MRO & Manufacturing
GE Aerospace Improves Supply Chain and Boosts Airbus Engine Deliveries
GE Aerospace’s lean model improves supply chain efficiency, increasing LEAP engine production and supporting Airbus deliveries in 2025.
GE Aerospace Turns the Tide on Supply Chain Woes, Boosting Airbus Deliveries
The global aviation industry has been navigating turbulent skies in recent years, largely due to persistent supply chain disruptions that began in the wake of the COVID-19 pandemic. These constraints have created significant headwinds for aircraft manufacturers and airlines alike, leading to production delays and a scarcity of spare parts. For European aerospace giant Airbus, a primary bottleneck has been the timely delivery of jet engines, a critical component for its popular A320neo family of aircraft. However, recent developments from GE Aerospace, a key engine supplier, signal a potential shift in this challenging environment. The company’s focused efforts to untangle its Supply-Chain are beginning to yield tangible results, offering a glimmer of hope for a more stable production landscape.
At the heart of this issue is CFM International, a joint venture between GE Aerospace and Safran Aircraft Engines, which produces the LEAP engine. These engines are a popular option for the Airbus A320neo and the exclusive powerplant for the Boeing 737 MAX. Production difficulties within the CFM partnership have had a cascading effect, impacting Airbus’s ability to meet its delivery targets and, consequently, the expansion plans of Airlines around the world. The financial repercussions of these delays are substantial, affecting the entire aviation ecosystem. Now, with GE Aerospace implementing strategic initiatives to overcome these hurdles, the industry is watching closely to see if this marks a turning point in the post-pandemic recovery.
Strategic Initiatives and Operational Overhauls
In response to the ongoing supply chain pressures, GE Aerospace has deployed a proprietary lean operating model known as “FLIGHT DECK.” This internal strategy is designed to drive sustainable performance and foster measurable improvements by embedding lean principles and tools throughout the company’s operations. The initiative focuses on creating a more resilient and efficient supply chain by working closely with supplier partners to identify and eliminate bottlenecks. The early results of this approach are promising, demonstrating that a systematic and collaborative effort can indeed make a significant impact on complex Manufacturing challenges.
The “FLIGHT DECK” model has already produced concrete results. For instance, at GE’s facility in Pune, India, the lead time for certain LEAP engine components has been reduced by 50%. This is a testament to the effectiveness of the lean principles being applied. Furthermore, the company has reported a substantial increase in materials received from key suppliers, with a 35% rise compared to the previous year. This improvement in the flow of materials is a critical step in stabilizing production and ensuring a more predictable output of finished engines.
Perhaps one of the most significant indicators of progress is the improved reliability of GE’s suppliers. According to the company, critical suppliers are now delivering to their commitments 95% of the time, a rate that has doubled from a year ago. This increased predictability is a cornerstone of a healthy supply chain and is essential for ramping up production to meet the high demand from customers like Airbus. As GE Aerospace continues to refine its “FLIGHT DECK” model, these operational gains are expected to become more widespread, further strengthening the company’s ability to navigate the complexities of the global supply chain.
“We knew that we were going to have a slower start than any of us would have wanted in 2025, but… in terms of LEAP deliveries, growing in the 15-20% range continues to be what we believe we will do in 2025. It’s all about the supply chain dynamics… with the supply base, we’re really encouraged by the sequential improvement that we’ve seen in our deliveries from our critical suppliers.”, Larry Culp, GE Aerospace CEO (May 2025)
The Ripple Effect: Improved Deliveries and Financial Performance
The operational improvements driven by GE Aerospace’s strategic initiatives are having a direct and positive impact on its ability to deliver engines to Airbus. GE Aerospace CEO Larry Culp recently announced that the company made significant progress in catching up on delayed jet engine deliveries to Airbus during the third quarter of 2025. This development is a welcome sign for Airbus, which has been grappling with engine shortages as it seeks to ramp up production of its narrowbody aircraft.
The numbers support this optimistic outlook. GE Aerospace reported a 40% year-over-year increase in the production of its LEAP engines in the third quarter of 2025. Looking at the full year, the company now anticipates a growth of over 20% in LEAP engine deliveries, an upward revision from the previously projected 15-20% range. This acceleration in production is a clear indication that the company’s supply chain fixes are taking hold and translating into a higher output of finished products.
This positive momentum is also reflected in GE Aerospace’s strong financial performance. The company reported a 26% increase in adjusted revenue to $11.3 billion for the third quarter of 2025. Adjusted earnings per share saw a 44% rise to $1.66, and free cash flow grew by 30% to $2.4 billion. Buoyed by these strong year-to-date results, GE Aerospace has raised its full-year financial guidance, signaling confidence in its ability to sustain this performance through the end of the year and beyond.
Conclusion: A Path to Stability and Future Growth
The progress made by GE Aerospace in resolving its supply chain issues offers a beacon of hope for the entire aviation industry. By implementing its “FLIGHT DECK” operating model and fostering closer collaboration with its suppliers, the company has demonstrated a clear path toward stabilizing its production and catching up on crucial engine deliveries to Airbus. This not only benefits the two aerospace giants but also has a positive ripple effect on airlines and the traveling public, who stand to gain from a more predictable and robust aircraft supply chain.
Looking ahead, the lessons learned from this period of disruption will likely shape the future of aerospace manufacturing. The emphasis on lean principles, supplier collaboration, and operational resilience will become even more critical as the industry continues to navigate a complex and ever-changing global landscape. While challenges may still lie ahead, the proactive and strategic approach taken by GE Aerospace serves as a powerful example of how to turn adversity into an opportunity for innovation and growth.
FAQ
Question: What is the “FLIGHT DECK” initiative?
Answer: “FLIGHT DECK” is GE Aerospace’s proprietary lean operating model designed to create sustainable performance and measurable improvements by integrating lean principles and tools across the company.
Question: How have GE’s supply chain improvements affected Airbus?
Answer: The improvements have allowed GE Aerospace to make progress in catching up on delayed jet engine deliveries to Airbus, particularly in the third quarter of 2025.
Question: What are the key performance indicators of GE’s supply chain recovery?
Answer: Key indicators include a 40% year-over-year increase in LEAP engine production in Q3 2025, a 35% increase in materials received from key suppliers, and a 95% on-time delivery rate from critical suppliers.
Sources
Photo Credit: Reuters
MRO & Manufacturing
Boeing and American Airlines Complete First 737 MAX Landing Gear Exchange
Boeing and American Airlines complete the first 737 MAX landing gear exchange, reducing AOG time ahead of the 144-month overhaul interval.
The Boeing Company and American Airlines (AAL) have completed the first landing gear exchange for a Boeing 737 MAX aircraft, marking the formal extension of Boeing’s overhaul program to the re-engined narrowbody platform.
Announced on September 14, 2026, from Boeing Global Services headquarters in Plano, Texas, the milestone involves the supply of overhauled and certified main and nose landing gear assemblies, along with installation kits. The exchange program allows operators to bypass traditional overhaul wait times by receiving ready-to-install gear, significantly reducing aircraft on-ground (AOG) time.
Expanding the Landing Gear Exchange Program
The Boeing 737 MAX entered commercial service in May 2017. According to Air Data News, the aircraft type features an extended landing gear overhaul interval of 144 months, an increase from the 120-month interval required for earlier 737 generations. The completion of this first exchange with American Airlines occurred well ahead of the 12-year maximum interval for the earliest airframes.
By utilizing the exchange program, airlines can reserve forward-exchange slots. This model eliminates the need for carriers to warehouse expensive spare landing gear inventory and shifts the technical overhaul and obsolescence risks directly to Boeing. The supplied kits exclude wheels, tires, and brakes, which operators manage separately.
William Ampofo, Senior Vice President of Parts, Distribution, and Supply Chain for Boeing Global Services, stated in the press release that the capability delivers “predictable, safe and cost-effective outcomes.” He noted that extending the program to the 737 MAX gives operators another proven tool to shorten downtime and align heavy maintenance with operational needs.
Scaling Global Overhaul Capacity
As the earliest 737 MAX aircraft progress through their maintenance lifecycles, Boeing is actively increasing its global overhaul capacity. The manufacturer is coordinating with certified Maintenance, Repair, and Overhaul (MRO) partners to expand the geographic availability of the exchange program. Neither Boeing nor American Airlines disclosed the specific aircraft registration involved in this initial exchange or the facility where the maintenance was performed.
Near-term priorities for the manufacturer include enlarging the exchange inventory capable of supporting the 737 MAX and adding forward-exchange slots closer to customer operations. Boeing also plans to track operational metrics as the program scales to quantify the exact downtime and cost benefits for operators.
AirPro News analysis
We view the early initiation of the 737 MAX landing gear exchange program as a strategic move by Boeing to secure aftermarket revenue while smoothing the maintenance pipeline for its largest narrowbody customers. By executing this first exchange well before the 144-month regulatory deadline for the 2017-vintage airframes, Boeing and American Airlines are likely stress-testing the supply chain and MRO logistics. This proactive approach should help prevent bottlenecks when the bulk of the early 737 MAX fleet comes due for mandatory gear overhauls in the late 2020s.
Sources: The Boeing Company
Photo Credit: The Boeing Company
MRO & Manufacturing
MSA Safety Launches A1X WinGrip Vacuum Anchor for MRO
MSA Safety’s A1X WinGrip uses gas-powered vacuum suction for fall protection during active aircraft refueling with no electronics.
On September 9, 2026, MSA Safety Incorporated announced the launch of the A1X WinGrip vacuum anchor, a non-invasive fall protection system designed to operate without electronics for safe deployment during active aircraft refueling.
In a press release issued by the Pittsburgh-based safety equipment manufacturer, the company detailed that the new system utilizes vacuum suction technology to create secure anchor points on aircraft wing surfaces and fuselages. The A1X is powered entirely by refillable air or gas-supplied cylinders, eliminating ignition risks in environments where fuel vapors are present.
Technical specifications and deployment
The A1X system is engineered to maintain its vacuum seal even during flow interruptions, providing a continuous safety margin for aviation maintenance technicians. It features an integrated audio alarm that delivers real-time status feedback regarding the anchor’s securement to the aircraft surface.
Each standard kit includes a primary vacuum anchor, a secondary “flying” anchor for triangulated configurations, a dedicated air cylinder, a pressure line, and personal protective equipment (PPE). The system builds upon the company’s existing All-In-One (AIO) WinGrip architecture while expanding compatibility across a broader range of aircraft types.
Industry application and upcoming exhibition
Fall protection remains a critical regulatory and safety requirement for aviation maintenance, repair, and overhaul (MRO) operations. MSA Safety, which reported $1.9 billion in revenue in 2025 and employs over 5,300 people globally, developed the A1X based on direct feedback from maintenance personnel working on the ramp and in hangars.
“The A1X vacuum anchor was developed from listening to the people who use WinGrip every day. We know that if a tool isn’t deployed, it isn’t protecting anyone, so we focus on removing every barrier between a technician and their safety equipment,” said Jose Sanchez, Senior Vice President and President of Europe, Middle East, and Africa (EMEA) Business for MSA Safety.
Sanchez noted that the system is the most capable and portable WinGrip anchor the company has built to date. The manufacturer plans to display the A1X vacuum anchor to the European aviation market at the upcoming MRO Europe exhibition in October 2026.
AirPro News analysis
We note that the elimination of electronic components in fall protection gear addresses a specific operational bottleneck in line maintenance. By allowing technicians to safely deploy anchor points during active refueling operations, airlines and MRO providers can conduct concurrent servicing tasks. This capability directly supports faster turnaround times on the ramp without compromising worker safety in hazardous, vapor-rich environments.
Sources: MSA Safety Incorporated
Photo Credit: MSA Safety Incorporated
MRO & Manufacturing
Flair Airlines Signs 15-Year LEAP-1B MRO Deal With Lufthansa Technik
Flair Airlines signs a 15-year exclusive agreement with Lufthansa Technik for LEAP-1B engine MRO and digital services in Calgary.
Flair Airlines has signed a 15-year exclusive agreement with Lufthansa Technik for LEAP-1B engine maintenance and digital technical operations services, localizing critical support for the Canadian ultra-low-cost carrier in Calgary, Alberta.
Announced in a press release on September 10, 2026, the contract covers the airline’s fleet of 18 Boeing 737 MAX 8 aircraft. The deal establishes Flair Airlines as the second major customer for Lufthansa Technik Canada’s newly opened engine repair facility, signaling a strategic shift toward domestic supply chain resilience for the operator.
Localized engine maintenance in Calgary
The core of the agreement centers on the CFM International LEAP-1B engines powering the Flair Airlines Boeing 737 MAX 8 fleet. Maintenance, Repair, and Overhaul (MRO) work will primarily take place at Lufthansa Technik’s interim eight-bay facility in Calgary.
The Calgary site, which was first announced in February 2025 to expand the maintenance provider’s North American footprint, has already inducted two of the airline’s LEAP-1B engines for quick-turn services. The Canadian operations will receive supplementary support from the company’s established network facilities in Hamburg, Germany, and Wrocław, Poland.
“Flair is building a more efficient airline, focused on excellence in execution and long-term growth. We’re proud to partner with Lufthansa Technik Canada, bringing world-class expertise, technology and new aviation capability here at home. This 15-year partnership strengthens our operation and supply chain resilience, supports skilled aviation expertise in Alberta and helps us continue making air travel more affordable for everyday Canadians.” — Len Corrado, CEO, Flair Airlines
Digital integration and technical operations
Beyond physical engine maintenance, the 15-year contract incorporates a comprehensive suite of digital services designed to optimize fleet reliability. Flair Airlines will integrate Lufthansa Technik’s AVIATAR platform, specifically utilizing its Condition Monitoring, Predictive Health Analytics, and Engineering Analytics Suite.
The digital overhaul extends to maintenance record-keeping and compliance. The airline will adopt the AMOS electronic Technical Logbook (eTLB) provided by Swiss AviationSoftware Ltd., alongside the flydocs digital records management system. This combination aims to streamline technical operations and reduce aircraft downtime through predictive maintenance modeling.
Georgios Ouzounidis, Vice President Corporate Sales Americas at Lufthansa Technik, noted the significance of the localized support structure. He stated that the company appreciates the confidence placed in them by the airline, adding that securing their second major customer for the Canadian engine repair station marks the beginning of a long-term partnership built on trust and performance.
AirPro News analysis
We view this 15-year commitment as a stabilizing move for Flair Airlines. By securing localized MRO capacity for its LEAP-1B engines, the carrier mitigates exposure to the global engine shop visit backlog that has grounded aircraft across the industry. For Lufthansa Technik, anchoring a domestic airline at its new Calgary facility validates its North American expansion strategy and provides a steady baseline of quick-turn and overhaul work to justify further regional investment.
Sources: Lufthansa Technik
Photo Credit: Lufthansa Technik
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