Transforming Military Fleet Readiness with Data-Driven Maintenance
Aero NextGen Delivers Predictive Analytics for a Leading Defense Aviation Provider
Client: Major Military & Defense Aviation Company
Industry: Military & Defense, Mission-Critical Aviation Operations
Teams Supported: Maintenance, Operations, Finance, Data/Analytics
Industry Context
Why Analytics & AI Are Mission Critical in Military & Defense Aviation
The military and defense aviation sector operates at the intersection of complexity, urgency, and accountability. Companies in this space manage fleets of high-value, mission-critical aircraft—often flying unique, non-commercial missions such as adversary air support, electronic warfare training, or tactical mission simulation. Every decision is high-stakes: downtime can compromise national security objectives, and cost overruns can jeopardize contract profitability or future bids.
Historically, these organizations have amassed vast troves of operational data—maintenance logs, flight hours, part usage, and more—often locked away in legacy ERP systems or bespoke data warehouses. The challenge? Turning this raw data into actionable intelligence that drives better decisions, from CAPEX/OPEX planning to predictive maintenance and contract pricing.
Today, the industry is rapidly evolving:
- Predictive Analytics & AI are enabling proactive fleet management, reducing AOG (Aircraft on Ground) incidents, and optimizing maintenance schedules.
- Data Warehousing & Integration are breaking down silos, making it possible to analyze everything from MTBUR (Mean Time Between Unscheduled Removals) to cost per flying hour.
- Cost-By-The-Hour Programs are becoming the norm for large military contracts, requiring precise forecasting and cost control.
- Fleet Readiness is now measured not just by uptime, but by the ability to anticipate and prevent mission-limiting failures.
The Challenge
Our client—a leading provider of mission-critical aviation services to the defense sector—had invested two years and significant resources into building a sophisticated data warehouse. Yet, despite this effort, business analytics and actionable insights remained out of reach for decision-makers. The ERP system in use contained over 10,000 tables, making it nearly impossible for internal teams to navigate and extract the handful of data sets needed for operational and financial reporting.
The business needed:
- Visibility: A clear CAPEX and OPEX view of direct maintenance spend on their fleet of advanced jets.
- Forecasting: The ability to predict maintenance spend, MTBUR rates by part number, and anticipate future needs.
- Actionability: Insights that could drive profitable cost-by-the-hour programs for large military contracts.
- Readiness: A path toward predictive maintenance and AI-driven decision support to maximize fleet uptime and mission success.
The Solution
Aero NextGen’s Analytics & AI Enablement
Aero NextGen was brought in as a trusted advisor and technology matchmaker to break the deadlock. Here’s how we delivered results:
1. Solution Partner Matchmaking
We matched the client with a specialized analytics provider whose Snowflake-native application could securely access and analyze their ERP data—no matter how complex or siloed. This partner’s expertise in aviation data meant they could cut through the noise of 10,000+ ERP tables and zero in on the critical data sets required for advanced analytics.
2. Data Mapping & Business Logic
Aero NextGen led the process of scoping, mapping, and defining the business logic for the analytics dashboards. We worked closely with maintenance, operations, and finance leaders to ensure every metric and forecast aligned with real-world decision-making.
3. Analytics Delivery
Within weeks, the client had access to:
- CAPEX & OPEX Dashboards: Real-time insights into direct maintenance spend across the entire fleet—by aircraft, contract, and mission profile.
- Maintenance Forecasting: MTBUR rates tracked by part number, enabling data-driven inventory and procurement planning.
- Spend Projections: Predictive models to forecast future maintenance costs, supporting the design of profitable cost-by-the-hour programs for military contracts.
4. AI & Predictive Maintenance Roadmap
With foundational analytics in place, the next phase is underway: leveraging AI to detect patterns, forecast work volume, and ultimately enable predictive maintenance. This will help the client avoid AOG situations and keep mission-critical jets ready for deployment at all times.
Strategic Impact
Fleet Readiness: The company is now positioned to anticipate and prevent failures, maximizing aircraft availability for critical missions.
Financial Precision: Real-time, granular cost tracking empowers finance and operations to build competitive, profitable contract bids with confidence.
Operational Agility: Maintenance and procurement teams can now plan proactively, reducing emergency repairs and optimizing inventory.
Competitive Advantage: With advanced analytics and predictive capabilities, the client is setting a new standard for military aviation service providers.
Industry Perspective
The Future of Analytics in Military & Defense Aviation
The shift toward data-driven decision-making is transforming military and defense aviation. Leaders are moving beyond reactive maintenance and siloed reporting toward holistic, real-time insights that drive operational excellence and contract profitability. AI and predictive analytics are not just buzzwords—they’re mission-critical tools for:
- Maximizing Fleet Uptime: Predicting and preventing failures before they impact readiness.
- Optimizing Spend: Pinpointing inefficiencies, reducing waste, and supporting more accurate, defensible contract pricing.
- Winning Contracts: Delivering cost-by-the-hour programs with certainty, transparency, and data-backed credibility.
- Continuous Improvement: Using every flight hour, maintenance event, and part replacement as an opportunity to learn, adapt, and improve.
Aero NextGen is at the forefront of this transformation—helping military and defense aviation leaders unlock the power of their data, accelerate their digital journey, and deliver mission success.
Ready to turn your data into mission success?
Contact us at Ask@aero-nextgen.com to see how Aero NextGen can help your organization unlock actionable insights and predictive capabilities—no matter how complex your data landscape.
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Aero NextGen matched us to the right solution providers that helped us standardize the data in such a way that we can now put it to use. Aero Nextgen’s ability to quickly understand the business needs and translate them into tangible solutions was impressive.
Ben Te Beek
Chief Executive Officer
Aero NextGen matched us to the right solution providers that helped us standardize the data in such a way that we can now put it to use. Aero Nextgen’s ability to quickly understand the business needs and translate them into tangible solutions was impressive.
Ben Te Beek
Chief Executive Officer
Aero NextGen matched us to the right solution providers that helped us standardize the data in such a way that we can now put it to use. Aero Nextgen’s ability to quickly understand the business needs and translate them into tangible solutions was impressive.
Ben Te Beek
Chief Executive Officer
We have been struggling to performance manage our shopfloors for ages. Aero NextGen has connected us to solution providers that solved this for us within weeks. We are now capable of tracking capacity, productivity, utilization, and operational efficiency with instantaneously. The level of expertise has made the engagement seamless for our internal teams.
Kenneth Wierzba
IT and Security Director – Safran
My experience working with Aero NextGen is extremely positive. We setup a battery shop in the middle of Brexit in under 6 months with their help. Thoroughly professional. Attention to detail is second to none with innovative and creative ideas.
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Mark Conroy
Managing Director at Avia Component Services
Aero Next Gen quickly identified our challenges and matched us with the right ERP solution. Their expertise saved us time, and transformed our MRO operations.
Daniel King
President of MRO Services Americas at IAG Aero Group
We generate a tremendous amount of data. Aero NextGen matched us to the right solution providers that helped us standardize the data in such a way that we can now put it to use. Aero Nextgen's ability to quickly understand the business needs and translate them into tangible solutions was impressive.
Ben Te Beek
Chief Executive Officer at SK AeroSafety Group
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