Engine Maintenance Bottlenecks Grounding Hundreds of Jets, IATA Warns

Global engine maintenance bottlenecks are grounding hundreds of next-generation single-aisle aircraft, prompting the International Air Transport Association (IATA) to call for urgent, coordinated action across the aerospace supply chain. A new study conducted with consultancy Emerton identifies durability issues, spare-parts shortages and constrained maintenance, repair and overhaul (MRO) capacity as the primary drivers of severe disruption to airline operations worldwide.

The crisis is particularly acute for the Pratt & Whitney Geared Turbofan (GTF) and CFM LEAP engine programs. As of March 2025, approximately 648 GTF-powered aircraft — roughly 28% of the global GTF fleet — were grounded awaiting critical components or maintenance slots. The situation for the LEAP is also intensifying: annual shop visits are projected to surge from roughly 600–800 in 2025 to more than 5,000 by 2040, placing further strain on global aircraft maintenance capacity.

Economic and Operational Fallout

IATA Director General Willie Walsh warned that the disruptions are costing airlines an estimated $11 billion in additional supply-chain expenses. The scarcity of serviceable engines is forcing carriers to retain older, less fuel-efficient jets, a trend IATA estimates has added $4.2 billion in extra fuel and environmental costs. Lease rates for certain aircraft categories — including narrowbodies such as the Airbus A321 — have climbed 20% to 30% as airlines scramble for capacity. To break the logjam, IATA is urging OEMs to expand the use of used serviceable material (USM) and accelerate approval of alternative repair solutions. Walsh also called for a transparent, competitive aftermarket that gives independent MRO providers better access to parts and technical data. Without structural reform, airline CEOs warn that engine scarcity will remain the primary constraint on global aviation growth for at least the next five years.