Transforming Chronic Fault Resolution for a Commercial Airline
Discover how a leading commercial airline achieved fleet-wide visibility through hourly updates rather than daily ones, significantly enhancing maintenance efficiency using Veryon Defect Analysis.
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~50% reduction
33% fewer
10% less
"The old system would miss it. Once we brought in Veryon, we realized the chronics were always there—we just didn’t see them."
Fleet Specialists Manager | Commercial Airline
About this commercial airline
The challenge
A leading Commercial Airline faced growing pressure to reduce chronic faults across its global fleet. The airline’s internal ATA-based defect management tool had significant limitations: updates ran only once a day, and recurring issues were often siloed under different ATA chapters, making them nearly impossible to correlate.
“You wouldn’t see if you had an APU error problem that could be in Chapter 36 or Chapter 49. The old system would miss it. Once we brought in Veryon, we realized the chronics were always there—we just didn’t see them.” - Fleet Specialists Manager.
This lack of visibility created inefficiencies, with repetitive log entries and unnecessary crew write-ups piling up before problems were solved. Maintenance leaders needed a system that could surface hidden issues faster and provide actionable insights across the entire fleet.
The solution
In 2019, the airline deployed Veryon Diagnostics and Defect Analysis to modernize its approach.
The new platform introduced:
- Natural Language Processing (NLP): Grouped defects across chapters and captured spelling variations, abbreviations, and shorthand mechanics commonly used.
- First-Time Fix Classification: Highlighted the most effective corrective actions upfront.
- Fleet-Level Dashboards: Delivered insights by tail or across the entire fleet.
- Custom Alerts: Shifted updates from once daily to every hour, improving response time.
“I can drill down and find the last five or ten years of an aircraft’s history. Mechanics and pilots don’t always write things up the same way, so being able to filter and exclude keywords is a massive advantage.” – Maintenance Control Manager.
Founded
1928
Company Size
100K+ employees
Product Used
Veryon Diagnostics
Solutions Used
Defect Analysis
Industry
Commercial airline
The outcome
The transformation was immediate. With hourly updates instead of daily, the airline’s teams gained real-time awareness of repeat issues.
- Hidden problems surfaced. Chronic faults initially appeared to increase, but only because the system was finally catching what had been missed.
- Faster resolution: Hourly defect updates enabled immediate responses instead of waiting for daily reports.
- Better manpower use: Technicians moved from searching for problems to fixing them.
- Reliability standards improved. With repeat defects reduced, the airline reset its chronic definition from three write-ups in 30 days to three in 45 days.
“I can drill down and find the last five or ten years of an aircraft’s history. Mechanics and pilots don’t always write things up the same way, so being able to filter and exclude keywords is a massive advantage.”
Maintenance Control Manager | Commercial Airline
The future
The airline continues to partner with Veryon to push the boundaries of maintenance efficiency. Recent innovations include:
- 15-minute data feeds for near real-time alerts.
- Integration of automated fault data with log pages for a single-screen view.
- Timeline correlation that maps faults to write-ups, making root cause analysis easier.
“The linguistics engine is a game changer. Whether it’s O2, oxygen, or zero-two, the system knows they’re the same. That saves us countless hours. But tools like this don’t replace technicians—they make them more efficient, safer, and more effective.” - Fleet Specialists Manager.
“The linguistics engine is a game changer. Whether it’s O2, oxygen, or zero-two, the system knows they’re the same. That saves us countless hours. But tools like this don’t replace technicians—they make them more efficient, safer, and more effective."
Fleet Specialists Manager | Commercial Airline
About Veryon Defect Analysis
Veryon Defect Analysis, part of the Veryon Diagnostics product suite, is the complete solution for automatic identification of chronic aircraft problems and recurring defect resolution management that is trusted by the world's leading major, regional, and cargo airlines.
Currently in use on 25% of the world’s commercial airline fleet, Veryon Defect Analysis helps achieve a 10% reduction in cancellations and delays. It also detects emerging failure modes that are yet to reach critical status. Custom-targeted alerts enable engineers to respond with greater speed and accuracy.
Improved accuracy
Leverage advanced technology and intelligent data analysis to identify, analyze, and act on unscheduled maintenance events at both the tail number and fleet level.
Earlier aircraft defect detection
Automatically identify new or changing chronic issues as early as the second repeat, offering a 33% reduction in chronic and repeating defects and helping airlines maintain aircraft availability.
Faster resolution
Immediately validate chronic aircraft defects with collaboration and workflow tools for seamless communication between MOC, reliability, and line maintenance, guaranteeing a single source of truth.
Key features
Chronic identification
Using natural language processing and machine learning. Veryon Defect Analysis analyzes aircraft defect text, automatically grouping like issues.
Custom notifications
Configure custom alerts and notifications based on defects to instantly notify maintenance personnel, resulting in fewer delays or cancellations.
Configurable dashboards
Configure dashboards using custom criteria to analyze defect and chronic trends for individual aircraft views and fleet comparisons.
Synonym dictionary
With its powerful and fast search, Veryon Defect Analysis allows users to identify chronic defects with spelling variations, synonyms, abbreviations, and more.
Integrated reporting
Veryon Defect Analysis includes a robust set of reporting tools with filtering and sorting by various criteria, including tail number, part, code, flight, and more.
Custom filtering
The ability to incorporate and integrate custom data elements from multiple sources as custom filter options for single source defect analysis.
See for yourself how Veryon Defect Analysis can maximize your aircraft uptime with a personalized demo.
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