Recurring Aircraft Defects Prompt Safety Review in Indian Aviation

Recurring Aircraft Defects Raise Safety Concerns in India’s Aviation Sector

India’s aviation sector, one of the fastest-growing globally, is facing heightened scrutiny following recent findings by the Directorate General of Civil Aviation (DGCA). The regulator identified multiple instances of recurring aircraft defects at two of India’s busiest airports, Mumbai and Delhi. These revelations follow a tragic Air India crash on June 12, 2025, in Ahmedabad that claimed 271 lives, prompting a sector-wide reassessment of safety protocols and maintenance standards.

The DGCA’s announcement on June 24, 2025, has ignited concerns about the adequacy of aircraft maintenance procedures and the robustness of regulatory oversight in India. While the regulator did not specify the airlines or the exact nature of the defects, the implications are profound. Mumbai and Delhi airports, handling millions of passengers annually, are critical hubs for domestic and international travel. Any safety lapses at these airports could have significant consequences.

This article examines the context of the DGCA’s findings, the challenges within India’s aviation maintenance ecosystem, and potential strategies to ensure safer skies.

Systemic Challenges in Aircraft Maintenance Oversight

Recurrent Defects and Audit Findings

The DGCA’s special audit, initiated after the Air India crash, revealed that certain aircraft defects reappeared “many times,” indicating inadequate resolution or inspection of previously reported issues. The audit involved comprehensive surveillance during night and early morning hours at major airports, including Delhi and Mumbai, covering flight operations, airworthiness, ramp safety, and more.

Although the DGCA did not name the airlines involved, Mumbai and Delhi are key bases for major carriers like IndiGo, Air India, and Air India Express. With India’s aviation market valued at approximately USD 30 billion in 2024, such lapses pose significant risks to both safety and industry reputation. The DGCA also noted issues like unserviceable ground handling equipment, inadequate tool control procedures, and maintenance engineers failing to follow safety protocols or record defects properly.

Additional findings included life vests not secured under seats, damaged corrosion-resistant tape on aircraft winglets, and outdated obstruction limitation data at one airport, highlighting systemic weaknesses in maintenance and oversight.

“The reappearance of defects on aircraft at two of India’s busiest airports highlights systemic challenges in maintenance oversight,” said Abhijith Ganapavaram, Reuters aviation correspondent.

Infrastructure and Human Resource Constraints

A key issue is the disparity between India’s rapid fleet expansion and its maintenance capacity. The surge in aircraft numbers has outpaced the development of maintenance, repair, and overhaul (MRO) infrastructure and skilled personnel, increasing the risk of oversights during high-traffic periods.

Dr. Ramesh Kumar, an aerospace engineering expert at IIT Bombay, noted that recurring defects may stem from gaps in training and quality assurance among maintenance teams. Continuous professional development and rigorous certification are essential to minimize human error in routine maintenance tasks. The DGCA’s findings of maintenance engineers ignoring safety protocols further underscore these challenges.

Additionally, the DGCA highlighted that at one airport, no survey had been conducted despite recent construction nearby, potentially compromising safety. This issue, while not directly linked to the Air India crash, emphasizes the need for comprehensive audits encompassing both aircraft and airport infrastructure.

Regulatory Gaps and Enforcement Limitations

While the DGCA conducts routine audits, the recurrence of defects suggests enforcement mechanisms may lack sufficient rigor. The regulator has mandated corrective actions within seven days, but long-term solutions require structural reforms.

Industry experts argue that penalties for non-compliance are often too lenient to drive change. More frequent, unannounced inspections, especially during off-peak hours, could uncover irregularities. Greater transparency in audit findings would also enhance public trust and industry accountability. The DGCA’s shift toward a “comprehensive special audit” framework post-crash aims to address these gaps by evaluating the aviation ecosystem holistically.

Globally, regulators are adopting data-driven, predictive maintenance models using AI and IoT technologies. India is exploring these tools, but widespread adoption requires investment, training, and alignment with international standards.

Pathways to Safer Skies

Adoption of Predictive Maintenance Technologies

To tackle recurring defects, Indian airlines and MRO providers are exploring predictive maintenance solutions. These technologies leverage real-time aircraft data to anticipate failures, enabling proactive interventions. AI and machine learning can identify root causes and track maintenance histories, reducing defect recurrence.

Globally, airlines using predictive analytics report improved aircraft availability, lower maintenance costs, and enhanced safety. For India, scaling these technologies across its aviation ecosystem could be transformative, though it demands technological upgrades and a shift toward preventive maintenance cultures.

Strengthening MRO Capabilities

India aspires to become a global MRO hub, a goal reliant on robust maintenance standards and regulatory oversight. Enhancing domestic MRO capabilities is critical to meet growing demand and reduce reliance on foreign facilities.

Government incentives, such as tax breaks and policy reforms, aim to attract MRO investment. However, success hinges on aligning quality and safety with global benchmarks. Collaboration with international experts, process standardization, and skill development programs are vital, supported by stringent monitoring and enforcement.

Improving Regulatory Frameworks

The DGCA must evolve into a proactive, technology-driven regulator. Upgrading audit methodologies, increasing staffing, and adopting digital surveillance tools are essential steps. Aligning with International Civil Aviation Organization (ICAO) guidelines will strengthen India’s regulatory framework.

Collaboration with global aviation bodies can facilitate knowledge sharing and benchmarking. Regulatory reforms should foster a safety-first culture, where compliance is a core value across all aviation stakeholders, not merely a procedural requirement.

Conclusion

The DGCA’s findings on recurring aircraft defects at Mumbai and Delhi airports are a critical wake-up call for India’s aviation sector. Despite its growth, maintaining rigorous safety standards is paramount. The recurrence of defects highlights the need for systemic improvements in maintenance practices, regulatory enforcement, and infrastructure development.

By embracing predictive maintenance, strengthening MRO capabilities, and reforming regulatory frameworks, India can restore confidence and ensure passenger safety. As the nation aims to lead globally in aviation, addressing these challenges with urgency and transparency will shape the sector’s long-term success.

FAQ

What did the DGCA find in its recent audit?
The DGCA identified multiple recurring aircraft defects at Mumbai and Delhi airports, indicating inadequate maintenance and monitoring, alongside issues like unserviceable equipment and non-compliance with safety protocols.

Which airlines were involved?
The DGCA did not specify airlines, but Mumbai and Delhi serve major carriers like IndiGo, Air India, and Air India Express.

What steps are being taken to address the issue?
Operators must implement corrective actions within seven days, and the DGCA is considering stricter penalties and ongoing surveillance.

How can recurring defects be prevented?
Predictive maintenance technologies, enhanced training, and robust regulatory oversight are key to preventing defect recurrence.

Is this issue unique to India?
No, recurring defects are a global challenge, but effective resolution is critical for safety and trust in India’s aviation sector.

Sources: Reuters, DGCA India, Airports Authority of India, ICAO