As demand surges toward peak freight seasons, such as the year-end holidays, a growing scarcity of essential spare parts is placing mounting pressure on freighter reliability and turnaround times.
“Shortages of some, including critical components like engine line-replaceable units (LRUs) and flight control parts, are directly contributing to extended AOG durations,” warns Toma Matutyte, CEO of Locatory. “During peak air cargo seasons, even a short delay in replacing a faulty component can throw an entire network off schedule.”
The impact isn’t limited to simple delays. When vital parts such as engine LRUs or flight control actuators are unavailable, grounded freighters become more than just operational disruptions—they become logistical liabilities. Operators are forced to turn to expensive, short-term fixes like cannibalising parts from other aircraft or paying premiums for expedited international shipping.
“We’re already seeing warning signs earlier in the year,” adds Matutyte. “Our most recent hard-to-find component reports show elevated demand for items such as electronic control units, brake assemblies, and various cockpit instrumentation systems, which could be an indication that shortages may intensify as we move toward autumn and winter.”
These shortages signal broader systemic issues: stretched MRO capacities, fractured global supply chains, and increased maintenance cycles on ageing fleets. For freighter operators—particularly those running older aircraft—this translates to reduced operational flexibility, longer ground times, and soaring costs, especially when sourcing last-minute parts under pressure.
Data confirms
A direct and alarming correlation has emerged between spikes in demand for specific spare parts and operational delays in the air cargo sector. For operators dependent on tight timetables and slim profit margins, this trend is creating a dangerous convergence of risk.
“There’s a strong and consistent correlation between sudden spikes in demand for specific spare parts and disruptions in airfreight operations,” Matutyte says. “Our monthly hard-to-find component reports, which reflect global RFQ volumes and marketplace dynamics, offer a unique window into how these shortages evolve.”
Key components like avionics units, cockpit displays, and hydraulic assemblies are frequently cited as pain points. “When demand for these items surges,” Matutyte explains, “it often signals not just increased wear or fleet utilisation but also bottlenecks in availability.”
Matutyte underscores the real-world implications: “Locatory.com data shows a 2.5x increase in AOG-related search activity during seasonal peaks, particularly for aging freighters. We all see that in practice, as it becomes real-world grounding events and missed cargo connections.”
Geographic disparities worsen the challenge. While major air cargo hubs may maintain some inventory buffers, more remote regions with lower supplier density face far greater vulnerability. “Delays linked to part shortages are more common and can have wider repercussions throughout the air cargo network,” Matutyte notes.
To mitigate such risks, early visibility into demand trends is essential. “Recognising these spikes early gives freighter operators a critical advantage in forward planning their inventory,” she says. “They can source from alternative global locations before shortages cascade into grounded assets and missed delivery windows.”
Smarter sourcing
The future of resilient freight operations may lie not in warehouses, but in data. By leveraging predictive analytics, historical pricing trends, and marketplace transparency, operators can shift from reactive to proactive maintenance logistics—especially crucial during seasonal demand spikes.
“By analysing trends in lead times and price volatility, operators can anticipate shortages and pre-position high-risk components,” says Matutyte. “It’s about moving from reactive maintenance logistics to a more strategic, anticipatory model.”
Digital platforms like Locatory.com provide that strategic edge. With real-time access to supplier inventories and pricing, operators can make informed decisions—minimising emergency shipments, maximising fleet uptime, and avoiding last-minute surprises.
But even as digital transformation accelerates procurement, barriers persist. “Documentation remains a common bottleneck,” Matutyte explains. “Even when a part is available, delays in paperwork—like FAA tags or trace histories—can halt the transaction.”
Then there’s the challenge of OEM restrictions. “Some buyers are contractually bound to specific suppliers, even when alternative airworthy units are available,” he says. “This reduces flexibility in critical moments.”
Part compatibility is another stumbling block. “In a digitised environment, standardisation is key, yet variations in how parts are described or categorised across sellers can create confusion,” he adds.
Despite these hurdles, marketplace platforms are helping carriers—large and small—level the playing field. “Platforms like Locatory.com help close the gap by offering not only visibility into thousands of supplier warehouses worldwide but also tools to filter by part condition, certification, and location,” Matutyte notes.
