Engine Upkeep and the Maintenance Industry Vision for 2025
As we charge into 2025, the aviation maintenance sector is bracing for a game-changing year. With over 9,000 engine overhauls and shop visits expected, the industry is facing an undeniable reality: aircraft are staying in the sky longer, and the demand for efficient, accessible, and innovative engine maintenance is skyrocketing.
Airlines and operators are pushing retirement ages beyond the conventional limits, driven by global supply chain chaos and constantly looming new aircraft production costs. This shift is rewriting the playbook for MRO providers, who must now find ways to streamline operations, maximize efficiency, and adapt to a rapidly changing landscape.
The ongoing supply chain disruptions remain one of the biggest hurdles. After years of pandemic-induced delays, geopolitical tensions, and material shortages, securing parts is a gamble. Operators are keeping aircraft in service longer, with average retirement ages pushing past 22 years. This shift requires leaner and more cost-effective MRO strategies to maintain profitability while meeting performance standards.
Supply Chain Disruptions Challenge MRO Providers
Adding to this complexity are the persistent troubles with Pratt & Whitney’s PW1100G engines. Affected by manufacturing defects in high-pressure turbine components, these issues have grounded numerous jets, including over 350 annually through 2026, forcing airlines to juggle schedules and rethink fleet management. For Indian carrier Go First, these problems have proven devastating, contributing to the airline’s bankruptcy earlier this year and leaving a cautionary tale of reliability risks amid rapid technological advancements.
Yet, the fallout from the PW1100G issues extends beyond Go First, affecting over 40 airlines globally and intensifying competition for engine slots in MRO facilities. With 32% of jets equipped with these engines now grounded, operators are scrambling to minimize disruptions. The ripple effect has created a surge in demand for reliable alternative engines, fueling challenges in the narrowbody segment and underscoring the importance of robust maintenance strategies.
Engine Component Shortage Redefines Inventory Management
Engine part availability still remains uncertain, and longer lead times are forcing MRO providers to rethink their entire approach to sourcing and stocking critical components. The answer lies in strategic diversification, stronger partnerships, and next-level inventory management systems that can handle today’s uncertainty.
Engine part availability still remains uncertain, and longer lead times are forcing MRO providers to rethink their entire approach to sourcing and stocking critical components. The answer lies in strategic diversification, stronger partnerships, and next-level inventory management systems that can handle today’s uncertainty.
At the same time, the surge in demand for engine services is only intensifying. Air traffic is climbing, but so are the maintenance needs for both older and newer aircraft engines. The challenges with next-gen engines like the LEAP and GTF models are only beginning to surface, as these cutting-edge technologies encounter performance roadblocks and operational issues that will require significant attention through 2025.
Yet, companies like Safran are adjusting their outlook, anticipating slower growth in their civil engine aftermarket business. While engine services are set for a solid mid-teens increase, spares will grow more modestly, reflecting a shift from the boom years of 2023 and 2024. Nevertheless, Safran’s projections remain strong, staying above historical norms and highlighting the critical role of aftermarket services in the aviation ecosystem.
Accelerating Turnarounds for Extended Engine Lifecycles
The real story of 2025, however, will be how the MRO industry tackles the ongoing pressure of increased shop visits, especially for legacy engines like the CFM56 and newer models such as the Leap-family engines. Safran’s figures show that CFM56 overhauls will peak in 2025 at about 2,300, and the Leap family will require nearly 2,000 visits, highlighting a massive shift toward servicing engines that are now approaching their overhaul milestones. These heavy checks, along with hospital visits, will make up a significant portion of the MRO market, especially as more and more aircraft are kept in service far beyond their original retirement schedules.
This extended engine lifecycle, particularly for the CFM56 and Leap engines, is driving the need for faster, more efficient turnarounds. Safran’s goal of achieving a 90-day turnaround for heavy Leap visits by 2025 is a bold declaration of intent, as the company ramps up its capacity with new facilities in Hyderabad, Queretaro, and Casablanca.
The Industry’s Choice for 2025: Adaptation
The question is: can the industry keep up? The demand for faster service times is colliding with the need for higher-quality maintenance, and the challenge is how to balance these priorities in an increasingly strained market.
In response, MRO providers are embracing technology like never before. Innovative engine maintenance tools, AI-driven diagnostics, and data analytics are no longer optional — they are essential to staying ahead of the curve. These innovations are not just about cutting costs. Now, they are also about ensuring that every engine remains in the air longer and that downtime is minimized. The combination of lean management practices and high-tech solutions will define the success of MRO operations in the coming years.
So, as we see now, the industry faces a stark choice: adapt or fall behind. With rising shop visit numbers and an increasing backlog of engine overhauls forecasted, MRO providers must be ready to act swiftly and strategically. 2025 is set to be a year of growth, but only for those who can innovate, execute, and overcome the unprecedented challenges ahead. The next chapter in engine maintenance will not be written by those who sit back — it will belong to those who forge the future with boldness and agility.
