Planning for Precision: How Full Flight Simulator Maintenance Keeps Training on Track

In the world of pilot training, precision is everything. That extends beyond the flight deck and into the very infrastructure that supports pilot certification—the full flight simulator (FFS). These sophisticated machines require meticulous maintenance, and any unplanned downtime can disrupt training schedules, impacting airlines and flight schools alike.

Full flight simulators are complex systems, that integrate advanced aircraft data, control loading, motion, visual projection, and avionics to replicate real-world flying conditions. Keeping them operational requires a rigorous maintenance schedule, ensuring compliance with aviation authorities and preventing unexpected failures. Martynas Burba, Head of Engineering at BAA Training Lithuania, one of the leading global aviation training organizations delivering both Ab Initio and Type Rating training, says that meticulous planning is at the heart of FFS Maintenance, Repair and Overhaul (MRO) operations.

“Good maintenance isn’t about reacting to failures—it’s about mitigating them before they even occur. A well-planned maintenance strategy allows us to maximize training availability while minimizing disruptions. It’s a balancing act between engineering precision and operational efficiency on the daily.”

Daily, Weekly, and Monthly Maintenance Cycles

Simulator maintenance follows a structured schedule, much like an aircraft’s upkeep. Daily inspections cover critical system checks, ensuring lighting, software calibration, and motion systems are fully operational. Weekly tasks involve deeper system diagnostics, while monthly maintenance includes extensive evaluations and software updates to maintain optimal performance. Failing to adhere to these schedules can result in costly downtime.

“If you neglect a simulator’s upkeep, you don’t just get a repair bill—you get cancelled training sessions, compliance risks, and a domino effect across an entire training program,” explains Burba.

Mitigating Downtime Risks Through Proactive Planning

Proactive maintenance is key to preventing unexpected failures. Regular inspections, data analysis, and real-time performance tracking allow engineers to address emerging issues before they escalate. Burba says that even with the best planning, breakdowns can still occur—making swift response protocols crucial to minimizing disruptions.

“Every FFS generates a massive amount of performance data—our job is to translate that into foresight. The earlier we spot deviations, the fewer disruptions we face. Training providers like us must also align maintenance schedules with client training needs. Since training slots are booked months in advance, even minor delays can disrupt multiple pilot cohorts.”

The Future: AI-Powered Self-Assessment?

While today’s maintenance planning relies on expert engineers and detailed scheduling, the future could look very different. Burba thinks that emerging AI technologies could transform how FFS maintenance is managed, offering real-time self-assessments that predict wear and tear before it becomes a problem.

“Right now, our engineers rely on a combination of data analysis and experience to predict failures. In the future, we could see AI-driven self-assessment tools that monitor performance 24/7, flagging potential issues before they arise. Imagine an FFS that can schedule its own maintenance, optimizing training availability without human intervention. It’s an exciting prospect.”

However, such features might become available sometime in the future, as risks associated with AI and access to internal data of both the training providers and the clients remain at the forefront of discussions.

Planning Today, Innovating for Tomorrow

For now, robust planning remains the cornerstone of successful FFS maintenance. But as technology advances, training providers may find themselves moving towards predictive, AI-driven solutions that make downtime a thing of the past.

“As with anything in aviation, it’s about staying ahead of the curve,” concludes Burba. “The better we plan today, the more we can innovate tomorrow.”

As the aviation industry continues to evolve, one thing remains clear: when it comes to full flight simulators, planning isn’t just important—it’s everything.