The global aviation industry must take urgent action to strengthen maintenance and supply chain resilience as airlines continue to grapple with aircraft delivery delays, spare parts shortages, engine reliability issues, and constrained MRO capacity, according to the International Air Transport Association (IATA).
Speaking at the inaugural World Maintenance and Engineering Symposium (WEMS) in Madrid, where MRO Business Today is the official media partner, IATA highlighted the growing financial and operational impact of supply chain disruptions across the aviation ecosystem.
According to IATA, supply chain challenges are expected to cost airlines more than $11 bn in 2025 alone, including $4.2 billion in delayed fuel savings due to older aircraft remaining in service longer than planned, $3.1bn in additional maintenance expenses, $2.6 billion in engine leasing costs, and $1.4bn tied up in increased spare parts inventory.
One of the most pressing concerns remains the engine MRO sector. Citing a joint study conducted with consulting firm Emerton, IATA revealed that 648 Pratt & Whitney GTF-powered aircraft were grounded in March 2025 while awaiting engine shop visits, spare engines, or replacement parts, representing approximately 28 per cent of the global GTF-powered fleet.
The challenge is expected to intensify in the coming years as next-generation narrowbody fleets continue to expand. Annual shop visits for CFM LEAP engines are projected to grow from approximately 600-800 in 2025 to more than 5,000 by 2040, while Pratt & Whitney GTF engine shop visits are expected to double from around 1,000 to 2,000 over the same period.
IATA noted that the aviation industry is facing a combination of production bottlenecks, certification delays, raw material shortages, labour constraints, engine durability challenges, and geopolitical disruptions. With aircraft order backlogs exceeding 18,000 units and delivery shortfalls surpassing 5,000 aircraft, airlines are increasingly relying on ageing fleets, driving higher maintenance demand across the sector.
To address these challenges, IATA outlined four strategic priorities for strengthening supply chain resilience.
The first is improving supply chain visibility by providing airlines with better access to information on parts availability, repair turnaround times, delivery schedules, and supply bottlenecks.
Secondly, IATA called for a more open aftermarket environment, encouraging greater access to approved repairs, used serviceable material, alternative parts, and competitive third-party MRO services.
The third priority focuses on accelerating the adoption of data-driven solutions, digitalisation, and artificial intelligence. IATA stressed that better integration of maintenance, inventory, and supply chain data can help airlines and MRO providers improve forecasting, sourcing, and decision-making.
The association also announced plans to make key features of its MRO SmartHub platform available to airlines through a data participation programme aimed at improving access to serviceable materials and alternative sourcing options.
Finally, IATA highlighted the growing need for skilled maintenance personnel. With Boeing forecasting demand for approximately 710,000 new maintenance technicians over the next 20 years, the industry faces increasing pressure to expand training capacity, accelerate workforce development, and improve cross-border recognition of qualifications.
