Global airlines lost at least $11 billion to supply chain failures in 2025, the International Air Transport Association (IATA) warned Wednesday, with higher fuel prices set to make that worse.
IATA Director General Willie Walsh said the global aircraft order backlog has reached more than 18,000 planes, and the average fleet age has climbed to a record 15.2 years. Airlines are flying without roughly 5,000 more fuel-efficient aircraft they had counted on, driving up lease rates and maintenance costs on top of the direct supply chain losses.
Stuart Fox, IATA’s director of flight and technical operations, presented four measures to the association’s inaugural World Maintenance and Engineering Symposium in Madrid: improve supply chain visibility, expand competition in the aftermarket, unlock the value of data and artificial intelligence (AI), and build the human workforce capable of sustaining it.
On visibility, IATA wants manufacturers to give airlines earlier and more reliable information on delivery delays, repair turnaround times, and parts availability, so airlines can plan their global networks with greater accuracy.
On the aftermarket, IATA called on manufacturers to adopt the principles in a recent agreement between the association and engine maker CFM International, which reinforces airlines’ access to external maintenance, repair, and overhaul (MRO) providers, alternative parts, and approved repairs. IATA said longstanding commercial restrictions on repair instructions, tooling, and spare parts distribution limit competition, lengthen waiting times, and push up costs.
On data, IATA pressed for better integration between airline maintenance systems and market intelligence tools to sharpen inventory management, improve warranty claims, and support decisions on whether to repair or replace components. AI can help predict demand, flag shortages, and cut manual workload. IATA has made its MRO SmartHub available to airlines at no cost through a data participation programme.
On the workforce, Boeing estimates 710,000 new maintenance technicians will be needed over the next 20 years. IATA called for faster recruitment timelines, expanded training capacity, and greater cross-border recognition of qualifications to close that gap.
Fox added that compliance deadlines for new aircraft equipment mandates must reflect what the supply chain can actually deliver. IATA has taken that concern to the International Civil Aviation Organization (ICAO), particularly around avionics and airspace safety upgrades.
“This is not about delaying safety. It is about making safety deliverable,” Fox said.
The symposium, IATA’s first dedicated to maintenance and engineering, brought together airlines, manufacturers, and maintenance providers in Madrid to address what the association described as persistent failures across the global aviation supply chain.

