SUPPLY CHAIN PRESSURES CONTINUE TO IMPACT AIRLINES

The International Air Transport Association (IATA) has identified four priority areas to strengthen the aviation supply chain, warning that ongoing shortages of aircraft, engines, spare parts and maintenance capacity are placing increasing pressure on airline operations. The recommendations were presented at the inaugural IATA World Maintenance and Engineering Symposium in Madrid.

According to IATA, the global aircraft order backlog now exceeds 18,000 aircraft, while the average age of the world airline fleet has reached a record 15.2 years. The association estimates that supply chain disruptions cost airlines at least US$11 billion during 2025 through higher lease rates, increased maintenance expenses and missed efficiency gains from delayed deliveries of newer aircraft.

IATA Director General Willie Walsh said the industry remains short of more than 5,000 fuel-efficient replacement aircraft that airlines had expected to enter service.

FOUR PRIORITIES FOR A MORE RESILIENT SUPPLY CHAIN

IATA’s recommendations focus on improving supply chain visibility, increasing competition within the aftermarket sector, accelerating the adoption of data and digital tools, and addressing workforce shortages.

The association is calling for manufacturers to provide earlier and more reliable information on aircraft delivery delays, repair turnaround times, spare parts availability and known bottlenecks, allowing airlines to plan fleet operations more effectively.

It also advocates wider access to third-party maintenance, repair and overhaul (MRO) providers, alternative parts and approved repair solutions. According to IATA, commercial restrictions on repair instructions, tooling and spare parts distribution can limit competition, increase costs and extend maintenance delays.

The association further highlighted the role of digitalisation and artificial intelligence in improving inventory management, forecasting parts shortages and supporting maintenance planning. At the same time, IATA warned that the industry must address a growing skills shortage, noting Boeing’s forecast that approximately 710,000 new maintenance technicians will be required globally over the next 20 years.

ENGINE MRO BOTTLENECKS UNDER SCRUTINY

Separately, IATA and consultancy Emerton released a study examining maintenance, repair and overhaul challenges affecting the latest generation of single-aisle aircraft engines, including CFM International’s LEAP engine and Pratt & Whitney’s Geared Turbofan (GTF) family.

The report identifies engine durability concerns, shortages of spare parts, limited availability of replacement engines and constrained aftermarket access as key factors disrupting airline operations. These challenges have reduced engine time on wing, increased demand for shop visits and complicated fleet planning.

At its peak in March 2025, 648 aircraft powered by Pratt & Whitney GTF engines were grounded while awaiting maintenance, spare engines or replacement parts. This represented approximately 28% of the global GTF-powered fleet at the time.

MAINTENANCE DEMAND SET TO GROW

The study notes that demand for engine maintenance will continue to increase as the global fleet expands. Deliveries of single-aisle aircraft engines reached approximately 2,000 units in 2024 and are expected to rise to around 3,700 annually between 2030 and 2040.

As a result, annual shop visits for LEAP engines are forecast to grow from between 600 and 800 in 2025 to more than 5,000 by 2040. GTF engine shop visits are expected to increase from around 1,000 annually to more than 2,000 over the same period.

To address these challenges, IATA recommends increasing spare parts availability, accelerating the approval of repair solutions, expanding access to used serviceable material and removing barriers that limit independent MRO participation. The association also calls for greater transparency and competition across the aftermarket sector to improve long-term operational resilience.

MANDATES MUST MATCH INDUSTRY CAPACITY

In addition to supply chain concerns, IATA urged regulators to adopt realistic timelines for aircraft equipment and avionics mandates. The association said compliance schedules must reflect certification timelines, equipment availability, installation capacity and broader supply chain constraints.

IATA has raised concerns with the International Civil Aviation Organization (ICAO) regarding implementation requirements linked to the Global Aeronautical Distress and Safety System (GADSS), Runway Overrun Awareness and Alerting Systems (ROAAS), and Automatic Dependent Surveillance-Broadcast (ADS-B).

The association maintains that maintaining safety improvements requires globally coordinated implementation schedules that are achievable within existing certification and maintenance capacity constraints.