Aero Star Aviation
An AI Virtual Assistant for Faster, Smarter Aircraft Maintenance
- AI Assistant (RAG)
- Text-to-SQL on Maintenance Data
- API Integration (Corridor)
- Data Engineering
- Cloud Infrastructure on GCP
- MLOps & CI/CD
- Role-Based Access & SSO
- Agile Product Management
HATCHWORKS TEAM
Product Owner, AI/ML Engineer, Software Developer, Data Engineer, Project Manager
Overview
Aero Star Aviation partnered with HatchWorks AI to design and deliver AVA (Aero Star Virtual Assistant), an AI platform that surfaces aircraft maintenance history from Corridor so technicians can prepare, diagnose, and resolve work orders faster. Phase one targets technicians; future phases extend to planners, managers, and customer service, and build a proprietary knowledge base.
The Challenge
The Goal
To equip technicians with instant, trustworthy answers from past work to reduce diagnosis time, raise first-time fix rates, and cut repeat repairs.
The Process
- Discovery & Workflow Mapping — Mapped technician journeys and common questions to desired responses and supporting data.
- Data Pipeline & Guardrails — Orchestrated data pipelines in Airflow using DAGs to extract and normalize Corridor data for search and analytics.
- MVP Development — Delivered a secure, device-friendly AI assistant (desktop/tablet/mobile) on GCP with role-based access.
- Validation Loops — Iterated with stakeholders to tune accuracy, recovery flows, and UX for shop-floor speed.
HatchWorks AI didn't just drop in a chatbot. They took the time to map our workflows, clean up how we use our data, and build an assistant our team actually trusts. AVA captures our knowledge, protects it inside our walls, and gives us a platform we can keep building on for years.
Christopher Grinnell
President @ Aero Star Aviation
The Outcome
We delivered a production-ready AI assistant that uses retrieval-augmented generation to answer technician questions with cited history. It adds text-to-SQL to pull structured facts from Cloud SQL, integrates Corridor via automated ETL and synchronization, and is deployed with Terraform-based infrastructure, centralized logging, and lightweight MLOps for smooth, reliable operations.
- Faster diagnosis: Relevant history surfaces in seconds, cutting search time.
- Higher first-time fix rates: Prior resolutions highlight pitfalls and proven steps.
- Shared knowledge: Technician insights become searchable, reducing repeats and rework.
- Scalable foundation: Ready to add pricing data and expand to planners, managers, and support.
The solution meets technicians where they work, with plain-language questions and cited answers, leveraging Corridor while building an independent knowledge base. It runs on a cloud-native architecture that’s easy to extend across roles and sites.
Key Stats
- Targeting 85%+ NPS from technicians using AVA.
- Pilot example: ~30% drop in recurring actuator issues after AVA insights.
- Shorter AOG TAT through faster troubleshooting.
The solution meets technicians where they work, with plain-language questions and cited answers, leveraging Corridor while building an independent knowledge base. It runs on a cloud-native architecture that’s easy to extend across roles and sites.
About Aero Star Aviation
Aero Star Aviation was founded in 2013. Specializing in Embraer Phenom & Preator Maintenance and Management dating back to the first Phenom production nearly 16 years ago. Aero Star Aviation is rapidly growing into the number 1 alternative for Embraer Phenom and Preator Maintenance and Management in the southern hemisphere. Our employees are completely specialized and educated on the Embraer aircraft to ensure the highest quality services to our customers. With locations in Dallas, TX and Ft. Lauderdale, FL, we pride ourselves on our customer connections and superior service.
About HatchWorks AI
HatchWorks AI is a digital innovation firm that builds AI-powered products and platforms to drive smarter business outcomes. Its multidisciplinary team—engineers, data scientists, UI/UX designers, and product strategists—transforms visionary ideas into enterprise-grade software. Committed to delivering exceptional experiences, HatchWorks AI uses Agile methodologies, cloud infrastructure, and advanced technologies to help clients navigate digital disruption and stay competitive.