Flight Path Frictions: Meeting the Surge in Engine Maintenance Demands

Release date: 2024 January 19

In aviation’s revival, the call for increased engine maintenance brings complex challenges. Airlines, striving to meet heightened servicing needs, face issues like longer wait times, rising costs, and a shortage of skilled personnel. Yet, the industry is doing its best to navigate these difficulties and respond effectively to the growing demands for engine maintenance.

In the post-pandemic era, passengers are making a comeback, and airlines are finding their rhythm akin to the pre-pandemic days. One might anticipate a similar trend in the maintenance market – with shops bustling, slots in high demand, and major MRO providers reporting profit upticks.

And it really does – but the scars left by the pandemic are still bleeding. Airlines are holding onto their wallets, working to recover from the financial challenges brought about by the pandemic and ongoing geopolitical uncertainties. Supply chain issues and inflation are adding complexity, impacting turnaround times, fleet availability, and parts procurement, creating significant challenges in the industry.

As a result, MRO providers are facing increased pressure to find innovative solutions and cost-saving measures to meet the demands of their airline customers. Aircraft engine MRO is a particularly obvious and important aspect in this scenario.

As we all know, crafted with – literally – tons of moving parts, aircraft engines showcase complexity, rendering their repair or replacement a demanding and time-consuming process. The specialized nature of this work necessitates specific tools and equipment, contributing to the overall financial investment.

Global Growth and Trends

This expensive engine matter hits airlines where it hurts. And such costs translate into heightened operating expenses, with rising airfares and moving cargo is also getting pricier. Furthermore, when an aircraft undergoes engine repairs or replacements, it is temporarily withdrawn from service, impacting the airline’s revenue. Safety concerns add an additional layer of complexity, underscoring the importance of thorough maintenance procedures.

Despite the financial hurdles, airlines persist in investing in aircraft engine repairs and replacements due to their indispensable role in ensuring safe and efficient flight operations. Additional insights into the costs associated with these endeavors include variations in the cost of a new aircraft engine, ranging from $1 million to $20 million, overhaul costs spanning from $250,000 to $1 million, and repair costs for an aircraft engine ranging from $1,000 to $100,000. These costs fluctuate based on factors like engine type, eventual damage severity, and regional labor rates.

In addition, the complex maintenance procedures required for engines also contribute to the overall time and resources needed for their upkeep. This can result in longer downtime for aircraft, further impacting the airline’s ability to generate revenue. Additionally, failure to properly maintain engines can lead to potential safety risks, highlighting the critical need for meticulous maintenance practices.

The global aircraft engine MRO market is anticipated to achieve a valuation of USD 51.41 billion by 2028, with a compound annual growth rate (CAGR) of 6.37% from 2023 to 2028. This growth is boosted by the escalating need for maintenance and repair services for aircraft engines, fueled by the continuous expansion of the global aircraft fleet.

Anticipating the Future of Aircraft Engine MRO

In terms of market trends, the increasing demand for maintenance and repair services stands out prominently. The global aircraft fleet is projected to witness an annual growth rate of 3.9% in the coming decade, consequently amplifying the demand for maintenance and repair services. Another noteworthy trend is the growing adoption of predictive maintenance, leveraging data analytics to anticipate potential aircraft engine failures and enabling proactive maintenance scheduling to minimize downtime.

Market segmentation plays a crucial role in understanding the dynamics of the aircraft engine MRO landscape. The segmentation is based on engine type, application, and region. Turbofan engines are foreseen to be the largest and fastest-growing segment over the next five years. In terms of application, commercial aviation is anticipated to dominate the market during this period. Geographically, North America is poised to be the largest market over the next five years.

Navigating the surge in aircraft engine maintenance demands poses a complex challenge, demanding a comprehensive and innovative approach. A range of key strategies has emerged to tackle this issue, each contributing to the overall goal of meeting heightened maintenance needs while maintaining operational efficiency and aircraft safety.

Collaborative Strategies in Addressing Maintenance Demands

One pivotal strategy involves a significant investment in predictive maintenance, where data analytics takes center stage in forecasting the demand for maintenance. This proactive approach empowers airlines to schedule maintenance preemptively, thus minimizing downtime and optimizing aircraft availability.

“The surge in aircraft engine maintenance demands is posing a complex challenge to the industry, requiring a complex approach.’ – explains Hanna Lavinskaja, Chief Business Development Officer at the Enginestands.com, an aircraft engine stands leasing service provider. – ‘Airlines and MRO businesses are investing in new technologies, expanding facilities, hiring more technicians, and partnering with other industry players to address the surge in demand.”

A collaborative approach is gaining prominence, with airlines, MRO providers, and engine manufacturers coming together to share insights, optimize processes, and foster innovation. Enhanced collaboration is proving instrumental in addressing the surge in maintenance demands.

Innovative Solutions: Automation, Robotics, and AR in Engine Maintenance

The integration of automation and robotics into maintenance processes is already seen as a game-changer, automating repetitive tasks, and enhancing precision. This not only boosts efficiency but also reduces reliance on manual labor.

Augmented Reality (AR) technology has also found its place in the field, offering real-time guidance to technicians during maintenance procedures. This innovative approach enhances the accuracy and efficiency of maintenance work while minimizing the risk of errors.

Effective streamlining of supply chain management is crucial to ensuring the availability of spare parts and components when needed, minimizing delays caused by shortages and facilitating timely maintenance. Yet, the shortage of skilled aviation technicians is a pressing concern, prompting initiatives such as specialized training programs and competitive compensation packages to attract more individuals to the field.

Utilizing data analytics for optimization is a contemporary strategy that identifies trends and patterns in engine performance, allowing for proactive maintenance scheduling and further minimizing unnecessary downtime.

By strategically implementing these diverse approaches, the aviation industry can effectively leverage the surge in aircraft engine maintenance demands, ensuring continued safety and reliability in air travel.

Looking ahead, the future of the aircraft engine MRO market hinges on the increasing demand for maintenance and repair services, the continued adoption of predictive maintenance, and the persistent challenge of rising labor costs. Additionally, the market is likely to be bolstered by the surging demand for new aircraft, as global airlines seek to modernize their fleets.



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