Grounded by Costs and Labor Shortages? How Data Can Help
EXSYN Aviation Solutions | Simplifying Aircraft Data
Transforming Aircraft Data into Reliable Insights. Your Complete Platform for Data Quality, Reporting, and Analytics.
Data plays a fundamental role in improving efficiency and reducing costs in aviation maintenance. Properly collected and analyzed, it can help airlines optimize staff planning, manage supplier performance, reduce repair costs, and improve inventory management. However, using data effectively requires discipline, consistency, and a well-structured system, without shortcuts or fragmented tools like standalone spreadsheets.
Labor Shortages in Maintenance
The aviation industry has been grappling with labor shortages for years, and maintenance is no exception. While cabin crew and baggage handler shortages are often highlighted in the media, the shortfall in certified aircraft maintenance engineers is just as critical. According to the Allianz Risk Barometer 2025, the shortage of skilled workforce ranks among the top five risks for the aviation sector. The Royal Aeronautical Society estimates that in the next decade, the industry will need 300,000 additional maintenance engineers, a demand unlikely to be met. Boeing projects that the aviation sector will require nearly 690,000 new maintenance technicians over the next two decades to meet growing demand. In the U.S. alone, the Federal Aviation Administration (FAA) projects a shortage of 13,000 mechanics by 2041. This workforce shortage is already driving up costs as competition for skilled labor intensifies.
With fewer mechanics available, airlines need to ensure that unplanned maintenance events are kept to a minimum. AOG situations can lead to delays, cancellations, and additional costs that most airlines can’t afford.
Using Data to Address Workforce Shortages
To mitigate labor shortages, airlines should focus on efficiency rather than just increasing hiring efforts. Data can be used in several ways:
In short, data won’t create more mechanics, but it will help airlines use the ones they have more effectively.
Rising Maintenance Costs
Cost control remains one of the biggest challenges in aviation maintenance. Labor and material costs are climbing, and fuel prices continue to be unpredictable. The Allianz Risk Barometer 2025 also highlights business interruption as a key concern for the aviation industry, with supply chain disruptions exacerbating maintenance delays. The International Air Transport Association (IATA) reports that the average age of the global fleet has increased to 14.8 years, with a record backlog of 17,000 aircraft awaiting production. Older aircraft require more frequent and costly maintenance, further straining budgets.
The FAA has previously estimated that flight delays cost the U.S. economy over $30 billion annually. Meanwhile, unplanned maintenance has historically represented around 27% of airline maintenance expenditures. Reducing that percentage even slightly can lead to substantial savings.
Data-Driven Cost Reduction
A disciplined approach to data can help airlines cut costs without cutting corners.
Emerging Risks in Aviation Maintenance
Beyond labor shortages and rising costs, the Allianz Risk Barometer 2025 identifies additional threats that have direct implications for maintenance operations:
Ensuring Data Reliability
Good data is only useful if it’s accurate and accessible. Airlines must ensure centralized data management to avoid fragmentation across multiple systems, preventing duplication and errors. System integration between maintenance, finance, and supply chain platforms allows real-time data exchange, minimizing manual work and inefficiencies. Routine validation of maintenance records, flight cycles, and component tracking is essential to maintain data integrity. Additionally, reducing reliance on external spreadsheets and standalone workarounds decreases the risk of errors and outdated information, ensuring a single, reliable source of truth for all operations.
How EXSYN Supports Data-Driven Maintenance
EXSYN enables airlines to transition from fragmented maintenance processes to a seamless, data-driven approach. With specialized apps tailored for predictive maintenance, workforce planning, inventory control, and compliance tracking, EXSYN simplifies complex maintenance challenges.
By detecting failure trends early, EXSYN’s predictive maintenance apps help airlines prevent costly AOG situations. Workforce planning tools ensure maintenance teams are deployed efficiently, while inventory management apps prevent part shortages and excessive stockpiling. Cost-tracking solutions offer insights into supplier performance and procurement efficiency, helping airlines reduce unnecessary expenditures. Meanwhile, EXSYN’s compliance and cybersecurity solutions automate sustainability reporting and protect critical maintenance data.
By integrating these capabilities, EXSYN empowers airlines to optimize resources, reduce costs, and enhance operational reliability.
Conclusion:
A structured approach to maintenance data is the foundation of efficient airline operations. Airlines that embrace predictive analytics, centralized data platforms, and automated tracking systems will not only cut costs but also gain a competitive edge in an increasingly complex industry.
Using data effectively is about building smarter, more resilient maintenance operations.