Health and usage monitoring systems (HUMS) are gaining traction beyond their traditional stronghold in large offshore and military fleets.
As hardware becomes lighter, analytics more sophisticated, and pricing more competitive, a growing number of civil operators are taking a fresh look at the technology. The debate is shifting from proof of performance to proof of value, with operators focused on how to measure the return on investment.
Speaking at the Vertical MRO Conference in Irving, Texas, Ronnie Ries, vice president of marketing at GPMS, framed the discussion clearly: “Today we’re here to talk about making the business case for it.”
At its core, HUMS is about turning aircraft data into actionable insight. As Ries explained, “HUMS is a series of sensors installed throughout the aircraft … to measure the vibrations that are happening within the aircraft.”
Those sensors continuously capture vibration data from key components, such as gearboxes, bearings, and rotating assemblies, allowing operators to detect anomalies early and shift from reactive maintenance to a more predictive approach.
“All objects in motion experience vibration,” Ries said. “But those changes in the vibrations indicate the undesirable condition.”
The value lies in early detection. According to Ries, advanced systems “can typically tell you when there’s damage, at least 100 hours prior to when an actual chip light would occur.”
That lead time allows operators to flush oil, correct misalignment, or schedule maintenance before a minor issue becomes a major event. And that’s where the financial case begins.
“The cost of doing that is nothing compared to the cost of the downtime, because when your aircraft isn’t flying, you’re not making money.”
Ries emphasized that even a relatively inexpensive bearing failure can become financially significant when paired with lost flight revenue, aircraft on ground (AOG) logistics, and contractual penalties.
Historically, HUMS adoption was hindered by practical limitations. Early systems were heavy, costly, and often complex to interpret. As sensor technology has evolved, however, those barriers have diminished. “It’s now more achievable because of this lighter technology,” Ries said.
Comparing older systems to “bricks,” he noted that modern solutions leverage updated sensors, cloud connectivity, and simplified interfaces.
“It’s become significantly more accurate,” he said, “because we’re using the latest generation sensors.”
Ease of use is critical, especially for small and mid-sized operators without dedicated vibration analysts. “It has to be easy to use,” Ries stressed.
Modern platforms automate data transfer via Wi-Fi or cellular connections and provide trend analysis through cloud-based systems, reducing the need for specialized interpretation.
Beyond maintenance savings, safety organizations are increasingly highlighting HUMS as a preventive tool. “The reality is, 30% of all maintenance related helicopter accidents happen within the first 10 hours after a maintenance event,” Ries said.
That statistic alone underscores HUMS’ potential role in post-maintenance validation. While not every issue can be predicted, vibration monitoring can reveal improper assembly, misalignments, and emerging component faults before they escalate.
Still, safety alone doesn’t always unlock budget approval.
“Safety is first. That’s what we always say. The reality is, not everybody prioritizes paying for safety,” Ries said.
To get leadership on board, operators need to take a hard look at what they’re already spending, especially the costs that tend to fly under the radar. Ries encouraged attendees to calculate unbudgeted replacement parts, AOG shipping charges, overtime troubleshooting hours, fuel burned during repeated track-and-balance flights, and contract penalties.
“It’s really quantifying all the money that you’re spending already that nobody thinks about,” he said.
Many of those costs are treated as routine operating expenses rather than avoidable inefficiencies. “For most people, this is just a line item that they pay every year — that they don’t think about differently,” Ries noted.
But industry data suggests measurable savings. “On average, you can save at least 30% hard costs with HUMS,” he said.
Even conservative estimates, about 5% to 10%, can shift the financial equation when applied across parts, labor, and downtime.
As Ries emphasized, not every benefit of HUMS can be captured in a spreadsheet. While the financial case matters, operators also report meaningful operational gains. Faster troubleshooting can take pressure off maintenance teams and boost morale. Reliable rotor track and balance data helps avoid chasing unnecessary adjustments. And flight data monitoring supports smoother, more disciplined flying, reinforcing best practices over time.
At the leadership level, the case for HUMS has to be framed with the audience in mind, Ries said. A CEO may focus on asset longevity and competitive positioning in contract bids. A CFO will zero in on budgets and return on investment. Meanwhile, a director of maintenance is typically concerned with dispatch reliability, fewer unscheduled events, and greater predictability in the maintenance plan.
Ultimately, Ries argued, making the business case for HUMS goes beyond explaining how the technology works. It requires operators to capture the right data, document avoided failures, and take a closer look at the long-accepted costs associated with downtime and operational risk.
As systems become lighter, more capable, and easier to implement, Ries suggested the conversation is shifting. For many operators, the more pressing question is no longer whether operators can justify investing in HUMS, but what it costs to continue operating without it.
In case you missed it: At the 2025 Vertical MRO Conference in Kelowna, B.C., GPMS’ Ronnie Ries hosted a panel with operators sharing their first-year experiences implementing HUMS across their fleets. Hear the full discussion on the Vertical MRO Podcast.
The Vertical MRO Conferences return this fall to Kelowna, B.C. October 5 – 7 and Irving, Texas, November 16-18, 2026. To see this year’s panelists and presentation offerings and to register, visit the Vertical MRO Conference’s website.
