A new NITI Aayog report has revealed that 133 aircraft from Indian carriers are grounded, making up 16% of India’s active fleet as of March 2025. The report shines a light on critical issues plaguing the country’s Maintenance, Repair, and Overhaul (MRO) ecosystem — a key pillar of aviation safety and growth.
Grounding Crisis: IndiGo, Go First Hit Hard
India’s largest airline, IndiGo, had 60 to 70 aircraft grounded by the end of January 2025. Go Airlines was hit even harder, with nearly half of its fleet grounded in FY24 due to persistent engine failures.
The NITI Aayog report cited supply chain bottlenecks, inadequate inspections, and a shortage of skilled staff as major reasons for delays in aircraft maintenance and operations.
“One Round of Checks Only”: A Technician’s View
Flight technician Abhiram Singh, who now works in Dubai with Emirates, described the stark difference in work culture and standards.
“In India, the ground staff does just one round of checks at the base. In Dubai, it’s three to four rounds per aircraft. Sometimes, engineers do not even turn up for the checks in India,” he said.
These practices are raising questions about the overall aviation safety standards in India, especially as the fleet continues to grow.
India’s MRO Industry: Growth on Paper, Gaps on Ground
Despite current issues, India plans to grow its MRO industry from $1.7 billion in 2021 to $4 billion by 2031, with a CAGR of 8.9%. The government aims to localize 90% of India’s MRO needs by 2040, reducing dependency on foreign service providers.
However, the reality on the ground presents challenges.
- Indian airlines spend 12–15% of their revenue on aircraft maintenance.
- Most engine and heavy checks are outsourced to foreign third-party vendors.
- Only a few companies like Air India Engineering Services, Air Works India, Taj Air, and GMR Aero Technic are active in the domestic MRO space.
What MRO Covers
There are four key segments in MRO:
- Line Maintenance – Done during operating hours
- Component Maintenance – Engine, landing gear checks
- Airframe Maintenance & Modifications – Takes aircraft out of service for up to 30 days
- Engine Maintenance – Conducted every 3–4 months
Additionally, there are 10 types of unscheduled/random inspections, further complicating fleet readiness when systems are inefficient.
The Road Ahead
India is expected to become the third-largest buyer of commercial planes after the US and China. But without overhauling its MRO framework, fleet expansion could outpace maintenance capacity — risking safety and reliability.
To compete globally, India needs to:
- Boost local MRO capabilities
- Retain skilled technicians
- Enforce stricter ground-check protocols
- Invest in MRO infrastructure and R&D
With the right steps, India can truly become a global MRO powerhouse — but time, talent, and technology must align.
