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aircraft reliability

London, United Kingdom: The UK Civil Aviation Authority (CAA) has formally asked Air India to provide a detailed explanation of an incident involving a Boeing 787-8 Dreamliner that departed London Heathrow Airport on February 1 despite a reported anomaly with a critical aircraft system. The regulator has warned the airline that failure to respond fully within one week could trigger regulatory action affecting its Dreamliner operations. Air India flight AI132, operating a Boeing 787-8 Dreamliner registered VT-ANX, departed Heathrow for Bengaluru after pilots noted irregular behaviour with a fuel control switch, a vital cockpit control that regulates fuel flow to the engines. During engine start, one of the two fuel control switches did not remain positively latched in the “RUN” position on the first two attempts before stabilising on the third. The flight continued without in-air issues and landed in Bengaluru. Upon arrival, the crew filed a defect report citing the anomaly, and the aircraft was grounded for inspection on February 2. The UK Civil Aviation Authority has taken the step of demanding a formal response from Air India, including: A comprehensive account of pre-flight maintenance actions taken before departure, A root-cause analysis of the fuel control switch event, A preventive action plan to reduce the risk of recurrence across Air India’s Dreamliner fleet, which comprises 33 aircraft. In official correspondence, the CAA emphasised that regulators routinely seek detailed explanations following incidents affecting safety-critical components, particularly when an aircraft departs with a potential defect. Air India said it conducted precautionary re-inspections of fuel control switches across its Boeing 787 fleet after the incident and reported no issues found during these checks. The airline acknowledged the Directorate General of Civil Aviation (DGCA) oversight and said it will comply with the regulator’s guidance to circulate Boeing’s recommended operating procedures for the switches to all flight crews. India’s DGCA also issued a clarification, stating that post-flight inspections determined the fuel switches were serviceable and functioning normally. According to the regulator, the switch may move if light pressure is applied in an incorrect direction, but its design does not indicate a defect when used according to approved procedures. The DGCA advised Air India to reinforce correct switch handling among pilots. Fuel control switches are crucial for aircraft safety. They allow pilots to start and shut down engines and are designed with locking mechanisms to prevent unintended movement. This category of component has been under heightened scrutiny following the June 2025 crash of an Air India Boeing 787-8 in Ahmedabad, where preliminary investigation reports indicated fuel control switches played a role in dual-engine power loss shortly after takeoff. That accident, which resulted in significant loss of life, triggered industry-wide inspections and close regulatory observation of Boeing 787 systems. Though the final accident report remains pending, aviation authorities worldwide have been monitoring similar technical aspects, including fuel system controls, in current operations. Air India faces a deadline to submit its response to the UK CAA within one week of the February 4 notice. The airline has stressed safety as its utmost priority and reiterated cooperation with international regulators and Boeing in evaluating the matter.

UK CAA Seeks Formal Explanation On Air India 787 Fuel Switch Event; DGCA Finds No Fault

Aviation Today News Desk / February 7, 2026

London, United Kingdom: The UK Civil Aviation Authority (CAA) has formally asked Air India to provide a detailed explanation of […]

Delhi, India: Nearly 50% of Indian commercial aircraft audited by the Directorate General of Civil Aviation (DGCA) have been identified with recurring technical defects, according to figures presented by the Ministry of Civil Aviation in the Lok Sabha on Thursday. The disclosures, based on inspections conducted between January 2025 and 3 February 2026, underscore heightened regulatory scrutiny of airline maintenance practices across the country. The DGCA analysed 754 aircraft belonging to six scheduled carriers for repetitive snags during routine safety checks and surveillance audits of these, 377 aircraft roughly half were found to have recurring defects, defined as technical issues that appeared repeatedly on the same aircraft despite previous corrective actions. Detailed airline-wise figures presented in Parliament show: IndiGo: 405 aircraft analysed, 148 flagged for recurring defects Air India: 166 analysed, 137 flagged Air India Express: 101 analysed, 54 flagged SpiceJet: 43 analysed, 16 flagged Akasa Air: 32 analysed, 14 flagged Government sources pointed out that many of the recurring issues relate to maintenance and equipment malfunctions. In the case of Air India, a spokesperson noted that most defects were in lower-priority “Category D” items such as seating equipment, tray tables and in-flight entertainment screens, which are not directly linked to aircraft safety. Repetitive defects can range in severity, but their recurrence suggests that root-cause analysis and corrective action may not always be sufficient or timely. To reinforce compliance and safety standards, the DGCA said it conducted an extensive set of oversight activities over the last year, including: 3,890 surveillance inspections 56 regulatory audits 84 checks of foreign aircraft (SOFA) 492 ramp inspections 874 spot checks and 550 night surveillance exercises The regulator is mandated to monitor and enforce compliance with civil aviation requirements, and flagged deficiencies are expected to be followed up with corrective action and enforcement where necessary. The audit findings come at a time when India’s aviation safety ecosystem faces sustained scrutiny following a series of reported technical events and operational challenges. In early February, an Air India Boeing 787 Dreamliner was temporarily grounded after a potential fuel control switch defect was reported by pilots following a London–Bengaluru flight. The UK Civil Aviation Authority has sought detailed explanations from the carrier. Additionally, passenger flight disruptions and operational bottlenecks at several airlines in recent months have fueled public and political examination of maintenance practices and regulatory readiness. Airline officials, particularly from the Air India Group, have stressed that rigorous checks and proactive inspections account for higher flagged numbers, and that many findings relate to cabin-level equipment rather than flight-critical systems. IndiGo has not publicly responded to The recurring defects should not necessarily be conflated with immediate safety risks, but they highlight the importance of systematic maintenance quality, effective root-cause resolution, and consistent compliance with global safety standards.

DGCA Says 377 Of 754 Indian Commercial Aircrafts Show Recurring Technical Defects

Aviation Today News Desk / February 6, 2026

Delhi, India: Nearly 50% of Indian commercial aircraft audited by the Directorate General of Civil Aviation (DGCA) have been identified

Delhi, India: Air India has grounded one of its Boeing 787-8 Dreamliner aircraft after a pilot reported a possible defect in the fuel control switch mechanism, prompting a detailed inspection and coordination with the airframe manufacturer, Boeing. The aircraft, operating as AI132 from London Heathrow to Bengaluru, landed safely at its destination on February 2, after the flight crew observed abnormal behaviour in the left engine’s fuel control switch during pre-flight engine checks, according to airline officials. In a statement, Air India confirmed that a pilot flagged the issue and the aircraft was immediately taken out of service as a precautionary safety measure while the concern is investigated. The airline has informed the Directorate General of Civil Aviation (DGCA) and engaged Boeing to prioritise a technical evaluation. “After receiving this initial information, we have grounded the aircraft and are involving the OEM (original equipment manufacturer) to get the pilot’s concerns checked on a priority basis,” an Air India spokesperson said. The matter has also been formally communicated to India’s aviation regulator, the DGCA. Fuel control switches regulate the flow of fuel to an aircraft’s engines and are designed with safeguards to prevent unintended movement. On the Boeing 787, these switches must be lifted and then moved to change position, reducing the likelihood of accidental operation. However, if such a switch were to shift from thle “RUN” to the “CUTOFF” position in flight, it would immediately halt fuel flow, leading to engine shutdown. The focus on fuel control switch behaviour stems from the June 12, 2025 crash of Air India Flight AI-171, another Boeing 787-8, near Ahmedabad, which killed 260 people. A preliminary investigation by the Aircraft Accident Investigation Bureau (AAIB) found that both engine fuel control switches moved from RUN to CUTOFF in quick succession just after takeoff, resulting in dual engine power loss. That incident triggered extensive regulatory scrutiny. In July 2025, Air India announced it had completed precautionary inspections of the fuel control switch locking mechanism on all Boeing 787-8 aircraft and found no defects at the time. Following the recent pilot report, Air India has begun focused inspections of fuel control switches across its Boeing Dreamliner fleet. According to an internal company communication seen by Reuters, these checks have so far not identified a systemic issue with other aircraft. Air India has reiterated that passenger and crew safety remains its top priority. Boeing has said it is assisting with the review.

Air India Grounds Boeing 787‑8 LDN–BLR Flight After Pilot Reports Fuel Switch Defect

Aviation Today News Desk / February 3, 2026

Delhi, India: Air India has grounded one of its Boeing 787-8 Dreamliner aircraft after a pilot reported a possible defect

New Delhi, India: India’s aircraft Maintenance, Repair and Overhaul (MRO) industry is projected to grow into a $4 billion market by 2031, supported by regulatory reforms, rising aircraft inductions and increasing participation from global aviation companies, Civil Aviation Minister K. Rammohan Naidu said. The minister made the remarks while addressing an aviation industry gathering, where he outlined the government’s strategy to transform India into a competitive global MRO destination and curb the country’s heavy reliance on overseas maintenance facilities. At present, nearly nine out of ten Indian-registered aircraft are maintained abroad, primarily due to cost disadvantages and regulatory complexities. This has resulted in substantial foreign exchange outflows, estimated by industry bodies at over $1.5 billion annually. Officials believe that strengthening domestic MRO capacity can reverse this trend while improving operational efficiency for Indian airlines. Naidu said the government has undertaken a series of policy measures to improve the sector’s viability, most notably the reduction of Goods and Services Tax (GST) on MRO services from 18 per cent to 5 per cent, placing India on a more level footing with established MRO hubs in Southeast Asia and the Middle East. “These reforms are intended to create a stable, predictable and investor-friendly environment,” the minister said, adding that lower taxation and streamlined compliance procedures have already begun to attract international players. The inauguration of new facilities, including Safran Aircraft Engine Services India, has been cited by the ministry as a key milestone in building a strong MRO ecosystem. The Safran facility is expected to support next-generation aircraft engines and contribute to skill development, technology transfer and local employment. India’s commercial aviation sector continues to expand rapidly. The country is currently the third-largest domestic aviation market globally, and its fleet size is expected to grow sharply over the next decade. Industry projections suggest that Indian airlines could be operating more than 1,500 aircraft by the early 2030s, significantly increasing demand for routine maintenance, heavy checks and engine overhauls. Government officials say a robust MRO sector will help airlines reduce aircraft downtime, lower operating costs and improve fleet availability. The sector is also expected to generate high-skilled jobs in engineering, tooling, quality assurance and aviation safety, while supporting allied industries such as component manufacturing and logistics. Naidu reiterated that developing domestic MRO capabilities aligns with the government’s broader “Make in India” and Atmanirbhar Bharat initiatives. By retaining maintenance work within the country, India aims to strengthen its position across the global aviation value chain and reduce long-term dependence on foreign service providers. The ministry has indicated that further policy fine-tuning and infrastructure development, particularly at major airports and upcoming aviation hubs, will continue as part of efforts to sustain long-term growth in the sector.

India Eyes $4 Billion MRO Market By 2031 To Cut Overseas Aircraft Maintenance

Aviation Today News Desk / December 17, 2025

New Delhi, India: India’s aircraft Maintenance, Repair and Overhaul (MRO) industry is projected to grow into a $4 billion market

Beijing, China: Air China and Rolls-Royce have completed their USD 315 million engine maintenance, repair and overhaul (MRO) facility in Beijing, marking a major expansion of Rolls-Royce’s service network in mainland China. The joint venture, Beijing Aero Engine Services Ltd (BAESL), will induct its first engine in December 2025, with full commercial operations scheduled for early 2026. The Beijing site will overhaul Trent 700, Trent XWB-84, and Trent 1000 engines, which power A330, A350 and Boeing 787 fleets operated by Chinese carriers. Rolls-Royce said BAESL is designed as a “digitally enabled, next-generation” shop with advanced tooling and automation. According to official Beijing investment authorities, the facility spans more than 80,000 sq. m and will employ up to 800 staff once fully ramped up. It is expected to reach an annual capacity of 250 engine shop visits by the mid-2030s. This is Rolls-Royce’s first MRO joint venture on mainland China and its fourth globally, complementing HAESL in Hong Kong, SAESL in Singapore, and N3 in Germany. For Air China, the project strengthens domestic overhaul capability for high-thrust wide-body engines, reducing dependency on overseas shops. Air China executives said the facility will support the “industrialisation and localisation” of China’s engine maintenance ecosystem. Rolls-Royce leaders noted that China’s expanding wide-body fleet with nearly 600 Trent engines in service requires long-term, locally available maintenance capacity. BAESL is situated in Shunyi District, inside the Beijing Capital International Airport Economic Zone. Infrastructure includes overhaul bays, advanced engine testing facilities, parts warehousing and digital monitoring centres. With the JV now structurally complete, Rolls-Royce and Air China will begin progressive operational readiness checks before the first Trent engine arrives later this year. The facility is expected to significantly cut turnaround times for Chinese operators and reinforce China’s position as a major MRO hub in the Asia-Pacific region.

Air China And Rolls-Royce Complete $315 Million Engine MRO Facility In Beijing

Aviation Today News Desk / November 25, 2025

Beijing, China: Air China and Rolls-Royce have completed their USD 315 million engine maintenance, repair and overhaul (MRO) facility in

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