The International Air Transport Association (IATA) has urged governments, manufacturers and aviation stakeholders to accelerate reforms across the global aviation supply chain, warning that persistent production and maintenance challenges are placing growing financial and operational pressure on airlines.
Addressing delegates at the first IATA World Maintenance and Engineering Symposium in Madrid on Wednesday, industry leaders highlighted the urgent need to improve supply chain resilience as the aviation sector continues to recover from disruptions triggered during the COVID-19 pandemic.
The association said airlines are confronting a series of interconnected challenges, including delayed aircraft deliveries, engine durability concerns, shortages of spare parts and raw materials, as well as limited maintenance capacity. These issues have contributed to an unprecedented aircraft order backlog of more than 18,000 jets, while the average age of the world's commercial fleet has risen to a record 15.2 years.
IATA Director General Willie Walsh said supply chain failures imposed costs of at least $11 billion on airlines in 2025, warning that financial pressures could intensify further alongside rising fuel prices.
Stuart Fox, IATA's Director of Flight and Technical Operations, said airlines are increasingly forced to keep older aircraft in service because new aircraft and replacement engines are not arriving on schedule. He noted that prolonged reliance on ageing fleets reduces operational efficiency and complicates industry efforts to improve sustainability.
According to IATA, the industry's supply chain disruptions generated losses exceeding $11 billion during 2025, diverting funds that could otherwise have supported network expansion, workforce investment, decarbonisation initiatives and other strategic priorities.
Engine maintenance continues to represent the most significant bottleneck, the association said. At the same time, aircraft delivery delays have widened the gap between expected and actual fleet growth, leaving airlines short of more than 5,000 aircraft they had anticipated receiving.
Fox warned that these constraints affect operating costs, airline capacity, network resilience and environmental performance, with passengers and cargo customers ultimately bearing the consequences.
To strengthen the aviation supply chain, IATA outlined four key priorities. The first focuses on improving visibility by encouraging manufacturers and suppliers to provide earlier and more reliable updates on delivery schedules, repair timelines, parts availability and known production constraints.
The second priority calls for greater competition within the maintenance, repair and overhaul (MRO) sector. IATA advocates expanding access to independent MRO providers, approved repair facilities and alternative spare-parts suppliers, arguing that restrictive commercial practices surrounding tooling, repair documentation and parts distribution unnecessarily extend aircraft downtime and increase airline costs.
The association also identified digital transformation as a critical area for improvement. By expanding data sharing and integrating artificial intelligence into maintenance operations, airlines could improve inventory planning, anticipate shortages and make more informed repair decisions.
Workforce development forms the fourth pillar of IATA's proposed reforms. Citing Boeing estimates, the association noted that the aviation industry will require approximately 710,000 additional maintenance technicians over the next two decades. IATA said changes to training programmes, licensing systems and recruitment strategies are essential to prevent long-term shortages of skilled personnel.
In addition, the organisation urged regulators to adopt more practical implementation schedules for new aviation safety requirements, including the Global Aeronautical Distress and Safety System (GADSS), Runway Overrun Awareness and Alerting Systems (ROAAS), and ADS-B upgrades.
Fox stressed that IATA's recommendation is intended to ensure safety improvements can be implemented effectively rather than postpone them, saying successful global adoption depends on realistic timelines that reflect certification processes, equipment availability and installation capacity.
Source: ZAWYA