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management, implementation of Electronic Work Instructions and optimal inclusion of additional data elements

management, implementation of Electronic Work Instructions and optimal inclusion of additional data elements

Interactive list componentlink componet- interactive

management, implementation of Electronic Work Instructions and optimal inclusion of additional data elements

management, implementation of Electronic Work Instructions and optimal inclusion of additional data elements

TRAINING SOLUTIONS CASE STUDY

An elevated approach to maintenance training

avianca set to save a significant cost annually and maintain regulatory requirements with Comprehensive Maintenance Training Solutions

The challenge

With over 21,000 employees, avianca is the largest airline in Colombia and the second-oldest airline in the world. Serving as Colombia's flagship carrier, avianca relies on the Boeing 787-8 Dreamliner for its long-haul routes.

As the airline expanded its fleet and maintenance staff, avianca realized that its training programs weren’t keeping up. Operational needs were outpacing existing training programs, putting the airline at risk of failing to meet staff regulatory requirements.

Despite its goal of continued growth, avianca faced several challenges in maintaining and scaling its Boeing 787 maintenance training program:

  • Limited training accessibility: Previous training systems depended on physical computer servers set up in a single location in Bogotá, limiting flexibility and scalability.
  • Capacity constraints: Training sessions had limited seats, forcing students to share simulation stations, which reduced hands-on experience quality.
  • Outdated instructional materials: Training relied heavily on static PDFs and lacked interactivity, making updates cumbersome and sessions less engaging.
  • High operational costs: Frequent travel and centralized training increased expenses and reduced efficiency.
MST - Computer Screen

Our approach

In partnership with Boeing, avianca adopted a comprehensive training solution by integrating four powerful tools:

  • Maintenance Training Services (MTS)
  • Advanced Boeing Learning Environment (ABLE)
  • Airplane Virtual Tour (AVT)
  • Maintenance Synthetic Trainer (MST)

With a new training ecosystem in place, avianca could successfully modernize and expand its maintenance training capabilities: 

  • Cloud-based training with ABLE: Enabled remote, multi-location access to interactive, modular training content with flexible display options (single, dual, or triple screens), supporting diverse classroom setups. 
  • Virtual simulation with MST: Provided immersive, realistic 3D airplane simulations for hands-on practice without the need for physical aircraft access, enhancing skill retention and confidence. 
  • Comprehensive courseware with MTS: Delivered up-to-date, regulatory-approved training materials, including manuals, videos, and virtual tours — all backed by Boeing engineering expertise. 
  • Customized lesson creation: Leveraged ABLE’s authoring tools to tailor lessons to avianca’s specific operational needs and regulatory requirements. 
  • Scalable infrastructure: Transitioned from server-dependent systems to cloud-based solutions, increasing training capacity and reducing both physical space and maintenance costs. 

Results

The integration of Boeing’s Comprehensive Maintenance Training Solutions brought significant benefits to avianca’s maintenance training program, including:

  • Expanded training accessibility: Enabled simultaneous training across multiple locations (Bogotá and Medellín), increasing seat availability and reducing bottlenecks. 
  • Enhanced training quality: Individualized simulation stations improved hands-on experience, boosting student engagement and practical skills. 
  • Up-to-date content: Continuous updates from Boeing ensured training materials reflected the latest standards, policies, and aircraft configurations. 
  • Improved regulatory compliance: Training aligned with strict international standards, facilitating smoother approval processes. 
  • Positive student feedback: Surveys indicate a 95% satisfaction rate, highlighting ease of use, realistic scenarios, and overall training effectiveness.

 
ABLE, MST, and MTS have revolutionized our maintenance training by providing flexible, immersive, and up-to-date learning experiences. This has allowed us to expand capacity, reduce costs, and maintain the highest standards of safety and operational excellence.

 

— Ferney Castrillon, Maintenance Training Instructor, avianca

Additionally, by moving to cloud-based and digital training solutions such as MTS, MST, and ABLE, Avianca can achieve significant cost savings through reduced travel, optimized resource use, and improved airplane availability. These cost savings are based on Boeing’s assumptions:

  • $230,000 saved from reduced employee travel and data center costs 
  • $600,000 saved on external training class expenses, including instructors and materials, or by not developing an in-house training program
  • $250,000 opportunity cost saved by not having a Boeing 787 airplane grounded for maintenance training

Other operational savings include a reduced need for physical classroom space, data center maintenance, and administrative overhead.

By leveraging Boeing’s Comprehensive Maintenance Training Solutions and optimizing internal resources, avianca can potentially save around $1 million annually through reduced travel, lower external training costs, and improved airplane availability. 

 
Transitioning to ABLE has given us the flexibility and scalability we needed to deliver high-quality 787 maintenance training across multiple locations. The cloud-based platform not only reduced our operational costs but also enhanced the learning experience for every student by providing individual, immersive simulation sessions.

 

— Luis Gonzalez, Maintenance Training Instructor, avianca

Conclusion

The collaboration between avianca and Boeing to implement ABLE, MST, and MTS transformed avianca’s maintenance training framework. By embracing innovative, cloud-based, and interactive training technologies, avianca effectively enhanced training accessibility, quality, and cost-efficiency.

This partnership positions avianca as a leader in aviation maintenance training in Latin America, highlighting the airline’s commitment to safety, operational excellence, and continuous improvement.