Widespread Recurring Defects Found in Indian Commercial Aircraft Fleets
A comprehensive analysis conducted by India's civil aviation ministry has uncovered alarming rates of recurring defects across the country's commercial aircraft fleets. The study, covering the period from January 2025 to February 2026, reveals that half of all analyzed planes experienced repetitive maintenance issues that persisted despite previous repair attempts.
Staggering Statistics Across Major Carriers
According to Minister of State for Aviation Murlidhar Mohol's written response in the Lok Sabha, 377 out of 754 commercial aircraft examined showed recurring defects. The data presents particularly concerning figures for India's two largest airline groups.
Air India Group Performance: The Tata-backed Air India group demonstrated the highest incidence rate, with 71% of its analyzed aircraft (191 out of 267 planes) experiencing recurring defects. Within this group, the full-service carrier Air India recorded defects in 82% of its planes (137 out of 166), while its low-cost subsidiary Air India Express reported defects in approximately 53% of its fleet (54 out of 101 aircraft).
IndiGo's Situation: India's largest carrier, IndiGo, showed recurring defects in 37% of its analyzed fleet (148 out of 405 aircraft), meaning approximately one in three of its planes experienced repetitive issues. The airline did not respond to media inquiries regarding these findings.
Understanding Recurring Defects and Safety Implications
Recurring defects are defined as the same malfunction or maintenance issue occurring three or more times within a specific number of flight segments on the same aircraft. These repetitive problems indicate that underlying root causes—such as component failures or systemic issues—have not been properly identified or eliminated through standard maintenance procedures.
An Air India spokesperson explained their higher numbers resulted from "an abundance of caution" in conducting comprehensive fleet checks. A senior Air India executive clarified that most issues involved non-safety items like:
- Torn seat covers
- Loose tray tables
- Malfunctioning seatback screens
- Other cabin amenities
The executive noted these issues would be resolved as the airline's narrow-body aircraft retrofit program progresses over the next two years.
Smaller Carriers Also Affected
The ministry's data revealed similar patterns among other domestic carriers:
- SpiceJet: 37% defect rate (16 out of 43 analyzed aircraft)
- Akasa Air: 44% defect rate (14 out of 32 analyzed aircraft)
These findings come as India's aviation sector continues its post-pandemic recovery, with the Air India group operating 297 aircraft and IndiGo maintaining a fleet of 440 planes during the study period.
Industry Practices and Regulatory Loopholes
Aviation expert Captain Mohan Ranganathan, a former member of the Civil Aviation Safety Advisory Council, explained how airlines manage defective components through the Minimum Equipment List (MEL) system:
- Category A: Critical components requiring same-day repair or replacement
- Category B: Components needing repair within 72 hours
- Category C: Non-critical items allowing up to 10 days for replacement
Ranganathan revealed that some airlines exploit a regulatory loophole by swapping Category C defective parts between aircraft, effectively extending the replacement timeline. "If a proper digital trail is maintained, the aviation regulator could identify such practices," he noted, emphasizing that Category C items typically don't impact flight safety.
An anonymous aviation expert confirmed that recurring defects don't necessarily correlate with airline safety, as many involve non-critical cabin components rather than essential flight systems. However, the high incidence rates across multiple carriers suggest systemic maintenance challenges within India's rapidly growing aviation industry.
