Engine MRO Bottlenecks Disrupting Airline Operations with Shop Visits Set to Rise Sevenfold by 2040, IATA Study Finds

Global – IATA, in collaboration with Emerton, has released a study warning that engine MRO bottlenecks affecting latest-generation single-aisle aircraft — LEAP engines from CFM and Geared Turbofan (GTF) engines from Pratt & Whitney — are disrupting airline operations and will worsen significantly as fleet growth accelerates, with annual shop visits forecast to rise from current levels to more than 7,000 combined by 2040.

• The number of grounded Pratt & Whitney GTF-powered aircraft peaked at 648 in March 2025 — 28% of the entire GTF fleet — with aircraft awaiting engine shop visits, spare engines, or parts. Affected airlines have had to retain older aircraft, extend leases, lease additional aircraft, and adjust capacity.
• Annual engine shop visits are forecast to rise dramatically: LEAP engine shop visits from approximately 600-800 in 2025 to more than 5,000 by 2040, and GTF engine shop visits from approximately 1,000 to more than 2,000 by 2040 — driven by fleet expansion with single-aisle engine deliveries expected to stabilise at approximately 3,700 per year between 2030 and 2040.
• The study identifies four priority actions: increasing engine parts availability through accelerated repair solution development and expanded licensed production; ensuring fair access to the MRO market by removing barriers to independent MRO participation; securing long-term access to predictable spare parts pricing through acquisition contracts; and adopting industry-wide transparent and competitive aftermarket principles.
• IATA renewed its agreement with CFM in January 2026, which includes provisions for customer choice, regulatory-approved non-OEM parts and repairs, and fair access for third-party MRO providers.

Statements

• "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," said Willie Walsh, Director General at IATA.

Source: IATA