Expertise, the right technology, design thinking — and deep-dive analytics
Genpact jumped on board, and helped the company revolutionize its maintenance systems from nose to tail. Our unique approach landed that perfect mix of domain knowledge, digital technology, design thinking, and smart analytics. All this helped the company better harness its sensors and system. Here’s how it played out:
Condition-based remote monitoring and diagnostics
Genpact receives 4 million records a month from a fleet of more than 40,000 engines flying across the globe. We get these records through Aircraft Communications Addressing and Reporting System (ACARS) data transmission models from more than 30 sensors fitted around different components of each engine. Armed with that data, a team of more than 30 engineers in our remote monitoring and diagnostics (RM&D) centers in India and the US analyzes over 190,000 operational alarms per year. That gives customers greater confidence in their asset reliability and performance 24/7/365.
Using a combination of off-the-shelf and custom analytic tools, the team diagnoses problems ranging from fuel consumption to engine blade damage. Drawing on the experience of hundreds of thousands of resolved alarms, the team has developed physics-based algorithms that provide early warning of more than 120 different failure mechanisms.
We combine our deep understanding of the physical characteristics of aircraft with the intelligent application of statistical methods. In that way, we continually improve relevant algorithms to increase the likelihood of finding problems while reducing false alarms. This depth of expertise, as well as operational excellence in executing downstream processes, has resulted in a 50% reduction of false alerts.
Sense and acquire
More than 30 sensors positioned strategically on the engine record key technical parameters several times during each flight phase — take-off, climb, cruise, and descent and landing. These sensors read engine characteristics such as temperatures, pressures, speeds, flows, and vibration. An engine condition monitoring system (ECM) acquires this information in the form of snapshots that indicate unusual engine condition reports and give flight summaries.
A critical aspect of the ECM system is the transfer of data from aircraft to an analytics engine. ACARS digital data-link systems are the primary means of communication. They transmit Aircraft Condition Monitoring System (ACMS) reports via a satellite link while the aircraft is in flight (Figure 1).