Transition Toward a Sustainable MRO Business in Aviation
Why is it important to rethink internal MRO processes and make them more sustainable?
The world of aviation is changing, with global warming imposing tremendous pressure on the airline industry to reduce its carbon footprint while simultaneously addressing economic and social factors to become more sustainable. Every part of the value chain must reflect on its own level of sustainability – including the aviation maintenance, repair, and overhaul (MRO) business.
This article demonstrates opportunities for improving an MRO company’s own operations to become more sustainable. It offers a holistic view of the environmental, economic, and social aspects that can be improved to achieve a more sustainable MRO footprint. Maintenance managers may use this article as a high-level handbook and identify aspects that they can follow up on within their organization.
According to the Greenhouse Gas Protocol report by the World Business Council for Sustainable Development and the World Resources Institute, a company’s emissions are divided into three scopes: Direct emissions fall under Scope 1, whereas Scopes 2 and 3 include all emissions that are indirectly produced and not fully within the company’s control. Thus, the focus of this article is on Scope 1 emissions.
Which aspects can potentially help an MRO organization to become more sustainable?
Analyzing equipment and tools is one of the most obvious opportunities to reduce emissions within an MRO company’s own operations. Using an all-electric vehicle fleet, for example, can significantly reduce emissions. Maintaining complex aircraft requires a variety of different tools and machines. Monitoring the life cycle of these devices and replacing them early on with more modern, energy-efficient versions ensures lower energy consumption.
Being sustainable is not just about reducing emissions – it is also about changing one’s mindset. Therefore, it is important for an MRO operator to train and educate its personnel to adopt greener behavior and practice a more conscious use of resources. In addition, robust health and safety standards can support this social aspect of sustainability in the long term. Sourcing from local suppliers can reduce transportation costs and enhance local social stability. Furthermore, it might be beneficial to cooperate with like-minded service providers (e.g. logistics partners) to strengthen sustainable operations.
Immense potential for improving efficiency, and consequently sustainability, lies within the planning department. With the help of digitalization, MRO companies can ensure that the right aircraft is maintained with the correct material and by an appropriately skilled workforce.
Digitalization in an MRO enterprise allows for the statistics-based identification of potential issues in an aircraft before they occur, as well as for the optimization of maintenance schedules. This is achieved through various technologies and tools, for instance:
- Predictive maintenance: using data and analytics, including artificial-intelligence-based tools, to evaluate large and complex datasets in order to predict when maintenance is needed, reducing the likelihood of unexpected failures and minimizing downtime
- Digital twin simulations: creating virtual replicas of aircraft components; allowing for testing and analysis without disrupting actual operations
- Internet of Things (IoT) sensors: collecting real-time data on aircraft performance and health; providing insights for maintenance planning
Furthermore, digital platforms and software play a crucial role in managing an aircraft inventory, tracking assets, and streamlining communication within the MRO operation. These platforms and software enable the better organization and tracking of spare parts and tools, as well as improved communication between maintenance teams and other stakeholders, eventually increasing the availability of spares.
Ultimately, digitalization in an aircraft MRO organization has immense potential to improve efficiency, reduce costs, and enhance the overall safety and reliability of aircraft maintenance.
Optimizing the consumption of utilities
To ensure a successful MRO business, a broad range of utilities is essential – but these also have a measurable impact on the environment. Some of the driving sources of water consumption are for aircraft cleaning, cooling, and the sanitation of the MRO facility, as well as for other industrial processes. Measures on reducing water consumption include investing in water-efficient equipment, in proper inspection procedures, and in incorporating measures to promote the recycling and reuse of water.
From the perspective of energy consumption, an MRO company’s sustainability efforts focus on reducing energy consumption in various aspects of their operations, including lighting; heating, ventilation, and air conditioning (HVAC); machinery; and overheads. This is achieved through energy audits, implementing energy-saving practices, and investing in energy-efficient technologies and equipment. As a real-case example, Lufthansa Technik’s switch from fluorescent lights to energy-efficient LEDs was backed by a convincing case – in one engine shop, the switch would save 600,000 kWh of electricity and reduce carbon emissions by 200 metric tons annually. Additionally, an MRO service provider may incorporate alternative sources of energy, such as installing solar panels and utilizing wind power or biogas, either through switching energy providers or implementing its own renewable energy sources.
Furthermore, green certifications involving the meeting of environmental standards and sustainable practices in the maintenance and repair of aircraft can help MRO operators to reduce their environmental impact and demonstrate their commitment to sustainability toward customers and regulatory bodies. Some common green certifications for aircraft MRO enterprises include ISO 14001, Leadership in Energy and Environmental Design (LEED), and the Eco-Management and Audit Scheme (EMAS).
Rethinking materials and production as an element of change
In addition to all the necessary utilities, MRO companies have a high demand for various materials, including spare parts, raw materials, or consumables like oils and sealers. From a sustainability perspective, two major aspects are important: first, searching for more eco-friendly alternatives, and second, optimizing or reducing consumption.
Raw materials made from recycled content or essential chemicals, such as biodegradable sealers, offer opportunities for developing more sustainable operations. Additionally, major MRO enterprises with high purchase volumes can encourage original equipment manufacturers (OEMs) to develop more eco-friendly products or multi-use products instead of single-use items. The packaging of spare parts, usually following ATA 300 standards, is typically conservative when it comes to safety and hence should also be rethought. Are there any opportunities to use sustainable containers, foam-molded inner parts, or tape for packaging?
Proactive and efficient inventory management is key to reducing material consumption. Aviation lubricants, filters, or chemicals, in particular, have short shelf lives; hence, monitoring and managing the stock can help to prevent unnecessary waste. A sustainable mindset throughout the industry fosters a more cooperative approach. The entire industry could mutually benefit by supporting the commercial exchange of stock materials nearing their expiration dates via online marketplaces. “Housekeeping” in warehouses further helps to reduce storage capacity requirements and save energy.
Commonly, a large amount of waste accumulates after releasing an aircraft back into service. A sustainable MRO business should ensure that waste is segregated as much as possible and work only with certified disposal companies that recycle most of the waste.
In addition to reducing Scope 1 emissions and implementing the aforementioned sustainable actions, MRO operators can also assist their customers in minimizing their environmental footprint. Lufthansa Technik, for example, offers airlines the option to install AeroSHARK®, a durable bionic film that optimizes the airflow around the fuselage, thus realizing significant fuel savings.
Summary and closing thoughts
This article identifies several aspects that an MRO enterprise can consider for more sustainable operations, for instance through the usage of energy-efficient equipment, digitalization, improved material management, or implementation of sustainability measures for various utilities.
Ultimately, costs will play a major role in any management decision. MRO companies can benefit financially either by implementing sustainability measures that will amortize themselves after a short period, such as solar panels, or by boosting their reputation through the promotion of responsible initiatives. Notably, there is no single game-changing measure, like sustainable aviation fuel for airlines. Instead, individual and smart combinations of various actions will yield the best benefit.
In summary, most of the actions are not specific to aviation and can also be applied to any other manufacturing company. Nevertheless, the media pressure on the aviation industry is significant and will motivate all relevant stakeholders along the value chain to become more sustainable across various dimensions.
Lufthansa Consulting, with its dedicated maintenance and sustainability teams, can help you to develop a tailored road map toward a greener MRO business. To learn more and discuss how your organization could benefit from our expertise, please contact us.
Authors:
Yasser Meddaikar is a Consultant in the Solution Group Maintenance & Engineering at Lufthansa Consulting.
Sebastian Pleines-Döpke is a Senior Consultant in the Solution Group Maintenance & Engineering at Lufthansa Consulting.
Yasser Meddaikar Sebastian Pleines-Döpke