In the high-stakes world of aviation MRO, time is money - and lately, time is in short supply. Throughout 2024 and into 2025, industry observers like IBA have flagged a troubling trend: engine induction times for new-generation powerplants like the LEAP-1A and PW1100G have surged by up to 150%, with some engines waiting as long as six months before even entering the shop.
The first thought that occurred to me was—these are new-age engines, designed to be highly efficient, reliable, and predictable when it comes to maintenance planning. So how is it that they now take an exhaustive six months just for induction? It’s a paradox that demands closer scrutiny.
For airlines, lessors, and MROs alike, this isn’t just a scheduling inconvenience—it’s a strategic risk. Let’s unpack what’s driving this delay, and more importantly, how the industry can respond.
What’s Behind the 6-Month Engine Induction Delay?
Engine induction- the point at which an engine physically enters the shop for maintenance—used to be a relatively predictable milestone. Today, it’s a moving target. Here’s why:
1. Capacity Crunch at MRO Facilities
MROs are operating at full tilt. With a surge in shop visits driven by early-life performance issues and maturing fleets, hangars are booked months in advance. New-gen engines, which require specialized tooling and trained technicians, often get pushed down the queue.
2. Parts Shortages and OEM Bottlenecks
Engines like the PW1100G are plagued by powder metal defects, while the LEAP-1A faces fuel nozzle coking and combustor wear. These issues demand specific parts—many of which are in short supply due to OEM production delays and global supply chain disruptions.
3. Labour and Skill Gaps
Even where physical capacity exists, the shortage of certified technicians—especially those trained on newer platforms—limits throughput. Training pipelines haven’t kept pace with fleet expansion.
4. Regulatory and Repair Exclusivity
Some repairs are OEM-exclusive, creating bottlenecks at authorized facilities. This limits flexibility and adds to wait times, especially when OEMs themselves are capacity-constrained.
Who’s feeling the impact?
Airlines:
Airlines are being forced to retain older aircraft or lease spare engines just to maintain operational schedules. This not only drives up operating costs but also reduces fleet flexibility, making it harder to respond to demand fluctuations or optimize route planning.
Lessors:
For lessors, engines stuck in MRO queues delay lease transitions and impair asset utilization. The unpredictability of shop visit timelines also complicates residual value forecasting and lease structuring, especially for newer engine types.
MROs:
MRO providers are caught in a balancing act—managing legacy engine workloads while grappling with the complexity of new-generation engines. The inability to meet promised turnaround times risks reputational damage and strains customer relationships.
OEMs:
OEMs are facing mounting pressure from all sides. On one hand, they’re dealing with production shortfalls and parts backlogs; on the other, they’re being held accountable for engine reliability and repair exclusivity. The bottlenecks at OEM-authorized shops are not only slowing down inductions but also impacting their ability to support fleet growth and maintain customer trust.
Digital Tools to Improve Aircraft Engine Maintenance Turnaround
While macro factors like OEM output and global logistics are hard to control, MROs and operators can take proactive steps to reduce induction friction:
Predictive Slot Management: Using AI to forecast demand and dynamically allocate shop slots based on engine condition, parts availability, and technician schedules.
Integrated Parts Planning: Synchronizing procurement with induction schedules to ensure critical components are available before the engine arrives.
Workforce Augmentation: Investing in AR-guided workflows and cross-training to reduce dependency on niche skills and improve technician productivity.
The Role of Aviation MRO Software in Reducing Delays
Digital transformation is more than a buzzword—it’s a necessity. Purpose-built aviation MRO software like Ramco Aviation, Aerospace & Defense provides:
- Real-time visibility into shop capacity, parts inventory, and technician availability.
- AI-driven slot optimization to reduce idle time and maximize throughput.
- Digital work orders and mobile workflows to streamline induction and reduce manual overhead.
- Integrated supplier collaboration to align parts delivery with shop schedules.
In short, aviation MRO software is no longer just a management tool—it’s a resilience lever that can help the industry tackle LEAP-1A engine induction delays, PW1100G MRO challenges, and persistent engine shop visit backlogs head-on.
Final Thought: From Bottleneck to Breakthrough
The six-month induction delay is a symptom of deeper structural challenges in the aviation MRO ecosystem. But with the right mix of process innovation, digital enablement, and strategic foresight, the industry can turn this bottleneck into a breakthrough.
Because in aviation, delays are inevitable—but being unprepared is optional.
