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One Shot Readiness Digital Twin AI Network


Maximizing Condition-Based Maintenance

A digital twin analytics solution to help fleet managers improve operational availability and safety

The Problem:

Energetic devices are pivotal in aviation mission execution and safety equipment. They perform critical functions such as launching weapons, triggering fire extinguishers, and aiding pilot ejections during emergencies. Despite the significance of these crucial components, fleets contend with persistent challenges like shortages, outdated parts, failed lots, and delivery delays. To exacerbate the challenge, there is currently no health-monitoring capability to assess remaining service life. For safety reasons, conservative “useful life” limits are therefore set, often leading to premature removal of parts with substantial remaining usability. Consequently, approximately 70,000 energetic parts are replaced annually with useful life remaining.

The Solution:

Imagine having a solution that integrates uncertainty, enhances pilot safety, addresses supply shortages, and extracts maximum value from component inventories. MaxUp® ORDAIN, Lone Star Analysis’ innovative technology, applies predictive analytics to deliver a more efficient approach to component lifecycle management. Leveraging existing maintenance and operational databases, along with analyses like cockpit thermal studies and weather data, the solution accurately forecasts component service life, both life expended and useful life remaining, over an 84-month period. All of this is accomplished without the need for installed aircraft sensors.

Pilot Safety

2007 PDRM Incident
  • To predict service life, failure analysis is performed across entire component populations.
  • Accurate assessments of component service life (expended and remaining) can be made.
  • These assessments are possible without installing cockpit sensors.

Supply Chain Shortages

Fleet Transition
  • Considerations include installation dates, operating locations, and environmental exposures.
  • Operationalized within a cloud-based environment.
  • Significantly reduce the annual cost of these components up to 59 percent.

Budget Efficiency

Sailors perform maintenance on ejection seats
  • Calculate stress accumulation over time for each component to predict service life: what is used up and what remains.
  • Deliver a fiscally responsible alternative to component lifecycle management.
  • Replicate thousands of other components in the DoD weapon system inventory.

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