Beyond Safety: The Real ROI of Flight Data Monitoring

When most operators think of Flight Data Monitoring (FDM), they think safety. And that’s fair — safety is the foundation. But the same data that helps identify operational risks can also uncover opportunities to improve efficiency, reduce wear, and lower maintenance costs.

In other words, FDM doesn’t just make flying safer — it can make it smarter and more cost-effective.

Below are a few examples of how some of our customers have leveraged their FDM data to improve their bottom line.

USING BRAKING DATA TO EXTEND COMPONENT LIFE

One operator noticed repeated instances of heavy brake applications during landing, but only at certain airports. By reviewing their FDM data, they discovered a clear pattern: some crews were braking aggressively to make an earlier taxiway exit — the one that offered the shortest taxi distance back to the apron.

Armed with this insight, the operator shared the data with their crews and adjusted expectations during arrival. That simple change led to more consistent brake use and reduced wear rates – extending the time between brake servicing.

Even without calculating exact savings, the benefit is obvious. Every additional landing cycle a brake assembly survives before replacement translates directly into cost avoidance — not to mention less downtime and reduced maintenance workload.

Brake application during landing rollout. Red indicates heaviest braking.

ENGINE TREND DATA THAT PREVENTED AN EXPENSIVE SURPRISE

In another example, an operator using our Engine Condition Trend Reporting (ECTR) service — available as part of our FDM program — identified a shrinking Exhaust Gas Temperature (EGT) margin on one of their Boeing 737s.

Over time, the EGT margin was narrowing, indicating performance degradation. Because the issue was caught early, their maintenance team was able to schedule an inspection and perform corrective work before it became critical.

After servicing, the EGT margin recovered, confirming the action was successful. Without trend data, the issue might not have been discovered until it led to an exceedance, in-flight failure, or an unplanned engine removal — both far more expensive outcomes.

OPERATIONAL INSIGHT THAT PAYS FOR ITSELF

These are just two examples of how FDM data can deliver financial value well beyond safety. Some of the most common areas where operators see returns include:

Fuel efficiency: Identifying non-optimal climb, cruise, or descent profiles.
Maintenance planning: Spotting system trends before they trigger alerts.
Training focus: Directing simulator or line training toward real-world trends rather than assumptions.
Asset health: Helping extend the lifespan of high-value components like brakes, tires, and engines.

Every insight adds up. Across hundreds or thousands of flights per year, small efficiency gains can result in significant cost avoidance — often easily exceeding the cost of the FDM program itself.

FROM SAFETY TO STRATEGY

Safety may be what brings operators to FDM. But efficiency, predictability, and cost reduction are what keep them invested.

When flight data is analyzed and shared effectively, it empowers operators to make smarter maintenance and operational decisions — protecting both safety and profitability.

That’s the real return on investment in FDM.

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Beyond Safety: The Real ROI of Flight Data Monitoring

USING BRAKING DATA TO EXTEND COMPONENT LIFE

ENGINE TREND DATA THAT PREVENTED AN EXPENSIVE SURPRISE

OPERATIONAL INSIGHT THAT PAYS FOR ITSELF

FROM SAFETY TO STRATEGY

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