�����ؿ�

In the aerospace and defense (A&D) industry, every second counts. Maintenance, Repair & Overhaul (MRO) operations must run like clockwork — delays are unacceptable. Yet, one of the most persistent and costly disruptions in these workflows is caused by something seemingly trivial: not knowing where critical tools and components are — such as torque wrenches, borescopes, engine cowls, landing gear actuators, tool carts, spare parts containers, or storage bins.

Aircraft on Ground (AOG) events — when an aircraft is grounded due to technical issues — can result in losses running into millions, not to mention penalties from contracts with airlines. But what if the root cause is not a complex technical failure but a single missing part — especially a reusable component (rotable)?

What does AOG (Aircraft on Ground) mean?

AOG refers to situations where an aircraft must remain grounded due to a maintenance issue until it is resolved. These events trigger immediate action to repair or replace components. AOG incidents disrupt flight schedules and impair military readiness — with consequences for safety-critical missions and enormous costs for airlines and service providers. The situation becomes particularly expensive when the cause is a missing or unavailable rotable.

The Silent Profit Killer: Why a Few Rotables and Missing Tools Cause the Majority of AOG Costs

Rotables are high-value aircraft components — such as avionics systems, brakes, or actuators — that can be maintained, overhauled, and reused multiple times. These parts are essential for safe operation and are subject to strict maintenance schedules. When they are missing or delayed, the consequences are serious.

A detailed study of a Boeing 777 fleet at an airline revealed that only 25 out of 115 parts — merely 21.74% — accounted for a staggering 91.04% of AOG-related costs.

But it’s not just rotables causing problems: a misplaced special tool — such as a rivet gun, engine mounts, or a calibrated torque wrench — can also bring an entire repair process to a halt.

And the problem isn’t confined to individual MRO workshops. Worldwide, support equipment like engine mounts and specialty tools regularly go missing or arrive late — due to a lack of transparency. Despite multimillion-dollar infrastructure investments, many MROs still rely on paper-based systems, isolated Excel spreadsheets, or tribal knowledge to locate critical parts.

The Outcome?

• Average replacement cost per AOG event: $8,785
• Average flight delay cost per AOG event: $22,754
• Total cost per incident: over $31,500

And that’s before factoring in ripple effects on schedules, productivity, and operational readiness. Boeing estimates a single AOG event can cost anywhere between $10,000 and $150,000 per hour depending on the aircraft type and route. Every unmanaged hour compounds operational and financial damage.

MRO teams know these causes all too well:

• Delays due to missing or misallocated parts
• Degradation or misuse of certified components
• Maintenance backlog caused by missing rotables
• Cost explosions due to emergency procurement or express manufacturing

An ABC analysis of rotable usage and delay frequency confirms what technicians have long known: a small number of components and tools cause the majority of problems.

But it’s not just about cost — it’s about transparency

These critical assets often vanish in uncoordinated supply chains, move between locations, or fall completely out of sight — due to insufficient tracking. Whether a torque wrench is missing from a local hangar or engine components get lost en route between continents, the result is the same: downtime and disruption.

In an industry where every minute counts and global processes interlock, real-time transparency of critical assets is no longer optional — it’s mandatory. What’s needed is a system-independent tracking approach that connects data, location, and process across tools, rotables, and fleets — wherever they are.

How Real-Time Tracking Prevents Costly AOG Events

Real-Time Location Systems (RTLS) close gaps in transparency and traceability. By combining technologies like Ultra-Wideband (UWB), RFID, GPS, and BLE, aerospace companies gain precise and immediate insights into the location of their tools, rotables, and assets — anytime, anywhere, with high accuracy.

With the �����ؿ� Platform, maintenance and logistics teams in the A&D sector can integrate various tracking technologies and benefit from:

• Increased work efficiency through automated workflows
• Automatic alerts when parts or tools go missing
• Tracking work-in-progress (WIP) through all maintenance phases
• Improved quality control and on-time delivery
• Locating rotables with 10 cm accuracy in fully stocked warehouses or hangars
• Regulatory compliance through automatic logging
• Predictive maintenance via digital twins and performance analytics

From Reactive to Proactive: Rethinking AOG Management

It’s not just about real-time tracking — it’s about intelligent, automated, and connected processes. When MRO organizations centralize their asset data, integrate it with existing ERP/MES/WMS systems, and automate workflows, they reduce turnaround time (TAT), minimize disruptions, and maximize readiness.

For rotables, this means:

• No more lost inventory: Real-time tracking and automatic bookings ensure every part, tool, or component is always locatable
• No more duplicate express orders: Avoid costly reordering triggered by incorrectly assumed losses
• No more maintenance stops or contractual penalties due to unknown part locations or conditions: Real-time location guarantees fast access to needed parts, preventing delays caused by untraceable assets

Conclusion: Visibility = Readiness

In aerospace and MRO, the cost of not knowing is enormous. Whether a rotable or special tool — lacking immediate visibility of critical assets causes delays that ripple through flight schedules, military readiness, and budgets.

The solution is clear: real-time asset tracking. With platforms like �����ؿ�, key assets — especially rotables — are always visible, traceable, and available when needed. In an industry where the difference between “Grounded” and “Go” can hinge on a single missing part, operating without full transparency is no longer an option.

Benefits in numbers:

• 20–35% reduction in AOG and turnaround times
• $5–15 million saved per site per year by avoiding losses and rework
• Return on investment in under 1 year

As one of the top 5 players in aerospace put it about �����ؿ�:
“We aimed for ROI within a year — with �����ؿ�, we achieved this goal. Moreover, the solution fundamentally changed our materials management. Our team now automatically tracks material usage and monitors expiration dates for materials in freezers, directly impacting our efficiency.”

Ready to reduce AOG times and maximize readiness?

‍Discover how real-time solutions can transform your MRO processes — schedule a free demo today.

‍

Sources

.

‍

‍