Reducing TAT for Engine MRO Facilities

In the aircraft engine maintenance, repair, and overhaul (MRO) industry, reducing turnaround time (TAT) has become not just a goal but a necessity. High TATs delay fleet readiness, disrupt airline schedules, and strain operational costs, especially as global demand for engine MRO continues to surge. As decision-makers in MRO workshops, understanding the importance of reducing TAT and investing in innovative solutions can position your facility as a leader in a competitive market.

The Growing Pressure on Engine MRO

The MRO market is experiencing unprecedented demand. A combination of aging fleets, deferred maintenance from the pandemic, and the arrival of new-generation engines with higher maintenance needs has pushed engine TATs up by 35% for legacy engines and an astonishing 150% for newer models. Airlines often face months-long delays just to secure a maintenance slot (1) (3).

In 2024, the global aviation MRO industry is expected to surpass $104 billion in spending, reflecting its central role in sustaining the aviation sector. However, capacity constraints, labour shortages, and supply chain disruptions remain major bottlenecks. By the end of this decade, MRO demand is projected to outstrip supply by 17%, exacerbating TAT challenges (2) (3).

Why TAT Matters to MRO Profitability

Longer TATs directly impact customer satisfaction and profitability. Airlines rely on MRO facilities to return engines quickly to service. Delays force airlines to lease expensive spare engines or ground aircraft, driving up operational costs. For Engine MRO facilities, inefficiencies in TAT lead to bottlenecks, increased labour costs, and the risk of losing contracts to more agile competitors.

Fast Facts:

• Over 70% of airline operators consider reducing TAT a top priority in selecting an MRO partner.
• Airlines estimate that every day of engine downtime costs tens of thousands of dollars in operational losses (3).

The Value of Advanced Test Systems

One of the most effective ways to address TAT is by optimizing engine testing processes. Traditional engine test setups can be time-intensive to calibrate, operate, and maintain. Introducing an easy-to-use and rapidly deployable test system, like MK Test’s Engine Test System Solution, can significantly enhance operational efficiency.

Why it Works:

• Ease of Setup: With minimal training required, your team can get the system operational quickly, reducing learning curves
• User-Friendly Interfaces: Simplifies diagnostics and testing workflows, speeding up processes while ensuring precision.
• Scalability: Suitable for a range of engine types and configurations, accommodating evolving MRO needs.

By reducing the complexity of engine diagnostics and functional testing, such systems can shorten the test phase, one of the critical bottlenecks in MRO workflows.

Strategic Investments for Long-Term Benefits

To compete in today’s challenging environment, Engine MRO providers must adopt a two-pronged approach: increase capacity and enhance efficiency. Investments in advanced tools, streamlined workflows, and skilled labour will yield long-term benefits.

Immediate Steps to Reduce TAT:

1. Integrate Technology: Leverage AI and automation for diagnostics and inventory management.
2. Modernize Tools: Transition to modular, plug-and-play systems for rapid deployment and testing.
3. Focus on Predictive Maintenance: Shift from reactive to predictive maintenance using real-time engine health monitoring systems.

By implementing these changes, facilities can better handle surges in demand and mitigate the risk of prolonged TATs affecting their bottom line.

Conclusion

The MRO industry’s challenges present an opportunity to rethink operational strategies. Reducing TAT is no longer optional—it’s a competitive imperative. By investing in user-friendly test systems like MK Test’s solution, you can enhance productivity, meet growing demand, and establish your facility as a trusted partner in the aviation ecosystem.

In a market poised to grow to $124 billion by 2034, the facilities that adapt and innovate today will lead tomorrow (1) (3). Prioritize TAT reduction to ensure your workshop remains ahead of the curve.

 

Sources cited in this article:

1. Statista provides data on the projected growth of the MRO market, forecasting its value to exceed $104 billion by 2024 and $124 billion by 2034, underscoring the critical nature of efficiency improvements.
2. Aviation Week Network highlights that engine shop TATs have increased by 35% for legacy engines and 150% for newer engines due to a confluence of factors, including deferred maintenance and increased demand.
3. Aviation Business News reports on the engine MRO industry’s capacity crisis, noting demand for shop visits is expected to exceed supply by 17% by the end of the decade. Airlines face operational challenges due to aging fleets and longer TATs.