Gallery: KLM E&M’s MRO Innovations At Amsterdam Schiphol

KLM Engineering & Maintenance (KLM E&M) is working with several industry and academic partners in its Bright Sky consortium to accelerate technology development for the aftermarket. Aviation Week visited the company’s Maker Space at Amsterdam Schiphol Airport on Oct. 16 to get a firsthand look at some of the technologies the consortium is developing to drive improvements in MRO processes.

Within the Maker Space, KLM E&M employees work together with Bright Sky partners including Royal NLR, TU Delft and technical services provider JetSupport to create innovations in-house. The consortium was awarded Dutch government funding to look at five focus areas through 2025: Smart MRO, Smart Availability, Smart Operations, Smart Access and Smart Training.

Under the Smart Training focus area, KLM E&M is developing a digital cockpit simulator that can be used for engine run-up training. Previously, this training has been completed in a simulator that is also used for pilot training, so availability has been an issue for KLM E&M. The company has developed a simulated environment for virtual reality (VR) goggles in which a technician can train for 35 engine type combinations. KLM E&M says the system enables it to reuse previously created training content, speeding up content generation. An eye tracker in the VR headset tracks a trainee’s progress in real time and KLM E&M says the virtual method allows trainees to repeatedly complete tasks until they can perform them perfectly. It is currently researching whether VR or augmented reality headsets are preferable for these types of training procedures, including the incorporation of haptic aspects for actions such as turning switches and dials. During Aviation Week’s visit, James Pozzi, MRO Editor, EMEA, tested VR training that simulated an Airbus A320 cockpit.

KLM E&M is also exploring the use of augmented and virtual reality for remote assistance and inspections. During Aviation Week’s visit, KLM E&M demonstrated an innovation in which a technician wearing a Microsoft HoloLens headset could digitally survey hail damage on an aircraft and collaborate with a remote inspector.

While wearing the HoloLens headset, a technician can interact with a damaged aircraft part to create a digital twin from photos. The technology uses neural radiance fields, a method powered by deep learning, to construct a 3D representation of a scene from two-dimensional images.

Once a digital model has been created, the technician on-site can use KLM E&M’s “communications hub” application to work with an off-site expert to assess damage and coordinate documentation and reporting. The company is hoping the technology could ultimately create a 3D model in just a few minutes, significantly decreasing overall inspection time. Together with NLR, KLM E&M is now looking at how the technology could be combined with drone swarms to perform larger-scale inspections.

Under the Smart MRO focus area, KLM E&M is developing robotics for repair and inspection processes. The robot pictured here has been programmed to perform autonomous engine blade inspections, checking to see if holes are blocked or plugged. The robot picks up engine blades and sets them on a platform, which rotates so 360-deg., 3D images can be taken to give a full view of the part.

NLR is using this same type of robot for autonomous inspections of a variety of parts, such as rotor blades and leading edges. It is hoping to incorporate artificial intelligence for automated detect defection, which could further reduce inspection times.

KLM E&M’s Maker Space also features several 3D printers that staff can use to experiment and come up with ideas. Paul Chun, vice president for technology at KLM E&M, says the “natural playground” has helped some of its engineers develop their own tooling. He adds that it has also been an asset to help interns develop new ideas, which is a key element in recruiting young talent.

Other technologies KLM E&M plans to research include blockchain to help improve supply chain management. It will soon begin a trial project with the Dutch Ministry of Defense to develop blockchain technology that could enable tracking of component history, status and condition. Chun says the technology could be used to inform supply chain stakeholders about upcoming maintenance, automate decision making processes about whether to repair or replace a part, and to safeguard against bogus parts. He says the technology could also provide advantages for customs and tariffs challenges.