Air India’s Widebody Fleet Retrofit Faces Major Delays

1 month ago Editor

Air India’s widebody fleet retrofit project, initially set to overhaul its Boeing 787 and 777 aircraft by 2025, has been delayed due to supply chain issues and vendor changes. The retrofits are now expected to extend well into 2026.

Air India’s ambitious plans to upgrade its fleet of widebody aircraft, which include 27 Boeing B787-8 and 13 B777 aircraft, have encountered substantial delays. The airline initially allocated over USD 400 million for the project, which was set to completely overhaul cabin interiors, adding new seats and advanced inflight entertainment systems across all classes.

Scheduled to begin in the second half of 2024, the retrofit program was intended to start with a Boeing 787-8 and be fully completed by the end of 2025. However, delays are already mounting, with only the A320neo undergoing retrofitting as of now.

Campbell Wilson, CEO of Air India, recently discussed the reasons for the setbacks, citing supply chain disruptions and difficulties with seat manufacturers. Despite initial plans to use Recaro’s CL3710 and R3 seats for economy class and the PL3530 for premium economy, regulatory certification and manufacturing delays have forced the airline to consider changing suppliers.

The new retrofit schedule has pushed the launch of the 787 refurbishment to April 2025, with expectations for the first retrofitted aircraft to rejoin the fleet by October 2025. Air India plans to retrofit 3-4 aircraft per month, but this rate may still result in the project extending beyond the planned 2025 completion date.

For the Boeing 777 fleet, the retrofit will be even further delayed, with a “refresh” slated for 2025 and a full retrofit beginning in 2026. This delay also reflects the airline’s shift in seat vendors.

Additionally, Air India Express’s induction of 737 MAX aircraft has been postponed, with 35 of the 50 white-tail 737 MAX jets expected by December 2024 already inducted. The remaining aircraft will now be delivered by June 2025, due to complications at Boeing.

Air India customers will face delays as the airline works through its widebody retrofitting process, with completion now unlikely before 2026.