Why the Future of Engine MRO needs to be planned today
The global aviation industry is entering a period of sustained growth. As airlines expand their fleets and OEM order backlogs continue to increase, engine maintenance is becoming one of the key capacity constraints across the aviation value chain. According to current market forecasts, the global MRO market is expected to grow to approximately USD 156 billion by 2035, with demand for engine MRO services increasingly exceeding available capacity.
At the same time, the engine portfolio is becoming more complex. Maintenance demand for LEAP and GTF engines is increasing, while legacy platforms such as CFM56, V2500, CF6 and PW4000 remain in operation significantly longer than originally anticipated. This parallel demand places additional pressure on existing MRO networks, resources and infrastructure.
Despite the strong market outlook, the industry is already facing structural capacity constraints. Turnaround times for many engine programs remain well above pre-crisis levels, while demand for spare parts and shop visits continues to grow faster than available capacity.
The key question is therefore no longer whether additional capacity is required, but how future Engine MRO sites need to be designed to remain competitive in the long term. This requires scalable and high-performance operating concepts that integrate processes, infrastructure, logistics and technology into one coherent system.
From a factory planning perspective, future MRO capacity must therefore be planned holistically, combining operational requirements with flexible layouts, efficient material flows, scalable infrastructure and a clear roadmap for future growth.
Our Added Value in Engine MRO Projects
Drawing on extensive experience from international aviation, engine MRO, and industrial projects, Metroplan supports clients throughout the entire development journey of new and expanding MRO operations. Our services range from market assessments, business case development, and financing support to the design of robust operating models, factory and facility layouts, and efficient material flow and intralogistics concepts.
We complement these capabilities with the development of equipment and tooling strategies, digitalization and digital twin concepts, as well as detailed preparation for implementation, ramp-up, and successful operational start-up.
By combining strategic consulting, factory planning, logistics expertise, digital transformation, and MRO-specific technology know-how, Metroplan creates reliable decision-making foundations and future-ready facility concepts. The result is high-performance, scalable, and economically sustainable Engine MRO operations, whether delivered as Greenfield developments or Brownfield expansions, from the initial vision through to successful entry into service.
NextGen Engine MRO
Five Success Factors for New Engine MRO Facilities
Building new engine MRO capacity requires far more than just planning workshops and infrastructure. A holistic approach that seamlessly integrates market requirements, the operating model, processes, technology, logistics, and implementation is crucial. This is precisely where Metroplan supports international aviation companies throughout the entire planning process for modern MRO projects—from the initial strategic assessment to successful commissioning.
Based on our experience with numerous aviation and engine MRO projects in Europe and the Middle East, five success factors have emerged that are critical to the performance and long-term competitiveness of modern MRO facilities. These factors form the foundation for scalable, efficient, and future-proof engine MRO facilities and should be taken into account early in the project phases.
Our article on MRO Capacity Building.
Step 1
Early Understanding of the Operating Model
Leading engine MRO facilities combine service, leasing, asset management, testing and manufacturing within an integrated operating model. Scalable, adaptable space concepts lay the foundation early on for unlocking new potential in the future.
Step 2
BIM-Based Factory Planning
We combine engine MRO expertise, factory planning and BIM to create digital factory models. Production processes, material flows, equipment, technical building services, utility requirements and expansion scenarios are integrated into a central model.
Step 3
Intralogistics and Supply Chain
Short turnaround times do not begin on the shop floor. Considering spare parts availability, material flows, storage capacities and future growth from the outset lays the foundation for a scalable, competitive MRO organization.
Step 4
Digitalization and Smart MRO Ecosystem
Future factory planning is not about designing workshops, but about creating connected, data-driven MRO ecosystems where supply chain, operations, digitalization and infrastructure work seamlessly together. This requires the right planning partners.
Step 5
Expertise in Plant, Tooling and Equipment
Industry-specific equipment expertise accelerates planning. Translating the requirements of complex MRO technologies into robust building, utility and technical building services concepts at an early stage lays the foundation for faster, future-ready projects.
Metroplan as Your Planning Partner for Your Engine MRO Facility
The challenges of the coming years are clear: The engine MRO market is growing faster than available capacity, spare parts shortages are lengthening turnaround times, and new generations of engines are placing greater demands on processes, infrastructure, and technology. The crucial question, therefore, is no longer whether additional capacity is needed, but how future MRO sites must be planned to remain competitive, scalable, and economically successful in the long term.
Our international project experience shows that the competitiveness of modern engine MRO sites is not determined by individual technologies, but by the intelligent interplay of the operating model, facility planning, intralogistics, digitalization, and technology selection. Metroplan combines these disciplines into an integrated planning approach and, drawing on deep expertise in engine MRO, plant, and factory planning, creates robust site concepts—from strategic alignment through space and infrastructure planning to successful implementation.
Metroplan’s key added value lies in its ability to combine market requirements, MRO processes, technologies, and infrastructure into a holistic facility concept. This results not only in new workshops but also in high-performance, scalable, and digitally integrated engine MRO ecosystems that meet the growing demands of the global aviation industry over the long term.
About the Authors
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Simon Vehof
Manager Business Development
Klaas A. Klonz
Director Fabrikplanung
Klaas A. Klonz // Senior Manager, Metroplan