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Engine Overhaul Delays Could Cause Capacity Shortages

Engine Overhaul Delays Threaten Airline Capacity in India
India’s airline industry is confronting significant operational challenges as unexpected increases in engine maintenance requirements, coupled with global supply chain disruptions, threaten to reduce aircraft availability and strain capacity. Airline executives report that commercial aircraft engines are being removed for servicing more frequently than anticipated, placing additional pressure on already overstretched maintenance facilities and exacerbating an expanding backlog of repairs.
Rising Maintenance Demands and Infrastructure Strain
The latest generation of aircraft engines, while praised for enhanced fuel efficiency, has demonstrated reduced durability under operational conditions. Airlines, pushing these engines to higher performance levels, are experiencing a surge in the frequency of required shop visits. This trend has intensified the burden on maintenance infrastructure, with service centres struggling to manage the growing volume of engine overhauls.
Isidro Porqueras Orea, Chief Operating Officer of IndiGo—India’s largest airline—highlighted the severity of the situation during the recent International Air Transport Association (IATA) meeting. He explained that engines are being removed earlier than planned, increasing the number of maintenance turnarounds. This challenge is compounded by a shortage of spare parts, creating what he described as a “perfect storm” for the industry.
IndiGo, which operates a fleet exceeding 300 aircraft, has been notably affected. Although the airline has not disclosed the precise number of grounded planes, Orea indicated that the figure had improved to “in the 40s” from a peak in the “mid-70s” during the September quarter. Nevertheless, he cautioned that repair timelines are expected to lengthen further in the coming years.
According to the Ministry of Civil Aviation, India had 680 operational aircraft as of March 2025. Estimates from the rating agency Icra suggest that approximately 133 of these aircraft were grounded by the end of the same period, underscoring the scale of the maintenance backlog.
Extended Overhaul Timelines and Market Implications
A senior executive from another domestic airline described the growing delays at service centres, noting that the waiting list for engine overhauls has expanded to 70-80 units. The typical turnaround time of 70-80 days has now extended to approximately 120 days for a complete jet engine overhaul. This increase in maintenance duration is accompanied by significant cost implications for airlines.
The prolonged overhaul timelines are also tightening the market for available engines, intensifying competition and driving up prices for leased units. These factors are contributing to operational disruptions and escalating maintenance expenses, which may hinder airlines’ ability to meet passenger demand and sustain capacity.
Pressure on Engine Manufacturers and Supply Chains
GE Aerospace, which supplies nearly 90% of India’s commercial aircraft engines through its own products and its joint venture with Safran, CFM International, is facing mounting pressure. Service slots at GE’s facilities are fully booked, and delays in spare parts deliveries are exacerbating the situation. H Lawrence Culp, Chairman and CEO of GE Aerospace, reported during an analyst call that spare parts delinquency has more than doubled year over year. He also noted a backlog of engines removed from aircraft but not yet inducted into maintenance shops.
Between GE Aerospace and CFM International, approximately 1,300 to 1,400 engines power Indian carriers, many installed on Airbus A320 and Boeing aircraft. As supply chain constraints persist alongside durability challenges, the risk of capacity shortages looms large for India’s rapidly expanding aviation sector.

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