Airlines Brace for Record Engine Maintenance Delays Amid Parts Shortage

Airlines are experiencing unprecedented engine maintenance delays, expected to peak in 2026, due to a parts and labor shortage. New and legacy engine turnaround times have increased significantly, leading to higher operational costs and constrained growth. Airlines face increasing operational burdens as they navigate these challenges.

Airlines are confronting their longest ever waits for engine maintenance, with demand likely to reach a peak in 2026, according to consultancy Bain. This situation is constraining carriers' growth and escalating costs amid a shortage of new aircraft.

A collision of part shortages, labor deficits, and unexpectedly high repairs for new-generation engines has put intense pressure on maintenance, repair, and overhaul (MRO) providers. Bain's report highlights that turnaround times for new-generation engines are 150% higher than pre-pandemic benchmarks and 35% higher for legacy engines.

Further complicating the scenario, delays in new aircraft deliveries mean airlines aren't retiring older planes, which require more complex maintenance and parts. Jim Harris, co-leader of Bain's global Aerospace and Defense practice, said, "Aircraft engine MRO demand is likely to experience a near-term peak in 2026 and remain constrained through the end of the decade."

Harris also warned that unless MRO companies swiftly address the capacity gap, airlines will face higher operational costs, exacerbated by the financial burden of decarbonizing air travel, potentially slowing passenger growth. Airlines have limited engine options for their jets, impacting their flexibility. CEO of Asia Digital Engineering (ADE) confirmed the industry's booming nature, with ADE set to open a new 14-line hangar in August.

Pratt & Whitney recently identified a rare powder metal defect affecting some A320neo engines, necessitating accelerated inspections that can take nearly a year. As a result, hundreds of aircraft have been grounded. Vietnamese aviation authorities are advising airlines to lease more aircraft to mitigate the impact of grounded planes.