Data-Driven Predictive Maintenance for Aircraft Components Through Sparse Event Logs

Effective predictive maintenance is crucial for ensuring aircraft reliability, reducing operational disruptions, and supporting spare part inventory management in airline operations. However, maintenance data is often sparse, with irregular observations, missing records, and imbalanced failure distributions, making accurate forecasting a significant challenge. This study proposes a data-driven framework for maintenance prediction under sparse observational data. We implement and compare two distinct methodologies: survival analysis via DeepHit for time-to-event prediction, and a latent space classifier with autoencoder backbone. Each method is evaluated on historical aircraft maintenance logs and component installation records, addressing challenges posed by limited and imbalanced datasets. Both models are trained and tested on ten years of maintenance logs and component installation records sourced from an airline MRO (Maintenance, Repair and Overhaul) company that services a fleet of more than 500 aircraft, offering a realistic and scalable setting for fleet-wide maintenance analysis. The latent space classifier demonstrates superior overall performance and consistency across diverse components and prediction horizons compared to DeepHit, which is constrained by its sensitivity to probability thresholds. The encoder-based method effectively transfers knowledge from high-data components to those with sparse maintenance histories, enabling reliable maintenance forecasting and enhanced inventory planning for large-scale airline operations.