AOG risk map

Core meaning

An **AOG risk map** is a structured representation of the process, part, and supplier risks that can lead to **aircraft-on-ground (AOG)** events—situations where an aircraft is unable to operate because required parts, repairs, or documentation are not available.

It typically combines:

– Critical aircraft parts, systems, or configurations that can cause AOG if unavailable or non-conforming.
– Manufacturing and maintenance process steps that affect those parts.
– Suppliers and logistics paths that provide those parts or services.
– Risk indicators such as likelihood of disruption, detection capability, and potential operational impact.

The result is a map—often visual but sometimes tabular—that links operational risks in factories, supply chains, and MRO (maintenance, repair, and overhaul) operations to their potential to create AOG situations.

Use in industrial and aerospace workflows

In aerospace manufacturing and MRO environments, an AOG risk map is commonly used to:

– Identify which parts or assemblies are AOG-critical and where they are produced or controlled.
– Trace how issues in upstream processes, quality controls, or suppliers could cascade into AOG events.
– Prioritize monitoring, contingency planning, and escalation paths for high-risk items.
– Align OT/IT, MES, ERP, and supply-chain systems around consistent AOG-critical object lists and risk attributes.

Operationally, manufacturing, supply chain, quality, and engineering teams may reference the AOG risk map when:

– Assessing the impact of process changes or capacity shifts on AOG-critical parts.
– Evaluating new or alternative suppliers for components with AOG exposure.
– Routing nonconformances, deviations, or concession requests involving AOG-critical items.
– Coordinating responses to disruptions (e.g., late deliveries, quality escapes) that could ground aircraft.

Structure and data sources

An AOG risk map often aggregates data from multiple systems, for example:

– **ERP/MRP**: part master data, criticality flags, demand profiles.
– **MES/production systems**: routings, work centers, process history, WIP positions.
– **Quality systems (QMS, LIMS, CAPA tools)**: nonconformance history, escape risks, defect trends.
– **Supplier and logistics systems**: lead times, performance, single- or sole-source exposure.

The “map” may be implemented as:

– A visual node-and-link diagram connecting parts, processes, suppliers, and AOG risk levels.
– A matrix or table with part numbers, plants, suppliers, and risk ratings.
– A model embedded in analytics or operations-intelligence platforms that supports filtering and alerts for AOG risk.

Boundaries and exclusions

An AOG risk map:

– **Includes**: risks specifically tied to aircraft being unable to depart or continue service due to missing, delayed, or non-conforming parts, documentation, or repairs.
– **Can include**: manufacturing, maintenance, supply, and logistics risks where their consequence is framed in terms of AOG probability or duration.
– **Excludes**: general enterprise risk maps that do not explicitly tie risks to AOG impact (e.g., purely financial or reputational risks without an AOG linkage).
– **Is not the same as**: a full safety hazard analysis (which focuses on hazards to people and equipment) or a generic FMEA, although those analyses may feed into an AOG risk map.

Common confusion and related terms

– **AOG vs. general production risk mapping**: AOG risk mapping is specifically oriented to aircraft-grounding consequences, not just late orders or production delays. A part can be high risk for schedule yet low AOG risk if it does not impact aircraft dispatch.
– **AOG risk map vs. critical part list**: A critical part list is typically a flat list of high-importance items. An AOG risk map adds structure, showing how those items link to processes, plants, suppliers, and potential failure paths.
– **AOG risk map vs. bow-tie or fault tree analysis**: Bow-tie or fault tree diagrams analyze causal chains for specific events. An AOG risk map is broader, aggregating many potential causes and pathways into one coherent view focused on AOG exposure.

Application in the site context

Within aerospace factories and regulated manufacturing environments, an AOG risk map is often maintained as part of broader risk and operations-intelligence practices. It is used to align MES, ERP, QMS, and supply-chain data around a shared understanding of AOG-critical items, making it easier to:

– Monitor production and quality signals that may affect AOG-critical parts.
– Coordinate cross-functional response when disruptions occur.
– Review and update risk assessments when there are changes in demand, suppliers, or process design.

The map is generally kept as a living artifact, subject to both periodic review and event-driven updates when material changes occur in products, processes, or supply networks that influence AOG risk.