MRO

By Saravanan Rajarajan S, AVP & Head of Consulting – Aviation, Aerospace & Defense, Ramco Systems The Aviation Maintenance, Repair, and Overhaul (MRO) industry witnessed significant transformation in 2025, driven by the need for greater efficiency and resilience. Organizations focused on strengthening data readiness for AI adoption, integrating intelligent planning tools, and accelerating digitization across engine maintenance workflows. These initiatives represented a strategic shift toward smarter operations and improved decision-making. As we look ahead to 2026, the pace of innovation is set to intensify. AI will move beyond isolated applications to become an integral part of the MRO ecosystem, enabling predictive insights, prescriptive maintenance actions, and real-time compliance validation. This article explores the major trends that shaped 2025 and provides a forward-looking perspective on what lies ahead in 2026. Major MRO Trends Witnessed in 2025 1.Data readiness for AI adoption had become a strategic priority To unlock AI’s potential, MROs are revisiting their data platforms and data quality. MROs are examining their underlining data capabilities and quality of the source systems. Existing infrastructures are reassessed for clear processes to collect the right data and governed by the right workflow controls. The MROs are holistically looking into different types of data, data formats, and relationships between structured and unstructured data sets; for example, task data available in AMM in digital formats correlated with MPD and customer work scope to derive meaningful and accurate information. 2.Maintenance Planning Leads Aviation’s AI adoption to Drive Efficiency Gains MROs are prioritizing AI integration in fleet maintenance planning to drive efficiency gains. Base maintenance MROs are focusing on the getting maximum productivity of their manpower by leveraging the process, data and technology. Repetitive tasks like night halts and A Checks are automated by considering multiple factors such as due dates, work centre capability, capacity, fleet routing, conflicting tasks, and staffing. By learning from historical data and operational constraints, AI systems continuously improve their scheduling capabilities, ensuring tasks are neither prematurely scheduled nor left overdue. MROs are moving beyond task-level planning to a more granular approach, breaking work down into subtasks and assigning them based on specific skill requirements. The operations are sequenced, timed and optimized to addresses both efficiency and capacity issues. 3.Engine MRO digitisation is deepening across the lifecycle Engine MRO saw a significant acceleration in digital adoption as they tackled rising shop visit volumes, labor shortages, and parts delays. Engine MROs and independents adopted cloud-native systems to manage their complex work scopes, parts forecasting, supply chain lags and ensured their systems to support seamless data exchange with customers and OEMs. MROs have leveraged AI solution to simulate shop visits, capacity, material forecasts and scrap rates to model their cost and margin predictions. This surge in digital tools is enabling engine MRO providers to deliver faster turnarounds, greater work scope accuracy, and improved margins. While 2025 was about laying the foundation through strengthening data platforms, automating planning processes, and digitizing engine MRO workflows, 2026 promises to build on these gains with transformative applications. The focus will shift from isolated digital initiatives to integrated ecosystems, where AI augments human expertise, predictive analytics becomes prescriptive, and compliance moves to real-time digital validation. In short, the industry is moving from digital adoption to digital orchestration. Key MRO Trends Expected in 2026 1.AI-Augmented Workforce and Increased Automation The MRO workforce in 2026 will work smarter, not just harder, thanks to AI and automation tools becoming standard practice. Rather than replacing human mechanics, AI will act as a co-pilot for technicians, providing decision support and information at their fingertips. We will see maintenance staff routinely using AI-driven decision support systems that analyse historical fault data to suggest troubleshooting steps or pinpoint likely problem areas. Mechanics might interact with these systems via natural language (or voice) to quickly pull up technical guidance, diagrams, or past repair solutions. This human-tech collaboration addresses both efficiency and the chronic labour shortage in the MRO field, by amplifying what each technician can do. 2.Predictive Maintenance Programs Will Evolve, Driving Greater Adoption and Maturity Predictive analytics will evolve into a holistic, connected ecosystem with the integration of Internet of Things (IoT) sensors and more sophisticated machine learning models. Predictive maintenance will transition from simply forecasting failures to providing prescriptive fixes, i.e. recommending specific corrective actions before a fault occurs. Another area of potential high adoption is inventory management – using predictive algorithms to auto-adjust spare parts stock and forecast demand, so the right part is on hand at the right time. 3.Smart Certificates to Replace Paper Trails with Real-Time Validation Parts traceability is expected to undergo a major transformation, moving from fragmented paper-based systems to digitally unified, tamper-proof ecosystems. Driven by growing concerns over counterfeit parts, authorities (like FAA and EASA) are expected to introduce stricter digital traceability mandates and audit standards by 2026, especially for engines and critical flight systems. Standardized digital documentation to replace traditional PDF or paper certificates will see increased adoption, with each part carrying a persistent, verified digital ID for instant airworthiness validation. Cloud-based traceability systems will increasingly support automated authenticity checks, document validation, and anomaly detection – especially critical in detecting unapproved parts entering the supply chain. The Road Forward for MRO The trends of 2025 and the outlook for 2026 highlight a clear message: the future of MRO is intelligent, connected, and proactive. Organizations that invested in data readiness and digital tools last year are now well-positioned to leverage AI-driven insights, predictive maintenance, and smart certification systems. As regulatory bodies tighten traceability standards and customers demand faster turnarounds, MROs that embrace these innovations will gain a decisive edge. The coming year will be about embedding technology into every facet of operations to create a resilient, agile, and future-ready MRO ecosystem. Those who act now will lead the next wave of transformation in aviation maintenance. (Views expressed are personal)

Washington, D.C. – December 03, 2025 Saudia Group has announced a strategic agreement with GE Aerospace to equip Saudia Airlines with GEnx-1B engines for its 2023 order of 39 Boeing 787-9 and 787-10 aircraft. The agreement includes the supply of engines, a multi-year maintenance, repair, and overhaul (MRO) program, and spare engines. It also encompasses a series of capability-building initiatives—delivered through Saudia Technic, the Group’s maintenance and engineering arm—designed to expand and localize the Kingdom’s aerospace expertise through technical training and knowledge transfer. His Excellency Engr. Ibrahim Al-Omar, Director General of Saudia Group, said, “This strategic partnership with GE Aerospace not only transforms the Group’s long-haul capability and expands our air connectivity, but also accelerates the localization of high-technology aviation expertise in the Kingdom. Through this agreement, we will be able to develop in-country technical capability for engines we previously maintained abroad, ensuring that investment, skills, and value remain within the Kingdom, in alignment with the Saudi Vision 2030.” GE Aerospace Chairman and CEO H. Lawrence Culp, Jr., added, “We are honored to support Saudia Group’s growth and are grateful for their trust in us. The GEnx engines will provide reliability, efficiency, and durability to power the airline’s expanded widebody fleet. Our collective efforts to further develop a skilled aerospace workforce that benefits the Kingdom and the United States will support our industry for decades to come.” Engineered with advanced materials and cutting-edge technologies, the GEnx engine family represents a major leap in modern propulsion with higher time-on-wing and reliability. Since its introduction in 2011, the GEnx family has accumulated more than 70 million flight hours and today powers two-thirds of all 787 aircraft in operation. GE Aerospace has a relationship spanning more than 40 years with the Saudi aerospace sector and continues to collaborate with Saudi partners to advance Vision 2030 by developing local talent and strengthening technical capabilities. GE Aerospace and its joint ventures currently power Saudi Arabia’s four largest commercial carriers and support the largest F110 fleet outside the United States.

Toulouse,28 November 2025: Analysis of a recent event involving an A320 Family aircraft has revealed that intense solar radiation may corrupt data critical to the functioning of flight controls.Airbus has consequently identified a significant number of A320 Family aircraft currently in-service which may be impacted. Airbus has worked proactively with the aviation authorities to request immediate precautionary action from operators via an Alert Operators Transmission (AOT) in order to implement the available software and/or hardware protection, and ensure the fleet is safe to fly. This AOT will be reflected in an Emergency Airworthiness Directive from the European Union Aviation Safety Agency (EASA). Airbus acknowledges these recommendations will lead to operational disruptions to passengers and customers. We apologise for the inconvenience caused and will work closely with operators, while keeping safety as our number one and overriding priority. (Pix Courtesy: Pedro Aragão/Airbus)

Hyderabad, November 26, 2025 At a ceremony in Hyderabad with the participation of Prime Minister Narendra Modi of India; in presence of Ross McInnes, Chairman of Safran’s Board of Directors; and Olivier Andriès, Chief Executive Officer, Safran inaugurated its largest MRO (maintenance, repair, overhaul) center for the CFM International[1] LEAP engine. The Group also announced two defense investments to support the Rafale program in India. These moves underscore Safran’s deepening commitment to “Make in India,” bolstering local manufacturing and creating jobs in the civil and military aerospace sectors. Safran CEO Olivier Andriès said: “I want to thank Prime Minister Narendra Modi and the Indian Government for their support and trust, which makes our growth in India possible. The two new MRO centers in Hyderabad dedicated to the LEAP and M88 engines — and our new joint venture with BEL — underscore India’s importance to our Group. We’re proud to support the rapid growth of India’s civil and defense aerospace markets and actively contribute to the country’s Make in India policy and strategic autonomy. Safran will triple its revenue in India to exceed 3 billion euros by 2030, of which half will be generated by our sites in India. At the same time, Safran will multiply by five its sourcing in the country.” The new LEAP engine MRO center represents a total investment of €200 million and will be operational in 2026. The 45,000-square-meter facility will ramp up to a capacity of 300 LEAP shop visits a year and boast a next-generation test bench. It will support the rapid growth in the region of the CFM International LEAP fleet, which powers most latest-generation narrowbody aircraft, including the Airbus A320neo and Boeing 737 MAX. India is CFM’s third-largest market, with five Indian carriers operating more than 400 LEAP-powered aircraft and 2,000 engines on order. The new site will employ more than 250 people at launch and up to 1,100 at full capacity. An on-site training center will train more than 100 Indian technicians and engineers each year, building skills and driving operational excellence. Safran also officially announced a new MRO shop dedicated to the M88 engine powering the Dassault Aviation Rafale fighter jet. Located in Hyderabad, adjacent to the LEAP engine center, the 5,000-square-meter facility represents an investment of over €40 million. It will provide MRO services for more than 600 engine modules a year and will employ up to 150 people at full capacity. Prioritizing engines on aircraft operated by the Indian Air Force (IAF), it will also perform MRO for other M88 export customers. India is a long-standing customer for Safran’s military engines. The country recently ordered 26 Rafale M naval variants and already operates 36 Rafale and 47 Mirage 2000 fighters. In addition, on 24 November in New Delhi, Safran signed a Joint Venture and Cooperation Agreement with Bharat Electronics Limited to manufacture Safran Electronics & Defense’s “Hammer” modular air-to-surface weapon. The Hammer can be integrated on multiple aircraft types, including the Rafale and India’s single-seat HAL Tejas. During the visit, Safran CEO Olivier Andriès also flagged two additional investments announced in February 2025, totaling more than €30 million: An engineering center in Bangalore specializing in avionics and actuators, now operational and growing to 250 employees. An electronics and actuation manufacturing facility in Bangalore with 400 employees, starting operations in 2026. Safran has been a strategic partner to the Indian Armed Forces for 70 years, notably in helicopter engines with Hindustan Aeronautics Limited (HAL). Defense cooperation has deepened in recent years, as illustrated by SAFHAL, the joint venture between Safran Helicopter Engines and HAL. In 2024, SAFHAL began designing the Aravalli engine for two future heavy helicopters for the Indian Armed Forces. Safran has operated in India for more than 70 years and today has 18 sites and employs 3,000 people in the country.

Denmark, 7th November 2025: Satair, an Airbus company, has entered into an agreement to acquire Unical Aviation Inc. (“Unical”), a global aircraft parts and components supplier of Used Serviceable Material (USM) and its subsidiary ecube, a global expert in aircraft storage, disassembly, and transition services. This strategic acquisition represents a significant milestone in Satair’s strategy in the USM space, and reinforces its commitment to providing comprehensive and integrated aftermarket solutions. The acquisition includes Unical’s and ecube’s seven operational sites and offices across North America, Spain, and the United Kingdom, with combined 2024 revenue of $298 million and headcount of 413, adding a strategic expansion to Satair’s global footprint. The transaction is subject to the customary regulatory approvals and is expected to be finalised in early 2026. Both the expertise and infrastructure of Unical and ecube across will play a key role in enhancing Satair’s capabilities as a reliable provider of USM solutions, complementing its current offering supported by its subsidiary, VAS Aero Services – acquired by Satair in 2022 – and leveraging VAS’s capabilities across engine, multi-fleet USM and end-of-life support. Richard Stoddart, CEO of Satair and Head of Airbus Material Services, said: “We are absolutely delighted to welcome Unical and ecube to Satair.” He added: “At its core, this acquisition is about enhancing aircraft lifecycle management capabilities in the aerospace aftermarket. Prolonging the lifespan of material resources is essential – not only is it the most effective way to maximise the value of assets, it is also integral to establishing responsible material practices that benefit both our customers and our industry’s long-term future.” Sharon Green, CEO of Unical, commented: “We are delighted to join forces with Satair. This partnership marks a pivotal moment for Unical, and I have full faith that together we will unlock significant value for our customers, employees, and stakeholders. As a global leader in USM and a premier provider of aircraft storage, disassembly, and transition services, Unical and ecube are a powerful and natural match for Satair’s ambitions in services growth, material availability, and sustainability. We’re proud of what we’ve built—and even more excited for what’s ahead.”