The OPs‑TIMAL project, funded under the German research grant FKZ 20X1711G, aimed to demonstrate how software‑based optimisation can increase value for all stakeholders in airline operations. The focus was on four aviation‑specific domains: fuel efficiency, optimal flight planning, predictive maintenance, and holistic ground handling. SAP was tasked with delivering a central, cloud‑based data orchestration and analytics platform that could integrate the heterogeneous, safety‑critical systems of airlines and their suppliers. Using SAP Data Intelligence, the platform ingested sensor and maintenance metadata from partner aircraft, processed it in real time, and forwarded application‑specific information to downstream systems that support holistic optimisation of aircraft maintenance planning.
In the predictive maintenance work package, SAP and Diehl collaborated to build forecasting models that predict component wear and failure likelihood. These models were trained on historical maintenance logs and sensor streams, leveraging the machine‑learning capabilities of the SAP Business Technology Platform (BTP) and open‑source libraries integrated into SAP Data Intelligence. The resulting models were able to forecast maintenance needs with a lead time that extends beyond the current reactive approach, thereby reducing unscheduled downtime and improving fleet utilisation. While the report does not provide explicit numerical accuracy figures, it reports that the platform can handle high‑volume data streams from multiple aircraft simultaneously and that the integration pipeline reduces data latency to sub‑minute levels, enabling near‑real‑time decision support.
The system architecture was validated through a structured approach based on ISO 9126 quality characteristics. Functionality, security and resilience, and integrability into existing customer landscapes were identified as key attributes. A questionnaire derived from these attributes was administered to IT professionals at Lufthansa and Swiss during a validation workshop held on 23/24 August 2022. Despite logistical challenges caused by the pandemic, the workshop yielded actionable insights that informed the refinement of the platform’s integration interfaces and security posture. The validation exercise confirmed that the platform meets the functional requirements of airline maintenance operations and can be embedded into existing IT ecosystems with minimal disruption.
SAP also coordinated the integration of partner systems, ensuring that data from Diehl, Air3x, TWT GmbH Science & Innovation, Fraunhofer FKIE, and Jeppesen could be harmonised within the orchestration layer. The project produced a series of demonstration videos in English (with optional subtitles) to showcase the platform’s capabilities, compensating for the inability to hold on‑site demonstrations during the COVID‑19 lockdown. These videos were subsequently used at industry events, internal project briefings, and marketing activities.
The project ran from early 2020 through the end of 2023, with the final report issued in 2023. SAP led the technical development and coordination, Diehl supplied aircraft maintenance data and domain expertise, Air3x and TWT GmbH contributed to data integration and analytics, Fraunhofer FKIE provided research support, and Jeppesen supplied flight‑planning data. Lufthansa and Swiss participated in the validation workshops, providing real‑world operational context. The collaboration demonstrates how a cloud‑based data orchestration platform, coupled with predictive analytics, can deliver tangible operational benefits in the highly regulated and data‑intensive aviation sector.