Aging Fleets, Thin Margins, Zero Slack: What 2026 Demands from Maintenance Leaders
Key Highlights
- Only a small percentage of MROs have scaled digital tools, but those that have are experiencing higher revenues, fewer inefficiencies and better workflow control.
- Data is increasingly viewed as a strategic asset, with operators seeking to connect and utilize data for predictive maintenance and operational transformation.
- 2026 will require aviation stakeholders to adopt a holistic digital approach, moving away from disconnected systems to stay competitive amid ongoing constraints.
If you’ve been around aviation maintenance for a while, 2026 probably doesn’t feel like it’s bringing brand-new problems, just making traditional struggles seem louder and harder to ignore.
The ongoing labor shortage is still the top constraint, and supply chain issues are lingering far longer than anyone planned. Fleets keep aging, utilization keeps climbing and MROs are being asked to keep aircraft moving faster with fewer people, less slack and very little margin for error.
What’s changing for 2026 is the tolerance for inefficiency. Operators and MROs who are pulling ahead of their competition in these market conditions know there just isn’t room anymore for errors like:
- Repeat work
- Missed signals
- Surprises that could have been avoided
Veryon’s software platform helps aviation professionals navigate these realities, and in my first year as CEO, I’ve seen just how persistent these constraints really are.
With the current state of our global economy, market inefficiencies will likely get more complex, which makes modern technologies with actionable data insight, the real near-term solution and differentiator.
Why constraints in aviation maintenance aren’t temporary
Starting with the workforce, there simply aren’t enough skilled mechanics to meet demand across regions or fleet types, and that shortage shows up in very real ways, such as:
- Work getting deferred
- Longer times for troubleshooting
- Experienced technicians spending too much time tracking information down
Hiring alone isn’t going to solve this issue. It requires a new way of working.
Team leaders need tangible data intelligence tools to cut down on the time spent deciphering inconsistent logbook entries. Agentic AI makes this all possible, revealing what needs attention now versus what can wait, regardless of a mechanic’s skill level or tenure.
Then there’s the supply chain.
In October 2025, IATA and Oliver Wyman estimated airlines would face more than $11 billion in additional costs tied to ongoing supply chain disruption. That includes billions in extra maintenance and leased engines just to keep aircraft flying when shop visits slip.
When parts are hard to get, every surprise gets expensive, and they all add up quickly. This includes:
- Missed trends
- Recurring issues that weren’t flagged early
- Components failing sooner than expected
Knowing what’s likely to fail and planning around it is how operators protect availability, budgets and their credibility with leadership.
How MRO demand is rising faster than digital adoption
With the continuation of aging fleets, MRO demand continues to climb.
Industry analysis shows the global MRO market is expected to reach $156 billion, surpassing pre-2019 highs, while aircraft utilization is projected to increase 39% by 2035. That means more flying, more wear and more maintenance work flowing into an already stretched system.
We’re seeing new positive developments, like:
- Independent MROs entering the market
- OEMs expanding in-house capabilities
- Operators launching their own MROs to control turnaround times and capture new revenue streams
But here’s where the tension shows up. Only about 6% of MROs have implemented digital tools at scale.
The rest are managing growing workloads with:
- Disconnected systems
- Manual workarounds
- Institutional knowledge that’s hard to scale
That’s where burnout creeps in. That’s where margins erode.
The MROs that have invested in digital maturity are seeing the difference, such as:
- Higher revenues
- Fewer inefficiencies
- Better control over workflow and parts planning
In 2026, digital capability will both support growth and determine who can handle demand without overwhelming their teams.
Why data is now being recognized as an asset
One of the most encouraging shifts I’m seeing is in the way our customers are thinking about data and the dependency to change their business processes and achieve a clear and actionable data strategy.
Our prospects choose Veryon because they see us as a partner for modern technology, but also for change management, as they typically must go through an operational transformation.
Commercial aviation has long leaned into predictive maintenance, largely driven by OEM platforms. Business aviation has lagged, but that gap is closing quickly.
Operators and MROs are actively looking for ways to connect data into their maintenance systems and actually use it, not just report on it. That shift in mindset is a real inflection point for the industry.
What 2026 demands from technology partners in aviation
The reality is clear. Labor isn’t loosening up, parts aren’t suddenly getting easier to find and fleets aren’t getting any younger. What can change is how intelligently we operate inside those constraints.
The operators and MROs that will pull ahead are those building a longer-term digital tech ops plan with the end result in mind.
Forward-thinking MROs and operators are moving away from homegrown systems that don’t talk to each other. Instead, they’re embracing secure, cloud-based platform strategies with partner ecosystems that can deliver actionable insights and interoperability across their organizations and fleets.
About the Author
Bethany Little
Bethany Little is CEO of Veryon.