Closing the MRO Talent Gap: How AI and Digital Solutions Keep Aircraft Ready to Fly
Key Highlights
- Supply chain disruptions and aircraft aging are forcing MROs to operate older fleets, increasing maintenance challenges and the need for proactive workforce training on new aircraft platforms.
- Digital tools such as AI, AR and mobile devices can automate routine tasks, improve technician support and optimize maintenance workflows, enhancing efficiency amid resource constraints.
- Adapting to new aircraft and engine technologies demands continuous workforce training and balancing maintenance of legacy platforms with emerging advanced systems.
Today’s maintenance, repair and overhaul (MRO) organizations have been hit with a two-fold challenge: an aging workforce and a shortage of fresh, skilled talent.
At the same time, pressure is mounting for these companies to keep aging aircraft mission-ready despite supply chain disruptions, while preparing to service a new generation of advanced engine platforms remain. The expectations are high in both the commercial and defense sectors.
In this article, VP Aerospace & Defense at IFS Rob Mather shares how MRO organizations can harness AI, digital tools and innovative workforce strategies to meet these challenges head-on.
Why is the talent gap significant for MROs?
The defense sector faces an increasing skills gap, with 48% of defense employers reporting shortages in engineering talent and 25% citing a lack of manufacturing and mechanical expertise. Recruitment of new technicians continues to lag far behind growing demand for MRO capabilities.
In the commercial MRO sector, the workforce is aging at an alarming pace. Employees nearing retirement—ages 55 to 60—make up 35% of the industry, while those aged 18 to 30 account for only a single-digit share. Industry projections indicate a need for nearly 700,000 new technicians over the next two decades.
How post-pandemic pressures impact MRO workforce and operations
How post-pandemic pressures impact MRO workforce and operations
A major catalyst for the current labor shortage has been the COVID-19 pandemic. These circumstances caused many MROs to face challenges such as:
- Financial difficulties
- Need to furlough employees
- Offers for early retirement for older technicians
Throughout the pandemic, demand for commercial and defense MROs has dropped, leading to pauses in recruitment for several organizations.
Aircraft fleets are also getting older, but they’re not aging out. In 2023, it was estimated that one-third of the 30,000 commercial aircraft in operation were over 20 years old.
During the height of the pandemic, new aircraft orders and fleet renewal programs were put on hold to cut costs, with many organizations still playing catch-up.
How can MROs respond to labor shortages for skilled AMTs?
The solution for MROs that aim to upgrade operations and expand their skilled workforce shouldn’t be about replacing experienced technicians with junior technicians. Rather, companies should focus on bridging the gap between newer and more experienced AMTs.
Experienced technicians come with legacy knowledge, enabling them to identify, troubleshoot and solve problems. In comparison, junior technicians often lack this hands-on knowledge, leaving them reliant on manuals or guidance of more experienced colleagues to complete tasks.
This type of legacy knowledge requires years of experience and is typically hard-won firsthand or shared in real-time by seasoned technicians.
MROs need to make being a maintenance technician an attractive career path for to younger generations, many of whom aren’t aware of the positive aspects of becoming an aircraft maintenance technician.
The aircraft maintenance industry can do more to increase the recruitment or retention rates of the emergent generation, such as:
- Using modern technological tools and systems
- Improving working conditions
- Increasing job awareness at earlier ages
- Enhancing diversity, equity and inclusion in the workplace
Why supply chain issues increase pressure to keep aging aircraft airworthy
The commercial aviation industry is driven by efficiency and managing tight margins, but continuing to operate with older aircraft is having a serious impact. Consequently, many commercial airlines are seeking newer, more efficient aircraft. However, major aircraft manufacturers' failures to meet demand have slowed or prevented this fleet renewal.
Boeing has faced several challenges in this area, such as:
- Supply chain disruptions
- Testing phase failures
- Inflight issues
- Workforce strikes
In January 2024, the FAA temporarily grounded all 737-9 MAX aircraft and forced Boeing to halt production of the 737 MAX, after a blowout of a 737-9 MAX door plug during a flight.
As a result, many airlines pivoted to the Airbus A320 family aircraft, but they have had their own supply chain issues for aircraft components. This has left a significant gap in new aircraft supply, and with demand rising, airlines have had to keep operating older aircraft.
Why new aircraft can create new problems for MROs
New airframes and engines come with new training practices and certifications for technicians. MRO organizations need to proactively manage workforce training for these new platforms and balance this with matching their demand to carry out work on legacy platforms.
When it comes to engine types, the 737-MAX and the A320neo are rising in popularity for commercial aircraft. The F-35 is also being deployed more frequently by military forces, including Poland and Canada.
However, MRO organizations have encountered challenges, such as the 737-MAX engine’s load-reduction mechanism fault, causing harmful smoke to enter aircrafts.
How digital tools can boost MRO capacity
In the digital age, MROs must find innovative ways to increase maintenance capacity with fewer resources. One solution is implementing new technology to automate monotonous tasks, which can make technicians' lives easier and reduce the chances of mistakes.
There are two different groups of digital technology solutions MROs can employ. AI-based solutions can help with monotonous tasks and provide optimized task scheduling, planning and assignment.
Non-AI technologies can improve MRO processes by:
- Increasing the use of mobile devices
- Improving engineer support with AR-supported video calling
- Enhancing precision and speed with embedded measurement tools
- Making supply chains more efficient with e-paper labelling.
There are five main areas in which these digital solutions will most help MROs. These are:
- Hands-on tech with aviation devices: Mobile devices with aviation-specific AI give technicians digital access to manuals, enable them to request materials, and get solution suggestions—keeping them at the aircraft and boosting efficiency.
- Context-switching: Digital job cards let technicians pause and resume tasks or start new ones while waiting for parts, maximizing productivity.
- Embedded tech for efficiency: Mobile devices enable both novice and experienced technicians to work smarter, whether performing live lidar measurements or having AR calls with senior staff.
- AI-driven maintenance: AI optimizes task sequencing and assigns work based on skill, experience, availability and location.
- Smart troubleshooting: AI copilots quickly locate procedures, answer questions and suggest fixes using past faults and NLP, reducing time wasted on manual searches.
Commercial and defense MROs face growing labor challenges, but the right mix of digital innovation and AI can help shift the momentum.
About the Author
Rob Mather
As Vice President, Aerospace and Defense Industries, Rob Mather is responsible for leading the charge on IFS’ global A&D industry marketing strategy, while also supporting product development, sales and partner ecosystem growth. Rob has over 15 years’ experience in the A&D sector, starting out in the field and having held a number of strategic R&D, Presales and Consulting positions at IFS, Mxi Technologies and Fugro Aviation.
Prior to his current position, Rob was instrumental in building and leading the global A&D Presales Solution Architecture team at IFS, playing a key role in a number of customer success engagements at some of the top names in commercial aviation and defense. He holds a degree in Aerospace Engineering from Carleton University in Ottawa, Canada, where he currently resides.