AI-Assisted Repair Management for Predictive Aircraft Readiness

CBM+/Predictive Maintenance

Problem Statement: Military flightline maintenance often depends on printed schedules, radios, whiteboards, manual forms, disconnected spreadsheets, and the memory of experienced personnel. These methods are familiar, but they do not create a persistent, shared operating picture. During aircraft generation, multiple teams coordinate in real time while commanders try to understand changing aircraft status, open issues, support constraints, personnel availability, parts impacts, and launch risk. Critical minutes are spent reconstructing status while the launch window is already closing, and operational history often disappears after radio calls, paper turnover, or end-of-shift cleanup.

Description of the Innovation Solution: MFE FORGE is an AI-assisted flightline maintenance and aircraft generation technology that digitizes today’s live workflow into one repair management and decision-support environment. It was intentionally modeled close to the processes maintainers already follow, then improved by digitally capturing handoffs, status checks, repair progress, support requests, safety events, lost tool reporting, and commander-ready summaries. Its AI layer uses current launch conditions, historical repair outcomes, weather impacts, support queues, personnel constraints, and aircraft-specific patterns to predict bottlenecks, explain delay drivers, estimate launch risk, and recommend earlier human-led action. The “Launch Success Advisor” provides probability for Go / Watch / Intervene guidance before a delay risk becomes unavoidable.

Benefits to the DOW: FORGE reduces status chasing, strengthens coordination, preserves turnover knowledge, and converts daily maintenance actions into reusable data for root-cause analysis and predictive decision-making. Benefits include faster aircraft recovery, fewer maintenance-driven delays and cancellations, improved readiness visibility, better manpower and support planning, and more informed commander decisions. These actions improve the mission complete and mission capable rates. Although built around Air Force-style aircraft generation, the same coordination problem exists across Army, Navy, Marine Corps, Coast Guard, and DLA-supported sustainment environments.

Innovation Challenges: Key challenges are global workflow standardization, data quality/compliant entry, integration into existing business rhythms, and ensuring AI recommendations remain explainable and human-led. Cybersecurity is currently a design strength, using AWS GovCloud, CAC/PIV identity controls, audit logging, role-based permissions, and secure cloud container architecture.

Technical Maturity / Demonstration Results: FORGE has been tested in a live parallel environment. Earlier testing showed 50% faster event and issue reporting and identified two one-hour bottlenecks not obvious through the legacy process. It is ready now as a commercial SaaS product but flexible for other arrangements.