Engine durability issues, spare parts shortages, limited spare engine availability, and constrained aftermarket access are disrupting airline operations, creating bottlenecks in the maintenance, repair and overhaul (MRO) of latest-generation single-aisle aircraft engines, namely LEAP engines from CFM, and Geared Turbofan (GTF) engines from Pratt & Whitney, according to the Single Aisle Aircraft Engines MRO: Strategic Levers to Address Supply Chain Challenges study, release by the International Air Transport Association (IATA), in collaboration with Emerton.
These pressures are creating costly operational challenges, including reduced engine time on wing, increased demand for engine shop visits and more complex airline maintenance planning.
“Engine MRO bottlenecks are disrupting airline operations. Without significant changes, this will only get worse as the fleet of latest-generation single-aisle aircraft grows. Manufacturers are investing in additional capacity, but capacity alone will not be enough. Airlines need better access to spare parts, more approved repair options, fair access to MRO capacity and greater competition in the aftermarket,” says Willie Walsh, IATA’s director general.
Key takeaways:
· The number of grounded Pratt & Whitney GTF-powered aircraft peaked in March 2025 at 648, 28% of the GTF-fleet. These aircraft were awaiting engine shop visits, spare engines or parts. Affected airlines had to adapt their fleet plans by retaining older aircraft, extending leases or leasing additional aircraft, and adjusting capacity.
· This acceleration of deliveries will significantly increase maintenance demand. Annual shop visits are forecast to rise from around 600–800 in 2025 to more than 5,000 by 2040 for LEAP engines, and 1,000 to more than 2,000 for GTF engines.
