Supply chain delays are on pace to cost the global airline industry more than 11 billion dollars in 2025, according to a joint study from the International Air Transport Association and Oliver Wyman, with nearly a third of that bill falling directly on maintenance shops. The report, Reviving the Commercial Aircraft Supply Chain, found that additional maintenance costs alone account for roughly 3.1 billion dollars of the total, as an aging global fleet requires more frequent and more expensive upkeep while new aircraft deliveries remain delayed.

The worldwide commercial aircraft order backlog reached a historic high of more than 17,000 airplanes in 2024, well above the roughly 13,000-per-year backlog seen from 2010 through 2019. That bottleneck is forcing airlines to keep older jets flying longer, a dynamic the report ties to three other cost categories: 4.2 billion dollars in excess fuel spending on less efficient older aircraft, 2.6 billion dollars in higher engine leasing costs as engines spend more time grounded for repair, and 1.4 billion dollars in surplus spare parts inventory airlines are holding to buffer against unpredictable parts shortages.

The study recommends several fixes aimed squarely at the maintenance, repair and overhaul sector, including opening aftermarket parts access beyond OEM-controlled licensing models, building shared maintenance data platforms, and accelerating repair approvals for alternative and used serviceable parts. IATA Director General Willie Walsh said the current bottlenecks have "sent costs spiralling" and that greater supply chain transparency could help both airlines and manufacturers plan around ongoing blockages.

Source: IATA -- https://www.iata.org/en/pressroom/2025-releases/2025-10-13-01/