The thing about airplanes is, they were never meant to sit still. But time has a way of grinding down even the best machines, and now, more than ever, the old planes are being asked to keep flying. Airlines, grappling with unprecedented supply chain disruptions and the soaring costs of new aircraft production, are turning to their aging fleets to meet operational demands. This shift has created a unique challenge: how to source and manage parts for aircraft that, in some cases, have exceeded 25 years of service.
The numbers tell the story. By 2020, nearly 9% of the global fleet, or approximately 2,400 aircraft, were over 25 years old, which is a sharp rise from just 5% in 2010. This trend is expected to continue, particularly as Airbus and Boeing, the industry’s giants, struggle to meet delivery schedules. For example, between January and April 2023, global deliveries of new aircraft fell by 7.4%, further delaying fleet renewals. Airlines are left with little choice but to rely on older models, creating a surge in demand for parts that are increasingly difficult to procure.
The Complexities of Maintaining Aging Fleets
Operating aging aircraft is not just a matter of keeping engines running. What it is, is a logistical puzzle with high stakes. The main challenges are parts obsolescence, skyrocketing maintenance costs, and supply chain bottlenecks.
Biggest online marketplaces, such as Locatory.com, stand as an important ally for MRO providers and airlines worldwide. By offering a marketplace for aviation parts, as well as services, Locatory.com connects buyers and sellers across the globe, ensuring access to hard-to-find components for older aircraft. With an extensive network spanning over 150 countries and thousands of clients, the platform is uniquely positioned to address the complexities of sourcing obsolete parts.
The Rise of Innovative Solutions
Manufacturers often prioritize producing components for newer models, leaving MRO providers scrambling for alternatives. Airlines face extended lead times, sometimes waiting months for a single part, while balancing the growing frequency and intensity of maintenance required for older aircraft.
Adding to the pressure is the cost factor. Operating and maintaining an older aircraft costs approximately 20-25% more than newer models, mainly due to the increasing frequency of unscheduled repairs and higher fuel inefficiencies. However, replacing these aircraft with new ones is not an easy decision, as delivery backlogs and financing challenges make fleet renewal an expensive proposition.
In response to these challenges, the aviation industry is embracing innovation to streamline parts sourcing and extend the operational life of older fleets. One of the most revolutionary tools at its disposal is additive manufacturing, commonly known as 3D printing. This technology has already transformed the way aircraft parts are designed and manufactured. Companies like Materials Solutions and Sintavia are leveraging 3D printing to produce parts that are no longer available from OEMs (original equipment manufacturers). These parts are manufactured on demand, reducing lead times dramatically and eliminating the need for large inventories.
Parts for the Past and the Support for Older Aircraft
One of Locatory.com’s key strengths lies in its advanced inventory management capabilities. Through the use of AI-driven tools, the platform streamlines procurement processes, providing real-time availability updates and predictive analytics. These features empower operators to plan maintenance schedules effectively, minimizing downtime and disruptions.
Then there are the partnerships. Partnerships aren’t just a handshake and a photo op, but more of the late-night calls, the urgent fixes, the quiet moments where the clock’s ticking, and you need a part yesterday. But Locatory.com has more than enough tools to cut through the noise. AI processes the requests (even the ones typed in and sent by email), quotes get sent, and before you’ve even had time to pour your coffee, the wheels are in motion. For those running older planes, every second counts, and we make sure they don’t waste one.
Answers the Industry Might Have Soon
The innovations, shaping the industry, have their answers to the problems of the future. For example, another game-changer is the use of digital scanning and digital libraries. These technologies create precise blueprints of existing parts, allowing manufacturers to replicate them even if the original design specifications are unavailable. This approach not only ensures the availability of obsolete parts but also facilitates collaboration between smaller suppliers, creating a more diverse and resilient supply ecosystem.
The rise of PMA (Parts Manufacturer Approval) parts is another promising development. These parts are FAA-approved and offer a cost-effective alternative to OEM components. The global PMA market has grown significantly, with airlines increasingly adopting these solutions to reduce costs without compromising safety.
Advanced inventory management systems are also proving indispensable. These systems use predictive analytics and artificial intelligence to forecast demand, optimize inventory levels, and streamline the procurement process. Airlines and MRO providers can now proactively address shortages, ensuring minimal disruption to operations.
Into the Future of Aging Fleets
Strategic partnerships are becoming the cornerstone of effective parts sourcing. Airlines, MRO providers, and parts suppliers are forming alliances to share resources, mitigate risks, and improve access to critical components. One standout example is Asia Digital Engineering (ADE), a Malaysia-based MRO provider. Facing a surge in demand for aircraft repairs due to delays in new plane deliveries, ADE has adopted innovative solutions like predictive maintenance software, and such measures have reduced repair times by up to 30% and kept their facilities fully booked until the end of 2025.
The aviation industry’s reliance on aging fleets is unlikely to wane anytime soon. Analysts predict that the average retirement age for aircraft will continue to rise, particularly as operators seek to maximize the value of their assets. This reality demands a fundamental shift in how the industry approaches parts sourcing and maintenance.
Looking ahead, the focus will increasingly be on fostering resilience through diversification. The combination of cutting-edge technologies, smarter inventory strategies, and stronger partnerships will be pivotal in addressing the challenges of aging fleets. Companies that can adapt to these new realities will not only survive but thrive, setting new standards for efficiency and innovation in the process.
The challenges of maintaining older aircraft may be daunting, but they also present an opportunity — one to rethink traditional practices and build a more agile, collaborative, and sustainable aviation ecosystem.
For aging fleets in particular, Locatory.com’s solutions are indispensable. The marketplace is also tailored to include PMA parts and specialized components that are often no longer available from OEMs. By diversifying sourcing options, Locatory.com ensures that operators can find cost-effective alternatives without compromising on quality or safety.
