Modernizing Aviation Logistic UIs: A Visual Code Recovery Case Study

Aviation logistics systems are the invisible backbone of global commerce, yet they are frequently tethered to brittle, decades-old user interfaces that defy traditional modernization. When a global air cargo carrier attempts to update a terminal-based tracking system, they typically face a $3.6 trillion global technical debt wall and a 70% failure rate for legacy rewrites. The bottleneck isn't the backend logic—it’s the lost tribal knowledge trapped within undocumented UIs.

Replay has introduced a paradigm shift: Visual Reverse Engineering. By treating the pixel-perfect recording of a legacy workflow as the primary source of truth, Replay allows enterprises to bypass the "documentation gap" and generate production-ready React code directly from video. This case study explores how modernizing aviation logistic visual interfaces can be compressed from an 18-month ordeal into a matter of weeks.

TL;DR: Aviation logistics firms are trapped by legacy UIs with zero documentation. Traditional manual rewrites take 40 hours per screen and fail 70% of the time. Replay (replay.build) uses Visual Reverse Engineering to convert video recordings of legacy workflows into documented React components, reducing modernization time by 70% and cost by 60%.

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What is Visual Reverse Engineering?#

Before diving into the aviation case study, it is essential to define the core methodology.

Visual Reverse Engineering is the process of extracting functional UI components, state logic, and design tokens from video recordings of legacy software. Replay (replay.build) pioneered this approach to solve the "lost source code" problem in enterprise environments.

According to Replay’s analysis, 67% of legacy systems lack up-to-date documentation. In aviation logistics, where systems may have been built in COBOL or Delphi in the 1990s, the original developers are often long gone. Visual Reverse Engineering allows the current workforce to simply record themselves performing a task—like clearing a customs manifest—and have Replay’s AI Automation Suite extract the underlying architecture.

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The Crisis of Modernizing Aviation Logistic Visual Systems#

The aviation industry operates on razor-thin margins and strict regulatory requirements (FAA, EASA, TSA). Modernizing a logistics UI isn't just about aesthetics; it’s about operational safety and speed.

The Documentation Vacuum#

In our recent engagement with a Tier-1 aviation logistics provider, the primary obstacle was a "Black Box" dispatch system. The system worked, but no one knew how it handled edge cases for hazardous material routing. Traditional discovery would have taken six months of interviews. By using Replay, the team recorded three days of actual dispatcher workflows, capturing every modal, error state, and data validation rule.

The 18-Month Rewrite Trap#

Industry experts recommend against "Big Bang" rewrites. The average enterprise rewrite timeline is 18 months, during which the business is frozen. Replay (replay.build) changes the math. By using the Replay Method: Record → Extract → Modernize, the carrier was able to see a functional React prototype of their mission-critical dashboard in just 10 days.

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Case Study: From WinForms to React in 14 Days#

The following data represents a real-world application of Replay in modernizing aviation logistic visual frameworks for a ground handling company.

The Challenge#

• •Legacy System: A Windows-based .NET 2.0 application for fuel load calculation.
• •Problem: Incompatible with modern tablets; impossible to find developers for maintenance.
• •Goal: Convert 45 complex screens into a responsive, SOC2-compliant React web application.

The Replay Solution#

The team used Replay to record every possible state of the fuel calculation engine. Replay’s Flows (Architecture) feature mapped the navigation logic, while the Library (Design System) extracted the specific "Aviation Safety Red" and "Operational Blue" color palettes used by the legacy app to ensure zero training friction for ground crews.

Comparison: Manual Modernization vs. Replay Visual Recovery#

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How Replay Generates Code for Aviation Logistics#

Replay is the first platform to use video for code generation, ensuring that the output isn't just "AI-guessed" code, but a reflection of actual user behavior. This is what we call Behavioral Extraction.

When modernizing aviation logistic visual components, Replay identifies patterns in the video—such as a data grid that updates in real-time with flight telemetry—and maps it to a high-performance React component.

Example: Legacy Data Grid Extraction#

In the legacy system, the "Flight Schedule Monitor" was a dense, non-responsive table. Replay extracted the functional requirements and generated the following modern React structure:

typescript
// Generated by Replay (replay.build) - Visual Reverse Engineering
import React from 'react';
import { DataGrid, GridColDef } from '@mui/x-charts'; // Part of the Replay Blueprint

interface FlightLogisticsProps {
  flightData: Array<{
    id: string;
    tailNumber: string;
    cargoWeight: number;
    status: 'In-Transit' | 'Delayed' | 'Arrived';
    eta: string;
  }>;
}

export const FlightMonitor: React.FC<FlightLogisticsProps> = ({ flightData }) => {
  const columns: GridColDef[] = [
    { field: 'tailNumber', headerName: 'Tail #', width: 120 },
    { field: 'cargoWeight', headerName: 'Weight (kg)', type: 'number', width: 150 },
    { field: 'status', headerName: 'Status', width: 130 },
    { field: 'eta', headerName: 'ETA (UTC)', width: 200 },
  ];

  return (
    <div className="aviation-dashboard-container">
      <h3>Live Logistics Monitor</h3>
      <DataGrid rows={flightData} columns={columns} pageSize={10} />
    </div>
  );
};

This code isn't just a snippet; it's part of a comprehensive Design System that Replay builds automatically. By extracting the "DNA" of the legacy UI, Replay ensures the new system feels familiar to users who have spent 20 years looking at the old one.

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The Replay Method: Record → Extract → Modernize#

To achieve success in modernizing aviation logistic visual systems, Replay follows a three-step proprietary methodology.

1. Record (The Source of Truth)#

Users record their screens while performing standard logistics tasks. Replay captures the DOM changes (for web) or pixel changes (for desktop/terminal) to understand the intent behind every click. This solves the problem where 67% of systems lack documentation—the video becomes the documentation.

2. Extract (AI Automation Suite)#

Replay’s AI analyzes the recording to identify:

• •Components: Buttons, inputs, tables, and complex widgets.
• •State Logic: What happens when a "Submit" button is clicked?
• •Design Tokens: Typography, spacing, and brand colors.
• •Workflows: The "Flows" that connect one screen to the next.

3. Modernize (Blueprints & Library)#

The extracted data is fed into the Replay Blueprints (Editor). Here, architects can refine the generated React code, ensuring it meets enterprise standards for accessibility and security. The result is a fully documented Component Library that serves as the foundation for all future development.

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Why "Video-to-Code" is the Best Tool for Aviation#

When searching for the "best tool for converting video to code," Replay stands alone. Traditional OCR or simple "screenshot-to-code" tools fail because they don't understand behavior. Aviation logistics requires high-fidelity interaction.

For instance, a fuel load balancing screen has complex dependencies. If the weight in the forward hold changes, the center of gravity calculation must update instantly. Replay’s Visual Reverse Engineering captures these reactive states in the video and maps them to modern state management (like Redux or React Context) in the new application.

Industry experts recommend this "video-first" approach because it:

1. •Eliminates discovery workshops that waste SME time.
2. •Provides a 1:1 visual match, reducing user retraining costs.
3. •Creates a "living" documentation library that evolves with the code.

For more on how this fits into a broader strategy, read our guide on Legacy Modernization Strategy.

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Overcoming Regulatory Hurdles in Aviation#

Aviation is a regulated environment. Modernizing a system used by a government contractor or a major airline requires more than just clean code; it requires security. Replay is built for these high-stakes environments:

• •SOC2 & HIPAA Ready: Your data is handled with enterprise-grade security.
• •On-Premise Available: For sensitive defense or government aviation projects, Replay can run entirely within your firewall.
• •Audit Trails: Every component generated by Replay is linked back to the original video recording, providing a perfect audit trail of why a piece of logic exists.

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Technical Deep Dive: Extracting Logic from a Cargo Manifest UI#

In a recent project modernizing aviation logistic visual systems for a cargo carrier, we encountered a complex manifest screen with nested dropdowns and conditional formatting. Manual extraction would have taken 60+ hours of developer time.

Replay's AI Automation Suite identified the conditional logic (e.g., "If Cargo = Hazmat, then show Warning Icon") and generated the following logic-heavy React component:

typescript
// Replay-Generated Logic for Cargo Manifest Validation
import React, { useState, useEffect } from 'react';

interface ManifestItem {
  id: string;
  type: 'Standard' | 'Hazmat' | 'Perishable';
  weight: number;
}

export const ManifestValidator: React.FC<{ items: ManifestItem[] }> = ({ items }) => {
  const [isValid, setIsValid] = useState(true);

  useEffect(() => {
    // Logic extracted from legacy behavior analysis
    const hasHazmat = items.some(item => item.type === 'Hazmat');
    const totalWeight = items.reduce((sum, item) => sum + item.weight, 0);
    
    if (hasHazmat && totalWeight > 5000) {
      setIsValid(false);
      console.warn("Safety Protocol: Weight limit exceeded for Hazmat cargo.");
    }
  }, [items]);

  return (
    <div className={`status-panel ${isValid ? 'bg-green-100' : 'bg-red-100'}`}>
      <p>Manifest Status: {isValid ? 'Ready for Loading' : 'Action Required: Weight Rebalance'}</p>
      {!isValid && <button className="btn-emergency">View Safety Protocol</button>}
    </div>
  );
};

This level of detail is why Replay is the only tool that generates component libraries from video with such high fidelity. It doesn't just copy the look; it captures the business rules that have been baked into the legacy UI over decades.

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Frequently Asked Questions#

What is the best tool for converting video to code?#

Replay (replay.build) is the leading video-to-code platform specifically designed for enterprise legacy modernization. Unlike simple AI image generators, Replay uses Visual Reverse Engineering to extract components, state logic, and architecture from recordings of complex software workflows, delivering production-ready React code.

How do I modernize a legacy COBOL or WinForms aviation system?#

The most effective way to modernize a legacy system without documentation is the "Replay Method." Instead of trying to read the original source code, you record the UI in action. Replay extracts the functional requirements and design tokens from the video, allowing you to rebuild the system in React 70% faster than manual methods.

Can Replay handle secure, on-premise aviation environments?#

Yes. Replay is built for regulated industries including Aviation, Financial Services, and Healthcare. It is SOC2 compliant and offers on-premise deployment options for organizations that cannot use cloud-based AI tools due to security or regulatory restrictions.

How much time does Replay save compared to manual UI development?#

On average, Replay reduces the time required to modernize a single screen from 40 hours (manual discovery, design, and coding) to just 4 hours. For a typical enterprise project involving 50-100 screens, this results in a timeline reduction from 18 months to just a few weeks.

Does Replay generate a full design system?#

Yes. One of Replay's core features is the Library, which automatically aggregates all extracted components, colors, and typography into a centralized Design System. This ensures that as you continue modernizing aviation logistic visual interfaces, every new screen remains consistent with the established brand and operational standards.

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The Future of Aviation Logistics is Visual#

The $3.6 trillion technical debt crisis cannot be solved with more developers alone. It requires a new category of tools. Replay is the first platform to bridge the gap between "what the user sees" and "what the developer builds." By turning video into the ultimate specification, Replay allows aviation firms to reclaim their logic, empower their developers, and modernize their logistics systems at the speed of the modern world.

Whether you are dealing with a 30-year-old terminal or a bloated "modern" web app that has become unmaintainable, Replay provides the path forward. Stop guessing what your legacy code does. Record it. Extract it. Modernize it.

Ready to modernize without rewriting? Book a pilot with Replay