Transforming Aerospace & Defense MRO with Digital Solutions

The Aerospace & Defence MRO Tipping Point: Are You Ready for the Future?

Discover how Digital Threads, AI, and Next-Generation Solutions are revolutionizing Maintenance, Repair, and Overhaul(MRO) operations.

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Abstract

The Maintenance, Repair, and Overhaul (MRO) sector in Aerospace & Defense is at a pivotal crossroads. Organizations face mounting pressure to reduce turnaround times, expand operational capacity, and leverage real-time data for faster, more informed decisions. Simultaneously, the demands of maintaining quality, readiness, and regulatory compliance are growing increasingly complex and urgent.

This whitepaper explores the accelerating transformation of the MRO landscape. It examines how emerging technologies—digital threads, AI-powered analytics, and paperless workflows—reshape sustainment strategies. Discover how leading organizations embrace digital evolution to boost operational efficiency, ensure mission readiness, and stay ahead in a rapidly changing environment.

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Key Insights

Digital tools fundamentally transform the Aerospace & Defense industry, particularly within the MRO sector. Modern digital solutions deliver measurable value by optimizing workflows, enhancing data integrity, and supporting stringent regulatory requirements. Advanced MRO platforms now harness vast volumes of data to enable more precise planning, faster execution, and predictive decision-making—all while significantly reducing reliance on manual processes. Industry studies suggest that digital transformation can minimize human error by up to 43% and boost operational efficiency by as much as 71%.

The shift to paperless MRO processes eliminates administrative bottlenecks and significantly improves operational efficiency. Digitization enhances traceability by enabling seamless documentation and retrieval of maintenance records, ensuring that every component’s lifecycle is accurately captured and easily accessible. This streamlines compliance with regulatory requirements and reduces downtime by accelerating the flow of information across teams and systems. As a result, paperless MRO is becoming a cornerstone of modern sustainment strategies.

With the global MRO market projected to reach $119 billion by 2026, the case for digital transformation has become a strategic imperative. As demand grows, so does the need for scalable, data-driven solutions that can deliver cost savings, enhance asset availability, and ensure operational excellence. A digitally integrated MRO ecosystem enables organizations to manage complexity, increase agility, and remain competitive in an increasingly fast-paced and regulated environment.

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Driving Collaborators

This whitepaper results from a strategic collaboration between Frost & Sullivan, iBase-t, and Tech Mahindra. It is grounded in insights from a comprehensive survey conducted by Frost & Sullivan, capturing the perspectives of MRO professionals across Tier 1 and Tier 2 suppliers, airline and military operators, and leading third-party MRO providers. The expert input gathered through this research has been critical in shaping the key findings, strategic insights, and actionable recommendations outlined in this report.