The thing on the underside of the aircraft that pulls signal from the satellite is an antenna, and
antennas on commercial aircraft have a specific maintenance pattern called no-fault-found. The airline
pulls the antenna because the system reports a fault. The maintenance team examines the antenna. The
maintenance team finds nothing wrong with it. The antenna is reinstalled on the aircraft. Everyone is
unhappy. The airline has paid for the maintenance window. Gogo has paid the airline for the downtime
under their service contract. The antenna fails again three weeks later, in the same way, for the same
reason that nobody has yet identified.
Gogo had been living with this for several years. The no-fault-found rate was a line on their
operating losses that everyone had stopped looking at because nobody could see what to do about it.
We took this project.
We started where every credible AI engagement should start: by assessing whether their data was ready
to be acted on by a model in the first place. Our team migrated their on-premise data infrastructure
to a cloud architecture, built a unified data platform aggregating more than twenty source streams
from the antennas, the maintenance records, and the flight telemetry, and trained predictive models on
the combined picture. The models began to anticipate antenna failures with better than ninety percent
accuracy, twenty to thirty days in advance. The pattern is the same one our chief technology officer,
Valentyn Kropov, has written about in the context of AI site reliability engineering: most production
failures take longer to diagnose than to fix, and the value of an AI-driven system sits in the minutes
between detection and resolution. The no-fault-found rate dropped by seventy-five percent.
But the seventy-five percent number is not the real story. The real story is what the models found.
The antennas were failing after the application of de-icing fluid at certain northern airports during
certain months of the year. The chemical was reaching the antenna housing and working through the seal
in a slow chemistry that had not appeared in any laboratory test, because no laboratory had thought to
run that specific test. Once the pattern became visible in the data, Gogo's engineers added a
protective layer to the antenna housing. The failure mode stopped. The savings went directly to
operating profit.
This is what an AI project looks like when it actually works. The model produced a finding. The
finding was specific. The finding could be acted on. The action was physical. The physical action
ended a problem that had been costing real money for many years. There is no demonstration here. It is
only an aircraft antenna, a piece of de-icing fluid chemistry, and a software pipeline that joined
them together long enough for a human engineer to see the connection. The data engineering and the AI
engineering were the same team, working from the same backlog, against the same audit trail. Most of
the failures we see in our industry come from the gap between those two functions. We do not run that
gap.