A report from Oliver Wyman and the International Air Transport Association estimates that commercial aircraft supply chain challenges could cost the airline industry more than $11 billion in 2025. The estimate combines four categories of cost, and maintenance-related items account for a large share of the total.

Delayed fuel efficiency gains represent the largest category at $4.2 billion, because airlines keep operating older, less efficient aircraft while waiting for new deliveries. Additional maintenance costs for aging fleets add $3.1 billion. Excess engine leasing costs may reach $2.6 billion as operators lease more engines to cover longer maintenance turnaround times. Excess inventory holding costs add $1.1 billion as airlines stockpile spare parts in response to unpredictable supply.

The worldwide commercial aircraft backlog reached a high of more than 17,000 aircraft in 2024, compared with a backlog of around 13,000 aircraft per year from 2010 to 2019. The current backlog equals approximately 14 years of production at current rates. The aircraft market has not fully recovered to its pre-pandemic size but is on track to do so by 2027.

The report traces the problem to a consolidated, tiered industry structure in which many aircraft components come from a single source. Original equipment manufacturers increasingly seek a larger share of profits from repairs and spare parts, and tight labor markets constrain hiring as older workers retire.

Actions the report lists include supply chain mapping, parts pooling, wider use of parts manufacturer approval arrangements and used serviceable materials, and expanded training for the workforce.

Source: Oliver Wyman - https://www.oliverwyman.com/our-expertise/insights/2025/oct/how-to-revive-aircraft-supply-chains-to-accelerate-delivery.html