“Our analysis shows that aircraft engine MRO demand is likely to experience a near-term peak in 2026 and remain constrained through the end of the decade.”
— Jim Harris, Co-Leader of Bain’s global Aerospace and Defense practice
Bain&Company’s latest survey supports industry speculation: MRO demand will peak in 2026, yet capacity shortages already bottleneck engine shops.
For MRO leaders, decreasing Turnaround Time (TaT) hinges on parts availability—simpler said than done with outdated, fragmented systems.
The Post-COVID Impact: A Continual Battle
Covid-19’s impact on the aviation industry is ongoing. 60% of the global fleet was grounded, leaving MRO teams struggling to recuperate:
- Deferred Maintenance Overload – Airlines postponed maintenance, resulting in a 45% drop in spending and substantial backlogs.
- New Aircraft Challenges – While next-generation aircraft promote sustainability, their engines unexpectedly require more repairs, partly due to powder metal contamination.
- Supply Chain Disruptions – Shortages force MROs to rely on Used Serviceable Materials (USM), increasingly sought by OEMs.
MROs now face unpredictable lead times and part shortages instead of recovery.
Next-Gen Engines: New Challenges
New engine models from CFM International’s LEAP and Pratt & Whitney’s GTF present fresh challenges:
- Increased Repair Rates – These engines need more frequent servicing due to emerging failure modes.
- Limited Certified Shops – Specialized accreditations are necessary, shrinking the number of authorized MROs.
- Resource Overstretch – MROs handle both legacy and new-generation engines, stretching expertise and capacity.
This challenges MROs with longer maintenance times.
MRO Operations: Fixing Fires
Ironically, instead of using real-time insights for timely kitting gate parts, MRO teams spend up to 70% manually chasing data—slogging through spreadsheets, emails, and disconnected systems to track parts, capacity, and repair schedules.
This inefficiency causes:
- Delayed Maintenance Completions
- Up to $10,000 Daily Costs Per Immobile Engine
- Decreasing Customer Satisfaction
Teams remain in constant firefighting mode rather than preventing issues.
The Pelico Solution: Regaining Control
Pelico has partnered with leading MRO shops for two years to develop a solution that reduces TaT and optimizes engine throughput.
With Pelico, MRO teams can:
- Reduce TaT – Early identification of missing parts aids prioritizing repairs and streamlining maintenance workflows, minimizing delays.
- Ensure Material Availability – Proactively addressing shortages enhances supply chain visibility, enabling use of alternatives like rotables and spare parts.
- Increase Engine Throughput – Optimizing shop capacity through strategic repair planning and alternative workflows ensures faster engine turnaround.
- Make Smarter Resource Decisions – Balancing OEM and MRO priorities ensures new and used part allocation optimizing cost-effectiveness and availability.
Results:
- 40% Reduction in TaT
- 94% Increase in Throughput
- 72% Boost in Team Productivity
Next Steps: Control Your MRO Operations
Without real-time visibility, MRO teams operate blindfolded. Regain control.
Pelico has helped MRO teams reduce TaT by 40%. Schedule a demo today.
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