Robinson Helicopters predict and deliver parts before they are needed, an efficient process thanks to our vertically integrated factory in Torrance, California, where 85% of our parts are manufactured.”
Over at Sikorsky, “The digital tools we’re using
in
rotorcraft maintenance bring several advantages, including improved predictive maintenance, reduced maintenance costs, and increased aircraft availability,” Schmidt said. “By leveraging these AI-powered tools and platforms, we’re able to improve the safety, efficiency, and performance of our rotorcraft.”
The rotorcraft industry’s adoption of digital tools is doing more than just making mechanics more efficient. “AI- driven analytics transform maintenance from
being reactive to predictive,
analyzing inputs to detect early warning signs of component wear or system issues,” Campagna said. “This predictive capability is a practical form of a digital
twin, where aircraft real-
world conditions are mirrored digitally, enabling proactive interventions. Instead
78 Sept/Oct 2025
of waiting for components to fail, the system identifies potential issues early, allowing maintenance teams to schedule interventions in advance. This reduces unscheduled downtime, optimizes fleet availability, and ensures operational readiness.”
The benefits from digitally backed predictive maintenance are very real. “Clients benefit directly through higher dispatch reliability, reduced operating costs, and improved safety margins,” he
said. “Predictive maintenance
also optimizes life cycle management by preventing unnecessary part replacements and extending component service life. The combined effect delivers greater operational efficiency, cost savings, and assured mission readiness.”
Bridging the Knowledge Gap
There is no doubt that Baby Boomers are the human knowledge base of the rotorcraft maintenance industry. The problem is that they are retiring, leaving younger, understandably less- knowledgeable technicians to fill the
void. “The experienced technicians who have spent decades working on these machines are retiring, which if not addressed will create a knowledge gap that no amount of automation can fill,” said Maria Aguirre, head of MRO for Airbus Helicopters in North America.
This is where the Digital Revolution can help bridge the gap. “By digitizing the legacy knowledge of retiring mechanics, such as converting paper manuals, notes, and tribal knowledge into a digital format, we can ensure this critical information is not lost,” Smith said. “This helps us pass along decades of mechanical intuition and skills, setting the next generation up for success.”
Even with the digitization of legacy data, the need for a direct non-digital transfer of knowledge from one generation to another remains. This is why Airbus Helicopters is reassigning some of its veteran technicians from doing hands- on repairs to training younger, newer employees. “This approach allows us to capture all that critical knowledge — the things you can only learn from years
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