Global spending on aircraft maintenance, repair and overhaul topped $136 billion in 2025, an 8% increase over 2024, according to Oliver Wyman's latest annual MRO industry survey. The firm's analysts describe the run of growth as an extended maintenance "super cycle," driven by an aging global fleet that requires more frequent servicing along with ongoing durability issues on newer aircraft models. Spending is projected to approach $193 billion by the end of the decade, nearly double the 2019 level.

Engine maintenance now accounts for more than half of total MRO spend, and the survey found that shop visits are taking longer and costing more than operators expected. Turnaround times on narrowbody engines regularly run 180 to 200 days or more for many operators, well above pre-pandemic norms, and more than half of survey respondents said they do not expect meaningful improvement within the next three years. Two-thirds of respondents reported that shop costs for the newest narrowbody engines are exceeding expectations by 21% or more, with a quarter reporting overruns of 50% or more.

Material cost inflation has also outpaced forecasts, running 100 to 200 basis points higher than expected across segments in 2025. About 90% of survey respondents said they are feeling the effects of tariffs, particularly on component purchases, repairs and engine overhauls. Labor rate inflation settled at 5.5% to 6.0% across most categories in 2025, more than double the roughly 3% average rate seen before the pandemic, while two-thirds of MRO operators said finding qualified aircraft technicians and mechanics has become moderately to very challenging.

The survey drew responses from more than 150 aviation professionals worldwide, most in senior or director-level roles.

Source: Oliver Wyman - https://www.oliverwyman.com/our-expertise/insights/2026/apr/aviation-mro-labor-and-material-supply-chain-paradigm.html