By tapping into the capabilities of AI and robotics for MRO activity, processes can be streamlined, precision can be enhanced, and operational efficiencies can be improved.

“Robots and autonomous industrial vehicles have been utilised for some time already to transport and store material containers and spare parts in our warehouses,” explains Claudia Nehrke, Lufthansa Technik’s head of digital transformation and governance. “Additionally, there is an increasing tendency to employ robots in maintenance processes, encompassing automated inspections, component measurement and repair throughout the entire process chain.”

In 2019, Lufthansa Technik announced it had developed the world’s first robot for cockpit control unit testing, ensuring precision on Airbus A320, A350 and Boeing 787 aircraft. A year later, the MRO provider revealed details about its collaboration with iSAM AG to create an adaptive robot system revolutionising airframe related components (ARC) repair processes, aimed at improving efficiency and safety and reducing material consumption while repairing critical components such as radomes, fan cowl doors and inlet cowls.

But it doesn’t stop there for Lufthansa Technik. Nehrke says: “We are also leveraging machine learning for optimisation challenges. From material management to engine condition monitoring, we are enhancing efficiency, predicting engine behaviour and ensuring smarter decision-making.”

Make light work

Artificial intelligence (AI) and robotics are helping MRO professionals make more informed decisions, optimising maintenance schedules and reducing downtime. “AI and robotics have the potential to streamline processes, enhance precision and contribute to overall operational efficiency,” Nehrke says. “AI, for instance, can be utilised for predictive maintenance, minimising the risk of unexpected failures and ultimately reducing costs. “The ability of AI to analyse vast amounts of data quickly and accurately complements the complexity of modern aircraft systems. This can, for example, lead to more proactive and predictive maintenance strategies, ensuring that potential issues are identified and addressed before they become critical. Robotics, on the other hand, can automate routine and labour-intensive tasks, allowing skilled technicians to focus on more complex and value‑added activities.”

For John Spruce, founder and chief executive of Kane Robotics, a manufacturer of robotic systems for sanding, grinding and finishing, the incorporation of AI is not just about automating tasks but enhancing the entire MRO process. He explains: “Using AI algorithms, cobots [collaborative robots] can analyse complex data, identify patterns and make informed decisions in real time.

“Incorporating AI, through vision system-enabled machine learning algorithms, has contributed directly to increases in efficiency, better decisionmaking and improved safety for the collaborative robot solutions we provide for our customers.”

Spruce adds: “AI-driven robotics enhance safety in MRO activities by executing tasks with precision and adhering to strict safety protocols. With advanced sensors and intelligent algorithms, cobots can navigate dynamic environments while safeguarding equipment and personnel.”

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The human touch

While AI and robotics offer immense potential, there are some challenges that the MRO industry needs to consider.

One of the significant issues is the high initial investment required for implementing AI and robotics. The cost of acquiring and maintaining the necessary hardware, software and infrastructure can be substantial. Additionally, training technicians and staff to work with AI and robotics technologies can also be time-consuming and costly.

Another challenge is the integration of AI and robotics into existing MRO systems and processes. MRO organisations may need to overhaul their existing infrastructure and workflows to fully leverage the benefits of these technologies. This may require significant time and effort, and there may be resistance to change from employees and stakeholders.

Furthermore, while AI and robotics can excel at repetitive tasks and gathering and analysing complex data, they may not possess the same level of adaptability and problemsolving skills as human technicians. Some tasks, especially those requiring complex decision-making or delicate manual dexterity, may still require human intervention.

Lufthansa Technik’s Nehrke says: “Human interaction will always be essential in collaboration with AI and robotics, regardless of technological advancements. While AI and robotics can enhance efficiency and automate certain tasks, human expertise is crucial for complex decision-making, creative problem-solving and adapting to unforeseen circumstances.

“The synergy between human skills and technological capabilities ensures a comprehensive and reliable approach in the field of MRO activities.”

Spruce agrees: “For the foreseeable future, human interaction will be required and even desired. In particular, the development of AI algorithms requires human interpretation of data sets during the ‘training’ of a machine learning algorithm.”

Training and development

As technology continues to advance, Nehrke explains that providing training programmes ensures that Lufthansa Technik’s workforce is well equipped to leverage the benefits of AI and robotics in MRO activities.

She says: “Competent training empowers our personnel to integrate these technologies seamlessly into their workflows, optimise operations, and make informed decisions. But even more than that, we are striving for broad digital literacy throughout the company.”

Nehrke adds: “Digital literacy at Lufthansa Technik embodies a comprehensive skill set, empowering individuals to use the full potential of digitalisation. Investing in digital literacy on all levels ensures that our workforce remains agile, innovative and equipped to thrive in the digital world.”

“There is no way AI and robotics can be successfully implemented without skilled engineers and technicians trained in the implementation and use of these technologies,” notes Spruce. “Their expertise is the basis for the effective integration of these innovations, ensuring that they deliver the best results for MRO organisations.

“Training engineers and technicians in AI and robotics also fosters innovation and adaptation within the MRO industry. Investing in continuous training and development ensures that the workforce remains current with evolving technological advancements that can enhance MRO operations.”

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A better equipped workforce

As automation across the MRO sector increases, there have been some concerns that AI and robotics technologies may replace human technicians, leading to job losses. It is therefore crucial to ensure that the integration of these technologies complements the skills and expertise of human workers, creating new job opportunities and enhancing their capabilities.

For Lufthansa Technik’s Nehrke, the scarcity of skilled labour in the MRO industry is a challenge but she highlights that AI provides a solution by automating routine tasks, relieving skilled labour of rather dull and repetitive tasks associated with MRO operations. “This can allow to focus on more complex tasks and utilise the expertise to create higher added value,” she explains. “Furthermore, there will be less need to deal with uncomfortable working positions, exposure to hazardous materials, or the cumbersome protective gear required for manual handling of such materials, such as dust protection for scarfing composite materials.”

Spruce adds: “AI and robotics are not going to take your job. However, someone utilising AI and robotics to do that job most likely will. These technology advancements are simply enabling better tools that will improve the precision and safety of work while enhancing productivity and ensuring good quality. Yes, AI and robotics will reshape jobs, but they will also create new opportunities and roles within the industry.

“Embracing these advancements means upskilling and adapting to new technologies, ultimately leading to a workforce that is better equipped to handle the evolving demands of the aviation MRO sector. Throughout this transition, it’s crucial to prioritise reskilling programmes and workforce development initiatives that empower the workforce to take advantage of these beneficial technologies.”

Beyond streamlined efficiencies

The future prospects of AI and robotics in MRO are promising, with trends such as machine learning and collaborative robots already shaping the industry.

For Kane Robotics’ Spruce, the combination of robotics and AI has the potential to enhance every aspect of MRO operations, from optimising maintenance procedures and improving safety protocols to reducing environmental impact. He says: “In an industry where safety is non-negotiable, the integration of AI and robotics is an opportunity to strengthen safety measures. Beyond just streamlining processes and boosting efficiency, these technologies can help to identify potential hazards and mitigate risks in real time, protecting the well-being of personnel and the integrity of aircraft systems.”

This feature was first published in MRO Management – April 2024. To read the magazine in full, click here.