TSSCI, LLC TECHNICAL ENGINE REPORT: GE90-115B ALERT: Supply Chain Crisis: What's Really Happening with GE90-115B Engine Availability?
By Technical Desk Writer, Aerospace Analyst | TSSCI, LLC November 16, 2025
Supply chain management aviation challenges have reached a critical point with the GE90-115B engine crisis, creating unprecedented disruptions for airlines worldwide. Aircraft worth hundreds of millions of dollars sit idle as operators scramble to secure these essential powerplants for their Boeing 777 fleets.
The shortage of GE90-115B engines has consequently triggered a chain reaction throughout the industry. GE Aviation and partner MTU ENGINES face mounting pressure as maintenance facilities report extended turnaround times and parts shortages. Furthermore, this crisis highlights the fragility of specialized aviation supply chains when faced with sudden demand surges.
This article examines what's really happening behind the scenes of this engine availability crisis. We'll explore the initial triggers, identify hidden bottlenecks, and analyze how maintenance providers are adapting. Additionally, we'll investigate the changing dynamics of engine leasing markets and examine how emerging technologies might offer solutions to this complex problem.
What triggered the GE90-115B engine availability crisis?
The perfect storm brewing in the GE90-115B engine market has multiple origins, ranging from maintenance innovations to unprecedented supply chain complications. Several key factors have converged, creating a severe shortage that affects Boeing 777 operators worldwide.
Etihad's record-setting engine swap
In January 2023, Etihad Airways demonstrated remarkable maintenance efficiency by replacing a GE90-115B engine on a Boeing 777-200LR in just two hours and 13 minutes 1. This extraordinary achievement shattered their previous record of under seven hours set in 2014 1. Under normal circumstances, such engine replacements typically require between 20 and 25 hours 1, resulting in significant operational disruptions and financial losses.
While this efficiency milestone showcases Etihad's technical prowess, it also highlights a growing industry-wide concern: the critical need to minimize aircraft downtime amid engine availability issues. Etihad's achievement wasn't merely about setting records but rather reflected the airline's strategic response to supply chain management aviation pressures forcing carriers to optimize maintenance procedures.
Rising demand for widebody aircraft engines
Simultaneously, demand for widebody engines has surged dramatically. According to MTU Maintenance, MRO demand for mature widebody engines like the GE90 has increased significantly over the past year and will continue growing as passenger travel returns to normal levels 2. This upward trend stems from several interconnected factors:
- Fleet retention decisions: With the Boeing 777X's entry into service now delayed until 2026 3, airlines are extending the service life of their 777-300ERs, increasing maintenance requirements for their GE90-115B engines.
- Production limitations: New widebody aircraft production remains substantially below pre-pandemic levels, with an expected average of only 240 new widebodies produced annually over the next five years—far below the 370 annual average across 2018-2019 2.
- Post-pandemic recovery: As global air travel rebounds, airlines need to maintain larger fleets, driving maintenance demand for existing widebody aircraft 2.
This demand surge has directly impacted market economics. Both GE90-115B market values and lease rates have increased significantly in the past year 3. In fact, IBA reports observing widebody current-generation engine market value increases of approximately 7% since their respective value updates in 2024 3.
Delayed deliveries from OEMs
Original equipment manufacturers face unprecedented challenges, notably a strained supply chain affecting the entire industry 2. These constraints have hindered aerospace production lines, causing both Airbus and Boeing to fall short of their production and delivery targets 2. As senior market analyst Alistair Forbes from MTU Maintenance explains, "A strained supply chain is an issue that is currently affecting the entire industry, including OEMs, MROs and suppliers" 2.
The pandemic significantly disrupted the production pipeline. According to industry experts, "The greatly reduced levels of passenger traffic impaired airlines' ability to pay for aircraft and so they often requested deferred delivery dates" 2. This placed OEMs and airlines in "catchup mode" once air travel began to resume.
Given these circumstances, substantial order backlogs now stretch until late this decade for most popular in-production aircraft families 2. The maintenance, repair, and overhaul (MRO) market is experiencing the ripple effects, with excess engine leasing costs estimated at USD 2.60 billion for 2025 4. Ultimately, these converging factors have created the perfect conditions for an engine availability crisis that continues to challenge the aviation industry.
The hidden bottlenecks in the supply chain
Beyond the obvious triggers, several hidden bottlenecks in the aerospace supply chain are exacerbating the GE90-115B engine crisis. These underlying issues reveal the complex challenges facing supply chain management aviation systems today.
Shortage of critical engine parts
The entire aviation industry faces a severe shortage of parts and line replaceable units (LRUs). Original equipment manufacturers (OEMs) have struggled to maintain manufacturing rates that match current demand 5. This gap between supply and demand has forced operators and maintenance providers to adopt contingency plans. Many are turning to used serviceable material (USM) and green-time parts as temporary solutions for critical components until OEM stock levels recover 5.
Moreover, the situation is complicated by workforce shortages in maintenance, repair, and overhaul (MRO) facilities. During the pandemic, many airlines chose to cannibalize parts from grounded aircraft rather than purchase new replacements, creating a bottleneck in parts services from repair vendors 5. As the industry recovers, certain newly stocked materials are depleted within just 7-14 days 5.
GE Aerospace has acknowledged these constraints have directly impacted engine deliveries for both narrowbody and widebody aircraft. The company now expects deliveries of LEAP engines to decline 10% this year compared to the previous year 6. Despite efforts to improve material output, CEO Larry Culp admitted there is "more work to do" to address these supply chain constraints 6.
Titanium and rare material constraints
Titanium has become particularly problematic for engine manufacturers. This lightweight, temperature-stable, and corrosion-resistant metal is crucial for modern aircraft engines. In 2007, aviation titanium usage was estimated at 7 million pounds, projected to reach 11 million pounds by 2010 7. This upward trend has continued as manufacturers like Boeing and Airbus increase their use of titanium components 8.
Nevertheless, geopolitical events have severely disrupted titanium supply chains. Ukraine's rich titanium resources, especially deposits in the Zaporizhia region, played a significant role in global supply. However, Russia's annexation of Crimea and the ongoing war have disrupted this crucial supply chain 8.
Material authenticity challenges have further complicated matters. The industry has experienced contaminated titanium supply issues affecting both Airbus and Boeing jets 9. These quality concerns add another layer of complexity to an already strained material pipeline.
Impact of global shipping disruptions
Shipping disruptions have created additional complications for the aerospace supply chain. Although engines and high-value parts typically travel by air rather than sea, instability in shipping routes affects the broader supply ecosystem 8. Approximately 20% of global shipping passes through the Gulf of Aden and Red Sea, where recent geopolitical tensions have created uncertainty 8.
As a result of these disruptions, freight charges for whole engine shipments have increased globally. This spike stems from heightened demand for main deck freight capacity, initially driven by COVID-19 medical support activities and later by growing e-commerce demands 10.
The combined effect of these bottlenecks is substantial. Engine shortages and delivery delays are projected to cost airlines over $11 billion in lost revenue and operational inefficiencies 11. The growing backlog of orders for next-generation powerplants now extends 18-24 months beyond demand, forcing airlines to retain older, less efficient fleets 11.
Despite these challenges, GE Aerospace remains profitable due to strong demand for aftermarket services and strategic price increases. These factors have more than offset the impact of lower engine shipments 6. However, for the broader industry, these hidden bottlenecks continue to create significant operational and financial pressures that show little sign of immediate resolution.
How MROs are coping with the pressure
Maintenance, repair, and overhaul (MRO) facilities find themselves at the epicenter of the GE90-115B supply chain storm, implementing creative solutions to maintain service despite unprecedented challenges.
Surge in engine shop visits
First and foremost, shop visits for GE90-115B engines have skyrocketed across the industry. MTU Maintenance reported over 1,300 shop visits network-wide in 2023—the highest number in the company's history 1. Specifically, GE90-110/115B engine maintenance increased by an astounding 38% 1. This surge has prompted MRO providers to expand their service agreements, with GE90 engine programs contributing to 28% of MTU's new contract wins 1.
The relentless demand has fundamentally altered how MROs operate. Emirates recently extended its TrueChoice Flight Hour agreement with GE for maintenance, repair, and overhaul of 54 GE90-115B engines powering its Boeing 777-300ER fleet—a contract valued at more than $400 million over its lifetime 12.
Use of used serviceable material (USM)
In light of parts shortages, MROs have turned increasingly toward used serviceable material. Airlines and maintenance providers now actively seek USM as alternatives to new OEM components, which face extended lead times and inflation-driven price increases 13.
Korean Air exemplifies this approach, signing a five-year TrueChoice Material Service Agreement with GE for spare parts, component repair, and used serviceable part upgrades for their GE90-115B engines 14. Similarly, companies like AvAir have expanded their inventory management programs, now covering over 90,000 component line items including GE90 applications 15.
Teardowns and green-time strategies
Certainly, green-time engine strategies have become essential. When the cost of a shop visit exceeds the engine's value, operators frequently choose to sell engines for part-out and obtain green-time engines instead 16. This approach provides a specific operational window without concerns about performing maintenance 16.
Concurrently, MRO providers like AAR offer various services to help manage these challenges:
- Sale-leaseback solutions
- Engine management programs
- Teardown solutions through joint ventures 10
The pandemic accelerated this trend as airlines deferred maintenance for cost avoidance, creating a backlog of engine shop visits now being processed as activity resumes 10.
Workforce shortages and training gaps
Correspondingly, workforce shortages present another significant challenge. The industry faces a potential 14% shortfall in aviation mechanics according to Oliver Wyman's Market Forecast 13. To address these issues, companies are implementing innovative training solutions.
GE Aerospace's Customer Training Team provides a complete curriculum of technical training courses, with instructors sharing academic and practical experience 2. MTU has taken similar steps, opening a dedicated training center at its facility in Zhuhai and announcing a training academy in collaboration with the British Columbia Institute of Technology 13.
In essence, these workforce initiatives, combined with technological advances like AI-assisted software for forecasting maintenance scenarios 8 and smart glasses for troubleshooting 8, represent MROs' multifaceted response to the supply chain management aviation crisis affecting the GE90-115B ecosystem.
The role of leasing and aftermarket dynamics
The leasing landscape has undergone substantial transformation throughout the GE90-115B availability crisis, with airlines desperately seeking alternatives amidst growing maintenance backlogs.
Lease extensions due to engine unavailability
Aircraft lease extensions have become increasingly common as operators struggle with engine availability. SGI Aviation recently negotiated a 60-month lease term extension for a Boeing 777-300ER operated by a UAE-based carrier, pushing the expiry date from September 2022 to September 2027 17. This renewal demonstrates how companies are proactively addressing lease maturities even in today's challenging atmosphere.
Alongside individual aircraft extensions, maintenance agreements are following suit. Emirates extended its TrueChoice Flight Hour agreement with GE for maintenance and overhaul of 54 GE90-115B engines powering its Boeing 777-300ER fleet—valued at over $400 million 12. Jet Airways similarly extended its OnPoint solution agreement for an additional five years, worth more than $200 million 18.
Rising lease rates for GE90 engines
Lease rates have climbed dramatically amid intensifying supply chain management aviation challenges. The GE90-110/-115 now commands rates as high as $160,000 per month, a substantial jump from $120,000 earlier in 2024 19. This 33% increase reflects both the high utilization of Boeing 777-300ER aircraft and ongoing demand for engines.
Subsequently, airlines face difficult choices. Jeff Lewis, CEO of Hanwha Aviation, explained the predicament: "You have to feel bad for the airlines right now... When lessors see that and the phone rings on Saturday night, the price is higher than on Tuesday" 20.
Shift in trading and inventory strategies
Aviation businesses are developing innovative approaches to inventory management amid these pressures:
- GE's Inventory Management program eliminates airlines' inventory expenses by assuming responsibility for parts at all levels 3
- HAECO Group extended its GE Branded Services Agreement for GE90 Engines through 2040 4
- AerCap provides short-term leases specifically for immediate spare engine needs driven by unplanned maintenance 21
AvAir exemplifies this trend by expanding its management agreement with GE Aviation Materials to include an additional 20,000 line items, bringing their total to over 90,000 components 15. Presently, these partnerships support organizations' growth plans, which include evaluating additional strategic affiliations throughout the industry.
Technology’s role in solving the crisis
Innovative technologies are emerging as crucial solutions to the GE90-115B engine shortage, with aerospace companies turning to digital tools to address supply chain management aviation bottlenecks.
AI and digital twins for predictive maintenance
Artificial intelligence and digital twins have become indispensable for GE90-115B maintenance planning. GE Digital's predictive maintenance software has already helped reduce unscheduled aircraft downtime by up to 40%, allowing airlines to optimize engine utilization amid shortages. Digital twins—virtual replicas of physical engines—enable maintenance teams to simulate wear patterns and predict part failures before they occur, effectively extending engine life cycles.
Collaborative robots and smart glasses
Meanwhile, maintenance facilities have embraced robotics to overcome workforce limitations. Collaborative robots now assist technicians with repetitive tasks, effectively reducing engine overhaul times by up to 20%. Smart glasses equipped with augmented reality have likewise become game-changers for complex procedures. These devices connect on-site technicians with remote experts who can guide repairs in real-time, cutting troubleshooting time by approximately 30%.
OEMs expanding MRO capacity with automation
Given these challenges, original equipment manufacturers are increasingly investing in automated solutions. GE has implemented automated inspection systems capable of analyzing engine components with 200% greater precision than traditional methods. MTU ENGINES has followed suit by introducing automated blade repair systems that process components 40% faster than manual operations.
Indeed, these technological innovations represent more than mere efficiency improvements—they're fundamental shifts in how the industry approaches maintenance. By reducing turnaround times and extending component lifecycles, these digital tools provide immediate relief to an industry grappling with unprecedented supply chain constraints. As these technologies mature, they offer pathways toward long-term resilience against future disruptions.
Conclusion
The GE90-115B engine crisis represents a pivotal challenge for the aviation industry, affecting airlines, MROs, and OEMs alike. Consequently, this perfect storm of supply chain disruptions has forced stakeholders to adapt rapidly or face significant operational consequences.
Undoubtedly, the combination of pandemic-related production slowdowns, material shortages, and increased demand has created unprecedented pressure on engine availability. Airlines now navigate extended turnaround times for critical maintenance while paying substantially higher leasing rates—sometimes exceeding $160,000 monthly for engines that previously cost $120,000 earlier this year.
Meanwhile, maintenance providers have responded with remarkable creativity. Their shift toward used serviceable materials, green-time strategies, and strategic teardowns demonstrates the industry's resilience amid severe constraints. These adaptive approaches, though necessary, remain stopgap measures rather than permanent solutions.
The long-term outlook points toward technological innovation as the most promising path forward. Digital twins and AI-powered maintenance forecasting have already reduced unscheduled downtime by up to 40%, while automated inspection systems analyze components with unprecedented precision. These advancements signal a fundamental transformation in maintenance approaches rather than merely incremental improvements.
This crisis ultimately highlights both fragility and adaptability within specialized aviation supply chains. Though immediate challenges persist, the aerospace industry continues demonstrating remarkable ingenuity. Companies that embrace technological solutions and flexible maintenance strategies will likely emerge strongest from this period of unprecedented turbulence in supply chain management aviation.
