Supply chain disruptions cost the global airline industry at least “$11bn” in 2025, a figure that is set to worsen as fuel prices rise and aircraft delivery backlogs persist, the International Air Transport Association (IATA) has said.
“Today’s higher fuel prices will only make that worse,” IATA director general Willie Walsh told the inaugural IATA World Maintenance and Engineering Symposium held recently in Madrid, where the association outlined four priorities it says are needed to address persistent weaknesses across the aerospace supply chain.
Walsh noted that the aircraft order backlog has surpassed “18,000” units and that average fleet age has reached a record “15.2” years. Airlines are also short of more than “5,000” fuel-efficient replacement aircraft they had anticipated, resulting in missed efficiency gains, higher lease rates, and rising maintenance costs.
“Alongside aircraft delivery delays, engine durability issues, shortages of materials and spare parts, and constrained maintenance capacity are disrupting airline operations. Addressing these challenges will require practical action and cooperation across the aviation value chain,” IATA’s director of Flight and Technical Operations Stuart Fox stated.
Fox presented four measures the association believes would materially improve conditions for airlines: enhance supply chain visibility; open up the aftermarket; unlock the value of data, digitalisation, and artificial intelligence (AI); and build human capacity.
On visibility, IATA called on manufacturers to provide earlier and more reliable information on delivery delays, repair turnaround times, parts availability, and known supply bottlenecks, giving airlines a better basis for planning their network operations.
The association also pressed for greater competition in the aftermarket, urging more manufacturers to adopt the principles established under the IATA-CFM agreement. It noted that longstanding commercial restrictions on repair instructions, tooling, approved repair networks, and spare parts distribution have limited airlines’ ability to use certified alternatives, driving up costs and wait times.
On data and technology, IATA called for tighter integration between airline maintenance systems and external market intelligence tools. It said AI can support inventory management, predict parts shortages, and reduce manual processes, and pointed to its cooperation with the International Airlines Technical Pool and the no-cost rollout of its MRO SmartHub platform as steps already taken in that direction.
The fourth priority concerns the workforce, Fox pointed out. Boeing has estimated that “710,000” new maintenance technicians will be needed over the next 20 years. IATA urged a review of recruitment, training, and licensing timelines, and called for greater cross-border recognition of technical qualifications to address the expected shortfall.
Fox acknowledged the pressure the industry is facing but stopped short of pessimism, saying, “The supply chain is under real pressure, but this is not a reason for pessimism. It is a reason for action.
“These four priorities alone are not complete solutions. But they would be an important step for OEMs, suppliers, MROs, lessors, regulators, and airlines working together to achieve the resilient aerospace supply chains that global connectivity needs,” he continued.
Separately, IATA raised concerns about the feasibility of aircraft equipment mandates, calling on regulators to ensure that compliance deadlines account for certification timelines, equipment availability, and installation capacity. It said it has taken these concerns to the International Civil Aviation Organisation (ICAO) in connection with requirements linked to the Global Aeronautical Distress and Safety System, Runway Overrun Awareness and Alerting Systems, and Automatic Dependent Surveillance-Broadcast systems.
“This is not about delaying safety. It is about making safety deliverable. Global safety improvements require globally coordinated implementation timelines that reflect certification, equipment availability, and installation capacity,” Fox stated.
