MRO SMS Transformation with SMS Pro: A Case Study

The Challenge: Overcoming MRO SMS Obstacles

Horizon MRO Solutions operated from a regional airport hub, servicing turboprops and regional jets for multiple carriers. With a team of 120 technicians and a reputation for quality maintenance, Horizon was well-positioned for growth. However, its safety management system struggled to meet the demands of modern aviation regulations and operational complexities. The following challenges were critical roadblocks for Horizon’s safety team:

• Inefficient Hazard Reporting: Horizon relied on paper-based forms and manual logs for hazard identification. This process was time-consuming, often taking 15 minutes per report, leading to underreporting. For instance, a near-miss involving a miscalibrated torque wrench went undocumented for weeks, increasing risk exposure and threatening compliance.
• Burdensome Audit Preparation: Preparing for FAA audits was a logistical nightmare. The safety team dedicated weeks to compiling records, reconciling discrepancies, and ensuring compliance with Part 5 standards. In 2023, an audit identified minor non-conformities due to incomplete documentation, highlighting the need for a more efficient system.
• Resource Limitations: With only three safety personnel, Horizon struggled to implement proactive risk management. Balancing SMS responsibilities with operational demands left little time for trend analysis, safety training, or policy updates, weakening compliance efforts and safety culture.
• Fragmented Data Management: Without a centralized performance monitoring system, safety data was scattered across spreadsheets and paper records. This fragmentation obscured critical trends, such as tool calibration errors, which accounted for 15% of maintenance-related incidents in 2022.

These obstacles not only jeopardized Horizon’s ability to meet FAA requirements but also hindered its goal of fostering a proactive safety culture. As discussed in our blog on MRO safety practices, integrated systems are essential for addressing such complexities in MRO operations.

"Our manual processes were a bottleneck. We needed a solution that could simplify compliance without overwhelming our small team," said Jane Rodriguez, Horizon’s Safety Manager.

The Solution: SMS Pro’s Tailored MRO Framework

In January 2024, Horizon partnered with SMS Pro, a cloud-based aviation SMS software designed to address MRO-specific challenges. SMS Pro’s comprehensive features and user-friendly interface made it an ideal fit for Horizon’s needs. The implementation process was structured in three phases: a gap analysis to identify deficiencies, staff training to ensure adoption, and a phased rollout completed by April 2024. Below are the key solutions SMS Pro provided:

Revolutionizing Hazard Reporting

SMS Pro’s confidential reporting system transformed Horizon’s hazard reporting process. Technicians could submit reports via mobile devices, even offline, with an intuitive interface that reduced submission time to under 3 minutes. Anonymous reporting options alleviated concerns about reprisal, encouraging broader participation. By June 2024, hazard report submissions had increased by 40%, from 25 to 35 per month, providing a richer dataset for risk analysis. This improvement aligns with strategies outlined in our blog on developing effective hazard reporting systems.

Streamlining Audit Preparation

The auditing system in SMS Pro automated much of the audit preparation process. Pre-built templates aligned with FAA Part 5 requirements enabled rapid compilation of compliance records. Centralized documentation and real-time audit trails eliminated discrepancies, reducing preparation time by 60%, from four weeks to ten days. This efficiency was critical during Horizon’s 2024 FAA audit, which it passed with zero findings.

Empowering Staff Through Training

SMS Pro’s training system delivered role-specific online modules covering hazard identification, risk assessment, and FAA compliance. Over 90% of Horizon’s staff completed initial training within two months, with automated scheduling for recurrent training. This investment in education strengthened the safety culture, as technicians felt more confident contributing to safety initiatives. The value of such training is reinforced in our blog on building safety training libraries.

Driving Insights with Data Analytics

The risk management system provided Horizon with real-time analytics and customizable dashboards. By aggregating data from hazard reports and maintenance logs, SMS Pro identified recurring issues, such as tool calibration errors, which were reduced by 25% through targeted interventions like enhanced calibration schedules. These analytics empowered the safety team to monitor key performance indicators (KPIs) and make data-driven decisions, ensuring compliance and operational efficiency.

SMS Pro’s role-based access ensured that safety managers, technicians, and executives had tailored system views, enhancing usability while maintaining data security. The cloud-based platform required no additional IT infrastructure, making it a cost-effective solution for Horizon’s lean operation. The business case for such a system is compelling, as detailed in our MRO business case.

"SMS Pro turned our data into actionable insights. It’s like having an extra safety manager working around the clock," Rodriguez remarked.

Results: Setting a New Standard for MRO Safety

By July 2024, six months after implementation, SMS Pro had delivered transformative results for Horizon MRO Solutions, establishing a new benchmark for safety and compliance:

• Flawless Audit Performance: Horizon passed its 2024 FAA Part 5 audit with zero findings, a first in its history. This success avoided potential fines and enhanced Horizon’s reputation among regulators and clients.
• Accelerated Hazard Resolution: The average time to resolve hazards dropped by 50%, from 14 days to 7 days, due to automated workflows and real-time notifications, minimizing risk exposure.
• Strengthened Safety Culture: Anonymous reporting and comprehensive training boosted staff engagement, with 85% of technicians submitting hazard reports by Q3 2024, up from 50% the previous year.
• Business Expansion: Horizon secured two new client contracts worth $1.2 million annually, as carriers prioritized MROs with robust SMS programs, demonstrating the commercial value of safety excellence.
• Operational Efficiency: Automation reduced administrative hours by 20 per week, saving approximately $30,000 annually in labor costs, allowing the safety team to focus on strategic initiatives.

These outcomes highlight SMS Pro’s ability to deliver measurable value for MROs, transforming compliance burdens into competitive advantages. Horizon’s success story underscores the importance of investing in a robust SMS, as outlined in our blog on MRO safety practices.

Key Takeaways for Aviation Safety Managers

Horizon’s transformation offers actionable insights for MROs looking to elevate their SMS programs:

• Embrace Automation: Tools like SMS Pro’s auditing and reporting systems streamline compliance, saving time and reducing errors, especially for resource-constrained MROs.
• Prioritize Training: Comprehensive, role-specific training empowers staff to engage with the SMS, fostering a proactive safety culture.
• Leverage Data: Centralized analytics enable trend identification and informed decision-making, critical for addressing recurring issues like equipment errors.
• Align with Business Goals: A robust SMS not only ensures compliance but also drives commercial success by attracting safety-conscious clients.

By addressing these areas, MROs can replicate Horizon’s success, achieving compliance, efficiency, and growth. SMS Pro’s scalability makes it an ideal partner for MROs of all sizes, as demonstrated by Horizon’s journey.