Speaking to AJW Group’s Director of Engines, Wasim Akhtar, Freighter Trends begins by asking about the differences between overhauling older CFM engines, compared to next-generation CFM engines.  
 

Akhtar replies that the market has a strong supply of USM for older CFM engines, allowing operators to source components at a lower cost compared to new parts from the OEMs.  
 
“This cost-saving opportunity makes overhauling older engines more financially feasible,” he continues, “particularly as these engines age and approach the end of their lifecycle.”  
 
“In contrast, next-generation CFM engines, being relatively new to the market, have a limited supply of USM. Operators are therefore often restricted to purchasing new materials directly from the OEM, making the overhaul process for these engines more costly,” Akhtar concludes.   

Next, Freighter Trends asks Akhtar what OEMs could do to develop more advanced and cost-effective repair solutions for ageing CFM56 engines.  
 
He observes that the data accumulated over the years on older CFM56 engines reveals that these engines have the potential to operate effectively for longer periods.  
 
“This knowledge could enable a shift towards more on-condition maintenance practices, where maintenance actions are based on the actual condition of the engine rather than on fixed intervals. By adopting this approach, operators could achieve more time on wing, extending the service life of their engines and reducing downtime, which in turn would lead to lower operational costs,” he advises. 

Finally, Freighter Trends asks how far supply chain disruptions and workforce shortages impacted turnaround times and costs for CFM engine overhauls.  

“One of the most immediate effects of these disruptions is the increase in TATs for engine overhauls,” replies Akhtar. 

Elaborating, he explains that the delays in sourcing necessary parts due to supply chain issues mean that engines spend more time in the shop, leading to extended downtime for operators. This not only disrupts operational schedules but also increases costs, as prolonged TATs often require operators to lease additional units or rely on spare engines to maintain their fleet. 

Workforce shortages have had a further impact, continues AJW Group’s Director of Engines, particularly due to the lack of experienced staff who are familiar with both older and newer engine types.  

“The combination of supply chain disruptions and workforce shortages has led to higher scrap rates during engine overhauls,” he states. “With experienced staff in short supply, there is a greater likelihood of parts being mishandled or improperly assessed, leading to more components being scrapped rather than refurbished or reused. This not only increases the cost of the overhaul due to the need for new parts but also adds to the strain on the already disrupted supply chain, creating a vicious cycle of delays and cost escalations,” Akhtar concludes.