Success Story Predictive Maintenance


The optimal utilization of an aircraft fleet is an essential success factor for airlines. Every minute an aircraft is on the ground translates into a financial loss. Unplanned technical defects are usually the cause. In our globalized world, an Aircraft-On-Ground (AOG) event can have far-reaching consequences for the disposition of aircraft, spare parts and specialists. The permanent analysis of data can provide early indications of impending component failures, including hidden component defects.

lead time before malfunctions matured and serious failure occurred


  • To reduce costly AOG events.
  • To lower maintenance costs.


  • In the majority of commercial aircraft types, the air supply, air conditioning and pressure maintenance in the cabin is controlled by air that is discharged into the aircraft interior through the engines and depending on altitude and required engine power, special valves must direct the airflow differently.
  • The air conditioning system is designed redundantly, but a so-called “double bleed failure” can still occur.
  • The incorrect closing of two valves simultaneously can potentially result in a sudden loss of pressure in the cabin in which case the aircraft must reach a low altitude in a very short amount of time and interrupt the flight.


  • By combining engine performance data with control inputs from the aircraft crew, Prexello is able to make predictions about hidden damage (Combining human-machine).
  • The early detection of malfunctions provided by Prexello results in large lead time that gives operators enough leeway to choose a suitable time and airport for maintenance before failure occurs.
  • Using Prexello a complete picture on the condition of the valves can be built even though most of the information about them can only be derived indirectly.
  • With Prexello even the smallest deviations in behavior become visible, long before malfunctions occur.


  • Prexello warned on signs of redundancy loss and other malfunctions two weeks before the critical situation occurred.
  • In this specific case, serious events were detected by Prexello which were not and could not be detected by manufacturer-specific technologies.
  • Without Prexello, these malfunctions would have resulted in unscheduled maintenance with increased costs as well as delay which would have resulted in financial loss as high as EUR 100,000/hour.

Your Contact

Carlos Ayala Jiménez

Carlos Ayala Jiménez

Phone:  +49 1516 2 60 74 21