Why AOG events are more frequent — and more costly — in 2026
Aircraft on Ground (AOG) scenarios have always posed significant operational and financial challenges for airlines. In 2026, however, AOG risks are rising — both in frequency and cost — driven by a confluence of industry-wide pressures. Understanding these forces is essential for operators seeking to keep fleets flying and costs under control.
Aging Fleets and Operational Strain
Persistent aircraft delivery delays have extended the service life of older aircraft well beyond initial planning assumptions. As fleets age, unscheduled maintenance events become more common and the availability of current-production replacement parts diminishes. This increases the probability that what should be routine maintenance turns into an AOG event with broader operational consequences.
How XS Aviation Helps: With a large inventory of quality-assured Airbus, Boeing and Embraer consumables and rotables, XS Aviation supports operators by quickly sourcing critical components needed to resolve AOG situations and keep aircraft in service.
Parts Scarcity Is a Core Bottleneck
Despite improvements since the supply chain disruptions of prior years, parts scarcity remains the single biggest factor prolonging AOG events. OEM production constraints and long turnaround times for repaired components mean that operators often wait days – not hours – for the parts they need. This extended downtime translates directly into higher costs through lost utilisation, schedule disruption and passenger compensation.
How XS Aviation Helps: Through global trading services tailored to the aviation market, XS Aviation works to meet timely demands for quality-assured parts, helping operators solve material shortages and turn AOG events around more quickly.
A New Cost Baseline for AOG Resolution
The cost of resolving AOG events has increased structurally. Expedited logistics, specialised couriers, higher labour rates and inflation in parts pricing mean that even minor AOG issues now command a higher price tag. For many operators, AOG cost structures in 2026 represent a new normal, not a temporary spike.
How XS Aviation Helps: By offering efficient surplus parts acquisition and management – including consignment partnerships that adapt to operators’ inventory needs – XS Aviation helps reduce the financial impact of sourcing parts during critical downtimes.
High Utilisation Leaves Little Margin for Error
Airlines are running aircraft harder than ever to maximise revenue from constrained fleets. With fewer spares available for substitution, a single grounded aircraft can rapidly cascade into widespread schedule disruption. The operational impact of an AOG event now extends far beyond the aircraft immediately affected.
How XS Aviation Helps: XS Aviation’s materials solutions provide operators with tailored support in managing surplus aircraft assets and forecasting parts demand, which strengthens readiness and reduces the likelihood of unplanned groundings.
Compliance Requirements Can Slow Recovery
Stringent regulatory requirements for part traceability and certification are vital for safety, but they also add time to AOG recovery. Airlines cannot return an aircraft to service without complete documentation, and any gap can delay resolution, especially when sourcing parts from non-traditional channels.
How XS Aviation Helps: With a commitment to quality-assured parts and transparent documentation, XS Aviation ensures that sourced components meet regulatory standards, helping operators resolve AOG events without compliance delays. (xsaviation.com)
The 2026 AOG Reality
In today’s aviation landscape, AOG events are more frequent and more expensive not because operators lack capability, but because the operational margin for recovery has narrowed. Aging fleets, constrained supply chains, rising costs and intense utilisation have combined to elevate AOG from a reactive challenge to a strategic priority.
For airlines and MROs, having trusted partners who understand the complexity of parts trading, surplus management, and rapid response is critical.
XS Aviation is that partner – offering tailored parts solutions, trading support, and consignment services that help operators mitigate AOG risk, reduce downtime and manage the financial impact of grounded aircraft.