FL Technics has published an analysis examining the causes of Aircraft on Ground (AOG) incidents and the strategies airlines and maintenance, repair and overhaul (MRO) providers can deploy to manage and mitigate their impact. The commentary, issued on 24 February 2026, is authored by Viktor Bulanov, Head of Sales and Customer Support at FL Technics.
AOG EVENTS AS OPERATIONAL AND FINANCIAL DISRUPTION
Network and cost implications
According to Bulanov, AOG incidents create simultaneous operational disruptions, including flight cancellations, passenger rebooking and cargo rerouting. These events can also affect crew duty times, network connectivity and maintenance scheduling.
Airlines must respond rapidly, adjusting schedules and deploying replacement aircraft where possible. Financial consequences extend beyond direct revenue loss from grounded aircraft to passenger compensation, logistics costs and urgent parts sourcing.
PRIMARY CAUSES OF AOG INCIDENTS
Component failure
Component failures remain a principal cause of AOG events. Wear or unexpected technical issues may require immediate replacement before an aircraft can return to service.
Supply chain constraints
Supply shortages, including long lead times at Original Equipment Manufacturers (OEMs) and shop backlogs, can delay repairs and extend maintenance windows.
Parts location mismatches
A further challenge arises when parts are not positioned where they are required, creating logistical delays during time-critical events.
GLOBAL NETWORK AND RAPID RESPONSE
FL Technics reports that it maintains strategically positioned inventories across Europe, the Americas, the Middle East and the Asia-Pacific region. The company supports Boeing 737, Airbus A320 and Embraer aircraft families with both complete components and critical expendables and consumables.
With more than 100 line maintenance stations, urgent shipping solutions and 24/7 support, the organisation states that it can dispatch parts or identify alternative sourcing solutions to reduce operational disruption.
DEMAND FORECASTING AS PREVENTION
Data-driven positioning of stock
Beyond rapid response, Bulanov highlights demand forecasting as a proactive method to reduce AOG risk. By analysing usage patterns, reliability data and maintenance schedules, potential failures can be identified in advance.
FL Technics tracks performance data across its global customer base to identify failure patterns and pre-position critical components accordingly. Pooling arrangements and exchange programmes are also used to reduce exposure to AOG events.
COLLABORATION ACROSS THE INDUSTRY
Shared forecasts and tools
The analysis emphasises collaboration between MROs, OEMs and airlines. Sharing maintenance forecasts, inventory data and usage patterns can reduce both the likelihood and impact of AOG incidents. Joint use of specialised tools and test equipment is also cited as a means of improving efficiency while limiting capital expenditure.
FL Technics states that its digital collaboration platform connects more than 1,000 suppliers and processes over 50,000 parts requests per month. Exchange programmes are described as contributing to reduced AOG response times.
BALANCING FLIGHT KITS AND REMOTE WAREHOUSING
Optimising onboard inventory
Flight kits, comprising lightweight critical components carried onboard, are presented as one method of AOG preparedness. However, each additional component increases fuel burn and requires regular updating. Bulanov advises balancing coverage against weight and inventory costs.
Remote warehousing provides an alternative, with parts stored at strategic locations. The company’s experience suggests carrying a limited number of lightweight critical items onboard while relying on regional warehousing for the remainder.
PREPAREDNESS FOR REMOTE STATIONS
Contingency planning
Remote locations present additional challenges, including economic constraints, strict quality requirements and complex logistics. Procurement expenses may increase significantly in such environments.
The analysis recommends that airlines identify critical network points, validate local support capabilities and develop emergency contingency plans. These may include testing customs processes, confirming handler capabilities and evaluating multiple transport options.
FL Technics states that it maintains ready-response arrangements with customs authorities and handlers, supported by a 24/7 AOG desk and alternative routing plans to deliver parts within defined response windows.
SOURCE AMD IMAGES © : FL Technics
