AI in Aviation Maintenance: Supporting, Not Replacing, the Human Factors

The mere mention of Artificial Intelligence (AI) can bring uncertainty—fear of the unknown, confusion, and concerns over job security. But as AirVenture attendees and others demonstrate year after year, our industry is also full of people with a natural curiosity, thirst for innovation, and a willingness to embrace new technology. Whether it has reached your shop directly, indirectly, or not at all yet, AI is here and is seeping fast into our industry’s core processes. As a proud teammate of “The People Company,” I hope to shed light on this new arrival, decreasing some of the fear and increasing some of that natural curiosity.
As Directors of Maintenance (DOMs), your role is a constant balancing act—ensuring every aircraft is safe and airworthy, coordinating inspections and maintenance schedules, managing vendors, training technicians, and staying on top of FAA compliance. It’s a high-pressure job with no room for error.
Enter AI—not as a replacement for your expertise, but as a powerful assistant to help DOMs and their teams make better, faster, and more informed decisions. There’s been plenty of buzz about AI, along with confusion. What is it? How is it different from automation? Will it replace jobs?
Let’s clear that up: AI isn’t here to take maintenance jobs away. AI cannot turn a wrench, remove panels, nor perform inspections. It’s here to help you do your job more efficiently and effectively. When used responsibly, AI handles repetitive, data-heavy tasks—freeing maintenance professionals to focus on what they do best: protecting the value of capital-intensive assets entrusted in their care, improving aircraft reliability, and ensuring readiness to dispatch.

Navigating the Maze of Compliance

At the recent NBAA Maintenance Conference, Gregory Feith, former Senior Air Safety Investigator with the National Transportation Safety Board (NTSB), revealed that many of the aircraft they investigated weren’t actually airworthy… because of paperwork. One missed sign off, one transposed number, or one absent form mistakenly filed in the wrong binder, and the airworthiness certificate is no longer effective, according to FAA regulations.
Regulatory compliance is as critical as it is time-consuming. AI can serve as a maintenance assistant, consolidating aircraft records, and tracking compliance with OEM guidance and regulatory requirements. AI can also be your digital watchdog, flagging potential gaps before they become problems. That kind of support doesn’t just check a box—it gives you peace of mind that every aircraft remains safe, compliant, and ready to fly. It also helps you protect the aircraft’s resale value, ensuring potential buyers that all documentation is in order.
Human interface is more critical than ever. Having a qualified technician review digital documents for issues such as uploading errors is essential. By combining AI-powered data tools with people-first leadership and training, DOMs can both ensure compliance and still have time to build high-performing teams that are not only technically sharp but also collaborative, adaptive, and focused on customer service.

Smarter Maintenance Scheduling

One of the biggest challenges DOMs face is juggling inspections and scheduled maintenance without disrupting flight schedules.
Take, for example, a scenario in which a Chief of Maintenance – Dan – starts his day scanning maintenance logs and the flight schedule. A red flag pops up: a jet en route to Tucson is scheduled to continue to Teterboro later that day—but is due for maintenance before arriving in New Jersey. Dan springs into action. He alerts flight scheduling to reassign another jet, coordinates with techs, verifies parts, and works with flight ops to minimize downtime. And of course, we know that all of this falls into place easily with no stumbling blocks, right?
But with AI, the situation can unfold differently.
AI-powered systems can analyze flight logs, component usage, maintenance history, weather patterns, and runway activity to forecast the best time and place for scheduled work. In this case, it might have identified a window of downtime in Arizona early that morning—just enough to complete the inspection without disrupting the day’s plan.
With Dan having oversight and the final authority to schedule his aircraft’s maintenance, AI can take on the complex analyses, freeing Dan to focus more on leading his team, optimizing processes, and ensuring safe, seamless operations.

Cutting Through Supply Chain Chaos

Delayed shipments or unavailable parts can quickly derail a maintenance schedule, grounding aircraft and frustrating clients.
Craig, who manages maintenance for a private fleet, opens his inbox to find a familiar problem: a critical part is not in the parts inventory, as previously thought. It’s the kind of curveball that causes cascading disruptions. The part is needed for a minor scheduled repair on an aircraft departing later that day.
This is where AI can have a strategic edge.
Predictive algorithms can anticipate parts requirements based on OEM guidelines, wear patterns, flight activity, and known supplier lead times. With that kind of foresight, DOMs can stock smarter—ordering high-risk components in advance, avoiding last-minute scrambles, and maintaining smoother operations even when the global supply chain hits turbulence. AI can also assist technicians in tracking their own stock parts, keeping track of life-limited parts and notifying them when a part required for a scheduled maintenance event is no longer available.
AI helps DOMs like Craig move from reactive to proactive, minimizing the disruptions that can frustrate operators and clients.

Doing More With Less—Easing the Workforce Gap

The aviation industry continues to face a persistent shortage of skilled technicians, forcing maintenance teams to do more with fewer hands.
At one MRO, two technicians just left, and three planes are scheduled for service. The DOM, Becky, is juggling more than the floor—she has also been asked by an aircraft owner
to provide a detailed analysis of internet capabilities onboard, including three upgrade options and pricing.
Becky is not sure where to start. Researching and writing an executive brief is not her strength.
This is yet another area where AI can be of assistance.
Using tools like ChatGPT or Microsoft Copilot, Becky can prompt the system with the specifications and request. Within minutes, she has three comparison options drafted. She still needs to verify the technical accuracy and tailor the summary—but instead of hours of research and writing, she can focus on what matters: providing expert recommendations and facilitating a solid decision.
AI does not replace expertise—it enhances it. It provides assistance, support, a watchful eye, and other job-critical functions that allow maintenance leaders the time to lead, solve problems, and support their organization and team.
Of course, technical knowledge and support is just one side of the coin. Great maintenance teams also need strong communication, critical thinking, and leadership skills. That is where programs like those from ServiceElements come in—offering tailored professional development for business aviation. Workshops on human factors, emotional intelligence, change management (especially great if you are newly integrating AI) and aviation-specific leadership equip individuals and teams to thrive under pressure, communicate clearly, and deliver exceptional service.

Another essential tool in your toolbox

Yes, AI can seem intimidating at first. But it’s not about taking over jobs—it’s about lifting up the professionals who keep aircraft in the sky. With today’s workforce shortages, technician expertise is definitely still needed, even in organizations taking advantage of AI.
By automating manual tasks, simplifying complex decisions, and streamlining multi-step processes, AI allows DOMs and their teams to focus on what really matters: safety, reliability, and providing value to the people and organizations they serve.
In leveraging AI in your department, you may find that it transforms from a cause for fear and confusion into another essential tool in your toolbox.

Michelle Morrison

Michelle is a facilitator, consultant and coach with ServiceElements.  She has over 25 years as a professional serving F100 global consulting firms to enhance organizational culture and design and facilitate professional learning.  Her core capabilities include change management, leadership and professional development, project management and performance consulting. Michelle lives in Cincinnati, OH with her four teenaged daughters, two dogs and four cats.  She lives near her parents – her Dad is a retired private jet pilot and her mom is a retired FBO owner – so she comes from a family passionate towards the flight industry!  She also serves as a PMI SW Ohio board member. Michelle currently combines her education (MBA and Project Management Professional (PMP) certification), experience, and passions to serve individuals in the business aviation industry.