Navigating Engine Shortages and Long Shop Visit TATs

Engine supply constraints, limited MRO capacity, and material shortages have extended shop visit turnaround times. For airlines, managing this environment requires more than reacting when an engine becomes due. It requires careful planning across the entire fleet.

Staggering Engine Shop Visits

Airlines may adjust engine maintenance schedules to avoid having several engines off-wing simultaneously. Without a staggered plan, three or four engines could require shop visits at the same time, increasing operational disruption, maintenance expenditure, and spare-engine demand.

In some cases, an engine may be removed before fully consuming its remaining LLP life to maintain a more manageable fleet maintenance schedule.

The plan typically considers:

• LLP remaining life

• Engine health and performance trends

• Previous inspection and shop visit findings

• Spare-engine availability

Similar utilization does not always lead to the same maintenance outcome. Two engines with comparable LLP life may show different performance trends. For example, one engine may need earlier attention due to faster EGT margin deterioration or adverse inspection findings.

Engine Exchanges as a Short-Term Solution

Pandemic-era disruption, persistent material shortages, and limited MRO capacity have contributed to longer and less predictable shop visits. This has made engine exchanges an increasingly relevant short-term solution.

Once a suitable engine has been sourced and accepted, removal and installation may be completed within days rather than waiting several months for a shop visit.

An engine exchange may offer:

• Faster return to service

• Greater short-term schedule predictability

• Reduced exposure to unexpected shop findings

• A potentially lower immediate cash requirement

However, the overall commercial benefit still depends on the engine’s condition, configuration, remaining life, records status, and exchange or lease terms.

Records Can Make or Break Acceptance

A replacement engine cannot be assessed on physical condition alone. Complete and consistent records are essential, particularly the back-to-birth traceability of each LLP.

The records should clearly reconcile:

• LLP part and serial numbers

• Installation and removal history

• Shop visit and maintenance records

• Accumulated flight hours and cycles

• Supporting release and certification documents

Differences in part identification, incomplete usage history, or gaps between shop visit input and output records can delay acceptance. Additional confirmation, such as a formal operator statement, may be required to substantiate accumulated LLP usage.

If the discrepancy cannot be resolved, the affected LLP or engine may not be accepted.

Do Not Overlook the QEC Kit

The Quick Engine Change, or QEC, kit is the collection of accessories and equipment required to prepare an engine for installation. Depending on the engine type and agreed configuration, this may include electrical components, harnesses, brackets, and fuel and oil system components.

If the QEC kit is incomplete, the parties may need to:

• Accept the engine as-is with a price adjustment

• Transfer components from another engine

• Repair or overhaul unserviceable components

• Purchase new or serviceable replacements

QEC completeness should therefore be confirmed early, as missing components can affect both installation time and total exchange cost.

When a Module Swap Makes More Sense

Modern turbofan engines consist of several major modules that can be removed and replaced separately. Instead of sending the complete engine for a full shop visit, an operator may replace only the module requiring attention.

A module swap may be considered when:

• Modules or LLPs have different remaining lives

• Only one section requires repair or replacement

• A complete spare engine is unavailable

• Module-level MRO capacity is more accessible

• A shorter turnaround time is required

• A full shop visit is not economically justified

Its feasibility still depends on engine configuration, technical compatibility, approved maintenance requirements, records, and overall economics.

Making the Right Engine Decision

Staggering shop visits, arranging an engine exchange, or replacing an individual module can help reduce operational disruption. However, every option involves trade-offs between time, cost, remaining life, technical condition, and records compliance.

Engines are high-cost, high-risk assets. The right technical and records expertise is essential before making the call.

Drop us an email at info@tbmaviation.com  for engine management and technical support across Indonesia, Southeast Asia and beyond.