Air France Industries KLM Engineering & Maintenance (AFI KLM E&M) celebrated the 10th anniversary of Prognos, its predictive maintenance suite designed to help airlines anticipate technical failures and improve fleet availability. Since the Prognos brand was established on October 18, 2016, the solution has evolved into a comprehensive suite covering aircraft, engines and Auxiliary Power Units (APUs).
Developed from AFI KLM E&M’s experience as both an airline operator and an MRO provider, Prognos was born from a clear ambition: identifying potential technical issues before they impact flight operations. What began as a graduation research project has grown into a mature solution combining advanced data analytics with the expertise of dedicated engineering teams.
Turning Data into Actionable Maintenance Decisions
Today, Prognos brings together three complementary solutions: Prognos for Aircraft, Prognos for Engine and Prognos for APU. By analysing operational data and identifying emerging technical issues, dedicated monitoring teams translate predictive insights into practical maintenance recommendations tailored to each operator’s needs.
The growth of Prognos for APU illustrates this evolution. Introduced in 2017 and operated by EPCOR, an AFI KLM E&M subsidiary, the solution has expanded from a single customer to more than 55 in 2026. Today, it monitors over 1,800 APUs across nine APU types and processes more than 3,500 APU reports daily.
Initially focused on performance trending, Prognos for APU has progressively developed predictive capabilities, providing operators with greater visibility into APU health and fleet performance.
Delivering Tangible Operational Benefits
Over the past decade, Prognos has contributed to improvements in maintenance decision-making and operational reliability.
In 2024, research conducted through Prognos on Boeing 787 air-conditioning systems contributed to a modification aimed at improving Air Cycle Machine reliability across the worldwide Boeing 787 fleet. In APU maintenance, predictive monitoring has also enabled timely removals ahead of potentially serious failures, including blade walk and bearing-related issues.
Anne Brachet, Executive Vice President Air France-KLM Engineering & Maintenance, said: “When we started developing Prognos ten years ago, we were looking for better ways to use the operational data already available to us. What has made the difference over the years is the close collaboration between our data specialists and engineering teams, and the experience we have gained from supporting different fleets around the world. That experience provides a strong foundation for the next stage of Prognos.”
Looking Ahead: From Predictive to Prescriptive Maintenance
As Prognos enters its second decade, AFI KLM E&M aims to further expand its capabilities across aircraft systems, engines and APUs, while progressively moving toward prescriptive maintenance. By advancing the use of artificial intelligence and refining predictive algorithms, Prognos aims to help airlines not only anticipate potential failures, but also determine the most appropriate maintenance action and when it should be performed.
Building on ten years of development and operational experience, this next step will help airlines make more informed maintenance decisions and manage their fleets with greater confidence.
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