Demo AeroCare MRO: aircraft maintenance day

Demo AeroCare MRO LLC maintains commercial aircraft for three airlines at Dubai and Doha hangars. It manages serialized rotable parts, consumables, tooling, labour, customer work packages, repair vendors, and airworthiness records. OSERP connects aircraft, maintenance event, task card, part issue, labour, inspection, release certificate, invoice, and customer settlement while keeping safety and export restrictions visible.

1. Set up aircraft, customers, and capabilities

Create legal company ACM, hangars DXB-H1 and DOH-H1, workshops, stores, and skill groups. Aircraft assets record registration, MSN, operator, model, location, hours, cycles, lease status, and maintenance programme. Customer contracts store labour rates, parts markup, turnaround time, currency, tax, and warranty.

Field	Demo value	Impact
Aircraft	A6-ACM	Asset and work-package key
MSN	41281	Manufacturer traceability
Work package	C-CHECK-2026-09	Scope and billing
Task card	27-41-00-010	Approved maintenance evidence
Part serial	PN-INV-004281	Installed/removal history
Shop finding	Crack at inspection point	Defect and engineering action
Release certificate	CRS-2026-0918	Airworthiness gate
Customer currency	USD	Invoice and settlement
Export class	Controlled component	Permission and compliance
Warranty	Manufacturer 24 months	Recovery and claim

The item master distinguishes serialized rotable, serialized repairable, expendable, consumable, tooling, and calibrated equipment. Each part records part number, revision, serial or batch, life limit, cycles, expiry, condition, location, and export classification.

2. Create a maintenance work package

Open Maintenance → Work Package → New. The header records aircraft, customer, hangar, check type, planned induction, target release, project, contract, currency, and approval. Task-card lines include ATA chapter, inspection, skill, estimated hours, tooling, parts, access, sign-off, and customer visibility.

For a C-check, budget 4,800 labour hours and USD 1,200,000. A work package cannot start until aircraft identity, approved scope, safety briefing, and customer authorisation are complete. Revisions add reason, engineering approval, and effective time; original task cards remain auditable.

3. Receive aircraft and inspect

The induction receipt records aircraft, arrival time, flight hours, cycles, fuel, condition, open defects, documents, and customer representative. A condition discrepancy creates a finding linked to task card and photo. Aircraft status changes arrived, inducted, under maintenance, inspection, released, or rejected.

The tooling check verifies calibration date, serial, custodian, and location. An expired tool cannot be issued to a controlled task. Safety isolation and permit fields record authorised person, start/end, hazard, and release.

4. Issue serialized parts and consume materials

The storekeeper issues part PN-INV-004281, serial S-88310, to task card 27-41-00-010. The movement records aircraft, work package, task, part, serial, condition, quantity, issuer, technician, and date. A removed part is returned with removal reason, hours, cycles, and quarantine status.

OSERP blocks a part that is expired, life-limited beyond threshold, quarantined, or export-restricted without approval. Consumables issue by batch and UoM. Inventory posting debits maintenance work-in-progress or cost and credits stores; a customer recharge is calculated from contract markup and evidence.

5. Capture labour and inspection

Technicians record employee, skill, task card, start/end, break, hours, shift, location, and sign-off. The supervisor approves labour daily. Inspector entries record inspection type, finding, evidence, independent check, and acceptance.

A crack finding creates engineering disposition: repair, replace, defer under approved MEL, or reject. Each disposition stores authority, reference, due date, and risk. A work package cannot close with open critical findings or unsigned task cards.

6. Vendor repair and warranty

Send the removed hydraulic pump to an approved repair vendor. The repair order stores part number, serial, condition, scope, quotation, currency, turnaround, warranty, export document, and expected return. Receipt records test report, new life status, repair serial, cost, and acceptance.

If the pump is under manufacturer warranty, create a claim linked to original purchase, serial, failure code, labour, freight, and approval. Reimbursement clears warranty receivable or reduces maintenance cost according to policy. A vendor invoice is matched to repair order, receipt, and approved quotation.

7. Customer billing and release certificate

The billing run selects completed task cards, approved labour, parts, consumables, vendor charges, and contract rules. Header fields include customer, aircraft, work package, currency, tax date, due date, and certificate reference. Detail shows task, hours, rate, part, markup, discount, and evidence.

Suppose approved labour is 4,620 hours at USD 145 = USD 669,900, parts and vendor charges USD 410,000, and materials markup USD 24,000. The invoice totals USD 1,103,900 before tax. Posting debits receivable and credits MRO revenue, parts recovery, and tax.

The certifying staff member creates a release certificate with aircraft, work package, task completion, open-item status, regulator reference, signature, and timestamp. Release is a controlled gate separate from invoice posting. Customer payment or a disputed amount remains linked to the invoice and aircraft.

8. Export control, currency, and close

Export-controlled parts require classification, destination, end user, licence, approval, and screening result. Restricted users cannot export lists or transfer a controlled serial without permission. The audit captures reviewer, decision, evidence, and expiry.

The customer pays USD while local labour and rent are AED or QAR. Payment imports bank rate, value date, fees, and reference; realised FX is separated from MRO margin. Month-end revaluation covers open USD receivable and vendor payable.

Close reconciles aircraft work packages to task cards, labour to payroll, parts to serial history, vendor repairs, warranty recoveries, release certificates, invoices, claims, tax, bank, FX, and open findings. A package cannot close while an airworthiness document or critical inspection is missing.

KPI	Baseline	After OSERP discipline	Improvement
Task-card sign-off lag	36 hours	6 hours	83% faster
Serialized-part trace retrieval	90 minutes	7 minutes	92% faster
Work-package cost variance	8.2%	2.4%	71% lower
Vendor repair turnaround	18 days	11 days	39% faster
Warranty recovery leakage	14%	3%	79% lower
Release-document exceptions	9 / check	1	89% lower

Practice challenge

Create an aircraft work package, receive the aircraft, issue a serialized part, record labour and inspection, send a component to a vendor, process a warranty claim, invoice the customer in USD, create a release certificate, and close the package. Explain every field, serial status, approval, journal, FX result, export rule, and evidence drill-down. Then attempt to issue an expired controlled part and release an unsigned task card; prove both controls reject the action.

Related: Inventory, Projects workflow, Multi-currency settlement, Advanced GL Mapping, and API library.