When it comes to aircraft maintenance, time is not just a scheduling factor—it is a crucial element for both operation and finances. If a necessary aircraft part is not available, a routine repair can quickly turn into an Aircraft on Ground (AOG) situation, which impacts fleet availability, costs, and of course, flight schedules.
Aircraft parts lead times are thus a critical consideration for airlines, and MROs.
What Is a Lead Time?
Lead time is the space between placing an order and the required part becoming available for procurement. Depending on the component, lead time can be influenced by processing, manufacturing, sourcing, inspection, certification, logistics, documentation, and of course, shipping.
Aviation parts in particular must meet very strict eligibility, quality, identification, and traceability standards, which can sometimes affect lead times. The FAA’s goes into detail regarding the specifics; check the AC 20-62E document for reference.
Why Lead Times Matter
1. Avoiding AOG Events
A delayed component can stretch out downtime and end up keeping an aircraft out of service due to maintenance needs.
In fact, parts shortages and extended maintenance turnaround times are two of the main concerns that contribute to AOG situations and interrupted operating schedules. Simply put, when a plane can’t fly, every hour of delay costs.
2. Limiting High Maintenance Costs
If a part cannot be sourced fast enough, operators will often choose to pay extra to expedite shipping of the component, search for alternative resources, make an exchange, or secure a part loan from another airline or operator. The estimate for aviation supply-chain delay costs in 2025 was over $11 billion.
3. Maintaining Fleet Availability
Having precise lead-time data means that maintenance and procurement teams can properly plan ahead instead of reacting to shortages. This ability is of significant importance as supply-chain issues, older fleets, and limited maintenance capacity are ongoing challenges facing the aviation world.
How Procurement Teams Can Improve Lead-Times
- Anticipate demand based on past usage and future maintenance schedules.
- Identify long-lead parts before they become critical.
- Build a relationship with a reliable supplier and notify of projected forecast demand early.
- Confirm certification and traceability prior to purchasing.
- Consider viable alternatives, such as approved used materials and certified parts or repairs.
- Stay current with supplier lead-time shifts instead of just depending on quoted delivery dates.
Final Thoughts
When talking about aircraft parts procurement, lead time is a major influence on things like aircraft availability, maintenance planning, inventory investment, and operational resilience. Approaching lead times as part of the overall maintenance strategy can help aircraft owners, operators, and MRO teams anticipate needs, avoid disruption, and stay off the ground and up in the air.