IATA: Urgent Action Needed to Alleviate Engine MRO Bottlenecks

The International Air Transport Association (IATA), in collaboration with Emerton, has released a new study focusing on bottlenecks in the maintenance, repair, and overhaul (MRO) of next-generation single-aisle aircraft engines, primarily covering CFM International's LEAP engines and Pratt & Whitney's Geared Turbofan (GTF) engines.

The study, titled Single-Aisle Engine MRO: Strategic Levers to Address Supply Chain Challenges, finds that engine durability issues, spare parts shortages, limited availability of spare engines, and restricted aftermarket access are disrupting airline operations. These pressures are driving up operating costs, including reduced time-on-wing, increased shop visit requirements, and greater complexity in airline maintenance planning.

As of March 2025, the number of aircraft grounded due to Pratt & Whitney GTF engine issues peaked at 648, accounting for 28% of the GTF fleet. These aircraft are awaiting engine shop visits, spare engines, or component supplies. Affected airlines have been forced to adjust fleet plans, including retaining older aircraft, extending lease terms, or taking additional aircraft on lease, while correspondingly adjusting capacity.

With the continued expansion of the next-generation single-aisle fleet, this challenge is expected to intensify. In 2024, single-aisle engine deliveries totaled 2,000 units, comprising 800 GTF engines and 1,200 LEAP engines. Between 2030 and 2040, annual engine deliveries are projected to stabilize at approximately 3,700 units, with 1,200 GTF engines and 2,500 LEAP engines.

Accelerating delivery volumes will significantly drive up maintenance demand. By 2040, annual shop visits for LEAP engines are projected to increase from approximately 600–800 in 2025 to over 5,000; for GTF engines, annual shop visits are expected to rise from 1,000 to over 2,000.

Willie Walsh, IATA's Director General, stated: "Engine MRO bottlenecks are disrupting airline operations. With the growing fleet of next-generation single-aisle aircraft, the situation will only worsen without significant changes. Manufacturers are investing to expand capacity, but capacity alone is not enough. Airlines need faster access to spare parts, more approved repair solutions, fair access to MRO capacity, and greater competition in the aftermarket."

Although no single solution can alleviate the current situation, the study identifies several areas where value chain stakeholders can take action to enhance resilience in both the near and long term:

• Improving the supply capacity of engine components;

• Ensuring fair access to the MRO market;

• Securing long-term spare parts availability;

• Adopting industry-wide best practices.

Implementing these priorities requires coordinated action across the aviation supply chain. Airlines, aircraft and engine manufacturers, MRO providers, and lessors must work together to increase component supply, expand repair options, and better align engine maintenance capacity with airline operational requirements.