Air India Crash Uncovers Major Gaps in India's Aviation Safety and MRO Infrastructure

The tragic Air India crash on June 12 has exposed serious fault lines in India’s booming aviation industry. Once touted as a sector on the rise—with mega aircraft deals, growing regional air networks, and rising global aspirations—the sector now finds itself facing urgent questions about its safety net, infrastructure, and preparedness for the demands of modern aviation.

The crash of a Boeing 787 Dreamliner in Ahmedabad, long considered one of the most reliable aircraft in service, has raised pressing concerns over the country’s aviation maintenance capabilities and safety protocols.

Black Box Recovery: A Weak Link

The Black Box of the ill-fated Air India Flight 171, comprising the Digital Flight Data Recorder (DFDR) and Cockpit Voice Recorder (CVR), was recovered a day after the incident. However, the device was found to be extensively damaged. Experts at the recently launched ₹9-crore AAIB lab in Delhi are attempting to retrieve the data. If unsuccessful, the Black Box will be shipped to the United States for decoding—highlighting India’s continued reliance on foreign support for critical investigations.

MRO Infrastructure: The Cracks Beneath the Surface

India’s Maintenance, Repair, and Overhaul (MRO) capacity remains inadequate—especially for wide-body aircraft like the Dreamliner. While companies like AIESL, GMR Aero Technic, and Tata Advanced Systems serve the MRO space, most facilities primarily support narrow-body aircraft such as the Airbus A320 and Boeing 737.

The sector suffers from:

A lack of MRO facilities equipped for wide-body aircraft

Shortage of skilled engineers

High import duties on essential aircraft parts

Outdated infrastructure needing urgent upgrades to meet global standards

Although Air India, in collaboration with Singapore Airlines Engineering (SIAEC), is building a new MRO facility at Bengaluru International Airport, it is still under development. Until then, most Indian airlines continue to depend on foreign MRO hubs, leading to longer aircraft downtime and increased costs.

Make in India: Progress Amidst Turbulence

Despite the challenges, India is slowly making strides in the global aerospace ecosystem. Several Indian companies are playing an active role in the aircraft components and aerostructures market:

Tata Advanced Systems: Producing cargo doors for Airbus A320neo

Aequs, Dynamatic Technologies, Mahindra Aerospace: Supplying parts for Airbus and Boeing programs

Dynamatic + Deutsche Aircraft: Rear fuselage for D328eco turboprop

Boeing Bengaluru Facility: High-end composite parts for global supply chains

The aircraft components market in India reached $16.22 billion in 2024 and is projected to nearly double by 2033. Over $2 billion worth of aviation components are exported annually, showcasing the strength of Indian MSMEs and aerospace startups.

Conclusion: From Wake-Up Call to Opportunity

The Air India Dreamliner crash has served as a stark wake-up call. If India is to continue its journey as a global aviation hub, it must fortify the foundational elements—invest in safety systems, scale up MRO capabilities, and train a skilled aviation workforce. Only then can the country truly soar, with both ambition and assurance.