In the complex world of aviation, aircraft maintenance is a critical aspect of airline operations. A recent case study conducted by Cirium’s Andrew Doyle, Senior Director Strategy, reveals surprising insights into how aircraft age impacts maintenance duration and efficiency, potentially costing airlines significant time and money.

Watch the case study in full via the link below. 

The data behind the findings

The analysis focused on an unnamed airline (referred to as “Airline X”) and its fleet, examining maintenance events over a 12-month period. Key observations emerged from a comprehensive review of maintenance, repair, and overhaul (MRO) providers’ performance using Cirium’s data capabilities.

Maintenance providers and performance

The study tracked 30 maintenance events across different MRO providers:

• 4 events handled by the airline’s in-house MRO division
• 4 external MRO providers performed the remaining maintenance

What became immediately apparent was the significant variation in ground time across different maintenance providers. Two MROs stood out:

• MRO A: Two checks overran by over 30 days, resulting in 75 lost operational days
• MRO D: 9 checks averaged 5.5 days longer than expected, causing nearly 50 lost days

The age factor: a critical correlation

Perhaps the most intriguing finding from the data was the correlation between aircraft age and maintenance duration.

• Aircraft 6-12 years old: Shortest ground times
• Aircraft 12-18 years old: Significant increase in maintenance duration (up to 32 days longer)
• Aircraft 18-24 years old: Slight reduction in ground time
• Aircraft over 24 years: Another substantial increase in maintenance duration

As aircraft age, they typically require more extensive maintenance. Components wear down, technological obsolescence becomes a factor, and the complexity of repairs increases. This translates directly into longer ground times and higher operational costs.

The value of data-driven insights

For the first time, airlines and MRO providers can compare maintenance performance across global providers, understand the direct impact of aircraft age on maintenance efficiency and make more informed decisions about fleet management and maintenance strategies.

The analysis provides unprecedented visibility into maintenance performance, offering a global benchmark for comparing MRO provider efficiency, insights into the true cost of an aging fleet and potential strategies for optimizing maintenance scheduling.

Aircraft maintenance is more than just a routine check – it’s a complex ecosystem where age, provider efficiency, and operational strategy intersect. As airlines continue to seek ways to optimize their operations, understanding these nuanced relationships becomes increasingly crucial.