India’s aviation sector is facing a fresh wave of operational disruption as commercial aircraft engines require maintenance far earlier than anticipated, overwhelming service centres and threatening to ground a growing number of planes.
Executives from leading carriers warn that newer generation engines—though more fuel efficient—are struggling under real-world conditions, prompting an unexpected rise in servicing frequency. Compounding the issue are persistent global supply chain disruptions, which continue to delay the delivery of critical spare parts and shrink available repair slots, creating a cascading backlog across the industry.
Surge in Engine Removals and Shop Turnarounds
“We are removing the engines earlier than decided, thereby putting increased pressure on the number of turnarounds in the shop. Secondly, on top of having to do more turnarounds, you have a shortage of spares. This is the perfect storm hitting the industry,” said Isidro Porqueras Orea, Chief Operating Officer at IndiGo, India’s largest airline, at the recent International Air Transport Association (IATA) meeting.
IndiGo, which operates a fleet of over 300 aircraft, has been significantly affected. While the airline has not disclosed exact figures, Orea confirmed that the number of grounded aircraft had dropped to “in the 40s,” a marked improvement from the “mid-70s” reported in the September quarter of 2024. However, he cautioned that engine repair turnaround times are expected to worsen in the coming years.
National Impact: Over 130 Aircraft Grounded
According to the Ministry of Civil Aviation, India had 680 operational aircraft as of March 2025. Of these, around 133 planes were grounded due to maintenance-related issues, based on estimates from credit rating agency ICRA.
A senior executive from another domestic carrier noted that servicing delays have increased significantly. “You have 70–80 engines in the waiting list to go to the shop. Instead of the typical 70–80 days, it now takes 120 days for a complete jet engine overhaul. There is also a significant cost factor that one has to bear,” the executive said.
GE Aerospace, CFM International Under Strain
GE Aerospace, which along with joint venture partner CFM International powers nearly 90% of India’s commercial aircraft fleet, is struggling to meet the surging demand. Their engines are commonly used in Airbus A320 and Boeing 737 aircraft, which dominate Indian skies.
“Our spare parts delinquency continues to increase, unfortunately—up over two times year over year. And our internal shop visit slots are full, with a pipeline of engines which have been removed but not yet inducted into our shops,” GE Aerospace Chairman and CEO H. Lawrence Culp said during a recent analyst call.
The engine maintenance bottleneck stems largely from the intense operational demands on the new-generation engines, which are being pushed harder and more frequently than in controlled testing environments. While these engines offer superior fuel efficiency, their reduced durability is now proving to be a significant operational liability.
CFM International said in a statement that it remains committed to ensuring fleet stability in India, citing safety and quality as ongoing top priorities. However, with 1,300 to 1,400 engines currently in service across Indian airlines, the task of supporting the fleet amid spiking maintenance demand is a growing challenge.
Future Uncertain as Maintenance Delays Loom
With both turnaround times and spare part shortages showing no signs of immediate improvement, Indian airlines could see rising costs and increased disruption, just as the sector aims for post-pandemic recovery and sustained growth.
Unless capacity at service centres improves and supply chain issues are resolved, the country’s carriers may be forced to reduce frequencies, delay fleet expansion, or lease spare engines at elevated costs—putting further strain on an already stretched industry.