Driving Sustainable MRO: Collins Aerospace Expands Deployment of ABI BoardMaster Diagnostic Technology

In a significant move to enhance sustainability and efficiency in electronic maintenance, Collins Aerospace has expanded the use of ABI’s BoardMaster diagnostic and test system to two additional global sites: the Netherlands and Puerto Rico. This marks the system’s integration into five Collins facilities across three countries, reinforcing the company’s long-term commitment to localised repair, supply chain resilience, and environmental responsibility.

The BoardMaster provides comprehensive board-level diagnostic capabilities that enable Collins technicians to isolate faults with unmatched precision. Capable of non-destructive testing and real-time fault identification, BoardMaster allows engineers to test analogue and digital components both in-circuit and out-of-circuit to identify faults without requiring a full disassembly or functional teardown. In practice, this has led to a dramatic reduction in downtime time. Repairs, that once required up to 50 hours of troubleshooting, can now be completed within 10 minutes. That acceleration translates to significantly reduced turnaround times and a substantial cut in material waste and logistics overhead. Rather than discarding line-replaceable units or shipping them offsite for assessment, Collins can now resolve issues at the component level, in-house, and with full confidence in repair integrity.

📸 Image: FAA via SamChui.com

While reducing costs and repair times are stand out benefits, this strategy delivers deeper value in three key aspects:

• Supply chain resilience has become increasingly critical as global disruptions continue to impact the availability of electronic components. By enabling in-house repair of printed circuit boards, Collins Aerospace reduces its dependence on external vendors and procurement reducing the impact of shortages and accelerating maintenance turnaround to ensure operational readiness, vital in high-stakes aerospace and defence programs.

• At the same time, the approach supports environmental sustainability. Discarding entire boards due to a minor component failure is incredibly wasteful and significantly contributes to the global e-waste crisis. The BoardMaster’s advanced diagnostic capabilities can pinpoint faults at the component level, dramatically reducing waste and extending the lifespan of valuable equipment.

• Perhaps most importantly, this strategy fosters workforce development. Providing engineers with sophisticated diagnostic tools and training not only enhances their technical skills but also boosts engagement, job satisfaction, and a sense of ownership. It’s an investment that is strengthening the company’s long-term capacity for innovation and resilience.

In July 2025, engineers at the Netherlands site completed an intensive ABI training program focused on advanced diagnostic techniques and customised workflow integration. One lead engineer at the training shared:

“We are enthusiastic and see many possibilities for the BoardMaster to help us repair PCBs. The training provided has given us the knowledge to use the BoardMaster in many different ways. ABI is a unique company where all employees work together passionately on unique products”

Collins Aerospace, having initially adopted the BoardMaster in 2019, has since seen remarkable, measurable success from the new strategy and the recent acquisitions in the Netherlands and Puerto Rico represents a significant expansion of that, increasing standardise high-quality, sustainable repair practices globally. As many organisations default to replacements over repair, Collins is setting a new standard, demonstrating that sustainability and performance can go hand in hand. As they continue to scale there BoardMaster deployment, it presents a compelling model for the aerospace sector and beyond. With each site integration, the company strengthens its maintenance strategy, prioritising repair-first thinking, localised expertise, and sustainable operations and ABI is proud to support this journey. Together, Collins Aerospace and ABI are continuing to prove that with the right tools and training, the future of maintenance is not replacement but repair!