Securing Predictive Maintenance: Protecting the Next Frontier of Aviation Reliability

Predictive maintenance has become one of the most significant developments in modern aviation, providing operators with the capability to identify potential failures before they disrupt operations. By combining sensor data, aircraft health monitoring systems and advanced analytics, airlines are already improving dispatch reliability and reducing avoidable delays. Delta, for example, has publicly reported that it prevented more than one thousand cancellations in 2022 through the use of predictive tools and targeted maintenance actions. The direction of travel is clear: data-driven maintenance is now an essential part of global aviation. 

Industry-wide, predictive maintenance is projected by IATA to save airlines more than three billion dollars annually by 2030, supported by fewer disruptions, optimised part replacement and improved fleet utilisation. These figures demonstrate why the technology is becoming a central component of operational strategy across commercial aviation. 

As adoption increases, so does the need to protect the integrity of the systems involved. Predictive maintenance depends on the accurate collection, transmission and analysis of large volumes of operational data. Any interference, whether due to cyber vulnerabilities, compromised inputs or inconsistent data quality, can affect decision-making and reduce trust in the outputs provided. 

Regulators have acknowledged this and have taken significant steps to support safe and secure integration. The FAA has published its AI Safety Assurance Roadmap, setting expectations for transparency, monitoring and the responsible use of AI in aviation systems. EASA has introduced Part-IS requirements for information security, reflecting the increasing importance of cybersecurity in connected operations. ICAO has included cybersecurity as a priority through its Aviation Cybersecurity Strategy, encouraging multilayered defence and international collaboration. Public reporting has also shown that even non-safety-critical systems may sometimes contain weaknesses that require corrective action. In 2018, researchers disclosed potential vulnerabilities in Boeing 787 maintenance systems, which were subsequently addressed. These examples highlight why continued vigilance is essential. 

For operators and maintenance providers, the practical challenge lies in ensuring that predictive systems support, rather than overwhelm, engineering teams. FedEx has noted that large fleets can generate substantial volumes of alerts, some of which may offer limited operational value if not appropriately filtered or prioritised. Accuracy, clarity and engineering relevance must remain central principles for effective implementation. 

Looking ahead, predictive maintenance is expected to evolve further. Digital twins, blockchain applications for data integrity and edge computing are all likely to enhance system resilience and reduce latency. These technologies will complement established maintenance tools, while also introducing new complexities that require careful oversight. 

This presents an important opportunity for the global aviation community, including organisations such as Brookfield Aviation. As new analytical capabilities shape maintenance planning and fleet management, the sector will require long-term workforce development, technical upskilling and specialised recruitment. Trusted partners with strong operational understanding and awareness of regulatory expectations will play a vital role in supporting aviation's digital transition. 

Predictive maintenance represents a significant step forward in aviation reliability. It improves efficiency, reduces cost and strengthens operational safety through the early identification of technical issues. Protecting the integrity of these systems is now equally important. Through strong cybersecurity, responsible data practices and sustained collaboration across regulators, operators and industry partners, aviation can ensure that predictive maintenance remains a dependable foundation for the next generation of aircraft operations. 

The future of maintenance will be shaped by people as much as technology. Engineers, analysts, pilots and operational leaders will continue to interpret data, apply judgement and ensure that digital tools provide real value. Training engineers to understand AI outputs and maintain cyber hygiene will be critical. Brookfield Aviation remains committed to supporting this global evolution by connecting the industry with the expertise it needs across every discipline.