Kalitta Air Company Profile

Kalitta Air is an all-cargo Part 121 airline based in Ypsilanti, Michigan. They pride themselves in providing on-time scheduled transportation services anywhere, anytime. Privately owned by Connie Kalitta, the organization operates an all-Boeing fleet with Boeing 747-400s, 777-200Fs and 777ERSF’s.

In 2022, Kalitta Air operated around 19,000 flights within the US and to places as far away as the UK and Australia. With over 900 employees who machine, design, and build virtually every component on a Boeing airplane in-house, they eliminate relying on outside parties for repairs, maintenance, and upgrades for its purposes. From the landing gear to complete engines, Kalitta Air manufactures everything but the bones and shell of the plane, making it a global leader in airline manufacturing and service operations.

Opportunity to Transform

Kalitta Air’s decision to partner with TrustFlight was driven by several key factors. At the forefront was their need for a flexible solution that could seamlessly integrate with their existing systems, particularly AMOS, which they had implemented just a few years prior. TrustFlight’s strong emphasis on integrations gave them the confidence that our ETL solution would be future-proof and adaptable to their daily operational requirements. They understood that while the data they generate would remain the same, they needed to improve the way they processed and managed that information. TrustFlight’s deep subject matter expertise in airworthiness and CAMO/technical services further solidified their choice. Our hands-on experience mirrored their own operations, allowing them to view us not just as a provider, but as their peers.

From an enterprise-wide perspective, they realized that simply replacing a process without adding true value would not bring lasting improvements. TrustFlight’s ETL solution allowed them to transform their operations from outdated, paper-based methods to an efficient, digital ecosystem. This shift helped them eliminate up to 85% of previously identified errors, significantly boosting operational efficiency by automating tasks and ensuring consistency.

Integrating TrustFlight’s ETL with their existing AMOS system was crucial for Kalitta Air. The two-way integration meant that the information they entered could flow seamlessly between departments, enhancing collaboration between maintenance and crew teams and reducing delays and human error. Furthermore, the ability to customize the Electronic Tech Log to resemble their existing processes minimized the need for extensive retraining, streamlining adoption across our large workforce.

Kalitta Air noted that what truly set TrustFlight apart was our balance of technical expertise and aviation experience. Our team understood the unique, real-world scenarios they face daily, allowing us to accommodate their specific requests with an informed perspective. This made the partnership with TrustFlight not only practical but a strategic advantage for Kalitta Air.

Strategy Execution

Kalitta Air’s journey with TrustFlight began in May 2023, following their initial assessment of the leading ETL providers at an Aircraft Commerce Conference. After a kick-off meeting, they established weekly project follow-ups to monitor progress and ensure the smooth implementation of the ETL solution. By September 2023, they had initiated parallel trials and were awaiting final authority approval for the change.

They began the trials with a small, controlled group on specific routes, using selected aircraft, mechanics, and crew. One of the initial challenges they faced was connectivity due to the global nature of their operations.

However, they noted that TrustFlight’s offline mode—allowing updates to be made without an active internet connection—proved invaluable.

Even when connectivity issues arose, they were able to continue processing inputs as a technical log offline, with the data syncing automatically to ground support once connectivity was restored. This built-in feature was an unexpected yet crucial solution for Kalitta Air, helping them maintain momentum during the trials.

The trials have been a resounding success to date, thanks in large part to the consistent two-way communication between Kalitta Air and TrustFlight. TrustFlight’s ability to speak their language and provide around-the-clock support meant that even minor issues were addressed promptly. They noted that his level of support was exactly what they were seeking in a partner.

Outcome

Kalitta Air’s trials have been a resounding success. Although they ran into some minor challenges during implementation, these challenges provided them with insightful information moving forward. They learned that it was vital to prepare the company for the change. To aid this transition, TrustFlight’s ETL made it easy to reduce friction by customizing the application, so it was familiar to Kalitta Air personnel. This is only one reason why the partnership was so successful.

As a result of the implementation, Kalitta Air knew they could eliminate up to 85% of identified errors by doing away with pen and paper. The key metrics they used to ensure their investment was conducive to their business success, was looking at the average error rates per page and per leg with the paper system across 19,000 flights and calculating that on a human hourly rate. They then factored this by the number of flights, processes, and corrections they had.

Although it is too early to quantify the impact, Kalitta Air believe the significant efficiency, safety and reliability gains are invaluable to the company’s goals.

Luke Usher - QC Records Manager, Kalitta Air

“We couldn’t be happier with our selection and the ongoing support that TrustFlight has provided, and we look forward to working with them in the coming months and years.”