Rising global passenger demand is placing growing strain on aircraft fleets and maintenance capacity, as delays to new aircraft and engine deliveries force airlines to keep older jets in service for longer, according to AerFin.
In an analysis of current market conditions, Asim Chalise, VP MRO sales - business development at AerFin, said traffic growth of 5.3% year-on-year, combined with high load factors, is increasing pressure across the aviation ecosystem.
“The gap between planned fleet renewal and actual delivery is now a defining feature of the market,” Chalise wrote, noting that extended aircraft lifecycles are driving higher maintenance demand, longer turnaround times and rising costs.
According to Chalise engine maintenance remains a key pressure point citing that a full shop visit for a CFM56-7B engine can cost between $5m and $7m, with even limited workscopes approaching $3.5m, making repeated overhauls difficult to justify for airlines already investing heavily in new aircraft.
As a result, airlines and lessors are increasingly adopting more targeted maintenance strategies. These include module swaps and so-called “quick-turn” or “hospital shop” visits, which focus on replacing specific components rather than undertaking full overhauls.
Chalise wrote that the “MRO Lite” approach allows operators to extend engine life at lower cost while bridging the gap until new aircraft deliveries stabilise.
Smaller, more agile MRO providers are particularly well positioned to deliver these services, he added, as they can offer faster turnaround times and more flexible workscopes than traditional overhaul programmes.
However, Chalise warned that the strategy depends on the availability of serviceable engine modules and is not a long-term substitute for fleet renewal.
“With more operators considering module swap strategies, access to the right material becomes critical,” he said, adding that AerFin has expanded its engine portfolio to support this demand.
The shift highlights how airlines are adapting maintenance strategies in response to ongoing supply chain constraints, as the industry works to balance cost, capacity and reliability.