A Workflow Restructuring Method for Aircraft Maintenance with AR Guidance and Version-Consistent Configuration Management

Abstract

Aircraft maintenance often suffers from mismatched document versions and delays in updating task steps after software changes. This study introduces a method that delivers maintenance instructions through AR glasses and links each step to OTA version data. The method was tested in two airline hangars across 26 maintenance tasks involving junior and senior technicians. Results show that junior staff made 61.3% fewer errors, and average task time decreased by 27.5% when using AR guidance. After a software update, revised steps reached AR devices within 15 minutes, removing the usual delay found in paper and PDF procedures. These findings indicate that connecting AR guidance with OTA updates can reduce the risk of outdated instructions and improve task execution in routine maintenance. The study is limited to hangar work and a single device type, and broader testing is needed to assess performance in line maintenance and mixed fleet environments.