n

 <\/p>\n","protected":false},"excerpt":{"rendered":"

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