Delta Airlines Predictive Maintenance Use Case

This Use Case/Case Study comes from a discussion between the leaders of the Delta TechOps group and GE Digital. Watch the full video or read full Transcript

✈️ Delta Airlines Predictive Maintenance Program: Summary

Overview

Delta Airlines operates nearly 900 aircraft with 3,000–4,000 daily departures. The airline is poised to add over 200 new planes in the next seven years. To maintain high reliability and efficiency across a growing and aging fleet, Delta has invested heavily in predictive maintenance, data science, and decision-making autonomy.

TechOps & Predictive Maintenance

Alice and Brad lead Delta’s Technical Operations (TechOps) and Predictive Technology Group, which focuses on:

• Engine and aircraft maintenance for Delta’s fleet.
  

• MRO services generating ~$1B annually from external clients.
  

• Predictive maintenance using sensor data and machine learning.
  

• Reliability engineering and decision science to optimize maintenance schedules.

Why a Single Monitoring Platform?

Delta adopted GE Digital’s SmartSignal (originally a small startup) to provide a unified monitoring system across all engine types (GE, Pratt & Whitney, Rolls-Royce). Benefits include:

• Simplified user training.

• Centralized diagnostics.

• Greater autonomy from OEMs.

• Real-time logistics and maintenance decision-making.

Team Empowerment & Real-Time Decision Making

A highly trained team of 8 analysts monitors engine data around the clock. They:

• Make critical flight decisions based on limited data snapshots.

• Trigger control center actions, including engine swaps and part shipments.

• Empower Delta to dispatch spare engines by truck proactively.

🛫 Case Highlight:

A Boeing 777 flying from Atlanta to Shanghai showed turbine distress. Delta deployed a chase aircraft to Shanghai with a fresh engine, averting a serious delay and safety issue.

Data Strategy: “Digital Life Ribbon”

Delta is building a Digital Life Ribbon—a unified data framework that:

• Integrates sensor data, operational history, and maintenance logs.

• Supports tailored maintenance plans by aircraft tail number.

• Informs decisions on asset retirement and investment.
  

Challenges Ahead

• Hiring enough maintainers to support fleet growth.

• Scaling predictive analytics across platforms (Airbus, Boeing, Bombardier).

• Managing data across a fragmented tool ecosystem.

• Driving cultural and organizational change to support data-driven decision-making.
  

Advice for Other Organizations

• Empower technical teams to act on data without bureaucracy.

• Centralize and structure data, making it actionable.

• Build trust over time between analytics teams and operations.

• Develop internal data science capabilities to reduce reliance on OEMs.

Key Quotes

“We don’t want an OEM telling us what to do. We want to control our aircraft.” – Brad
“If we take care of our people, our people will take care of our customers.” – Ed Bastian (CEO, Delta Airlines)

Glossary of Terms – Delta Predictive Maintenance Summary

TechOps (Technical Operations)

The department responsible for maintaining an airline’s fleet, including aircraft, engines, and components. At Delta, TechOps includes predictive analytics and maintenance operations.

MRO (Maintenance, Repair, and Overhaul)

A sector of aviation focused on servicing aircraft, engines, and parts—either for the airline’s own fleet or for external clients (like cargo carriers or military).

Predictive Maintenance

A proactive approach that uses data to identify potential mechanical failures before they happen. It helps airlines avoid unscheduled downtime by detecting early warning signs.

SmartSignal

A GE Digital software platform that analyzes engine performance data to detect anomalies. It enables “predictive health monitoring” across different engine types.

OEM (Original Equipment Manufacturer)

The company that originally made a product—in this case, aircraft or engines. Examples include GE, Rolls-Royce, Airbus, and Boeing. OEMs often offer their own monitoring tools.

“Single Pane of Glass”

A unified dashboard or platform that provides access to data from multiple systems or sources in one place, simplifying decision-making and monitoring.

Snapshot Data (vs. Streaming Data)

• Snapshot Data: A single data point or reading taken at a specific time, like during takeoff.

• Streaming Data: Continuous, real-time data transmission from systems.

Delta uses snapshot data for maintenance decisions due to system constraints.

Borescope

A tool that allows mechanics to visually inspect the interior of engines without disassembly. It’s used to confirm internal damage or degradation.

ACMS (Aircraft Condition Monitoring System)

A system that collects and reports aircraft health data. Teams can program it to track specific performance indicators.

AWS Data Lake

A cloud-based storage solution by Amazon Web Services that allows organizations to store structured and unstructured data at scale. It’s used for advanced analytics, machine learning, and data integration.

Digital Life Ribbon

A term used by Delta to describe the continuous digital history of an aircraft’s operations, maintenance, and performance data, enabling smarter decision-making across its lifespan.

Condition-Based Maintenance

A strategy where maintenance is performed only when data indicates a need, rather than on a fixed schedule. This helps avoid over- or under-maintaining components.

Derated Takeoff

A technique where engines are used at less than full power during takeoff to reduce wear and tear. It extends engine life and reduces fuel consumption.

EGT Margin (Exhaust Gas Temperature Margin)

The difference between actual exhaust gas temperature and the maximum safe operating temperature of an engine. Maintaining a high margin is crucial for engine longevity.