Case Study: Aircraft Manufacturing Company improves aircraft engine monitoring and reduces flight disruptions with Genpact

Highly refined monitoring fuels growth for a flight engine maker

Aircraft Manufacturing Company worked with Genpact to make sense of millions of flight records generated by more than 38,000 aircraft engines around the world. The challenge was to monitor engine conditions in real time, identify potential failures early, and prevent events that could lead to downtime, delays, cancellations, or in-flight incidents.

Genpact implemented a condition-based remote monitoring and diagnostics solution using ACARS data, sensor analytics, and physics-based algorithms to prioritize alerts, diagnose issues, and support faster maintenance decisions. The program helped avoid nearly 400 events, reduced false alerts by 50%, and contributed to major savings for airlines by reducing delays and cancellations, with reported impact of more than $250 million a year and as much as $2 billion in savings cited in the case study.