The aviation industry is in dire need of maintenance technicians. Without intervention, the technician deficit could reach 60,000 in 2029. However, if technicians across various functions achieve top-quartile productivity levels, this gap could shrink to 11,000 workers, note McKinsey’s Christian Langer, Daniel Leblanc, Vik Krishnan, and coauthors. Maintenance, repair, and overall organizations could achieve this productivity boost by reinforcing operational fundamentals, implementing AI and digital solutions, and upskilling workforces.
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A tree map compares two scenarios for the projected 2029 shortage of aviation maintenance technicians, measured as number of employees. In a no-action scenario, the shortage could reach 60,000 technicians. In an improved-productivity scenario, where technicians across functions reach top-quartile productivity levels, the shortage could be reduced to 11,000. The reduction is attributed to productivity gains across maintenance areas, including engine maintenance (18,000), line maintenance (13,000), base maintenance (10,000), component maintenance (5,000), and modifications maintenance (4,000). Overall, the exhibit shows that productivity improvements could mitigate more than 80 percent of the projected shortfall.
Source: 2025 CAE Aviation Talent Forecast; McKinsey Civil Aviation Center of Excellence.
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To read the article, see “Addressing the shortage of aviation maintenance technicians,” March 24, 2026.