2025

Aviation Maintenance Benchmark Report

Critical insights for aviation leaders who refuse to fall behind.

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Introduction: What this report is—and why it matters

The aviation industry is at a turning point. Technician shortages, aging fleets, regulatory complexity, and operational inefficiencies are forcing operators to reassess their maintenance strategies. On the surface, things may appear to run smoothly. But beneath the routine, subtle friction points—hard to spot but costly—are slowing even the best-run operations.

This report delivers insights from over 800 aviation professionals across business and commercial aviation. The findings cut through the noise, challenging assumptions and offering actionable perspectives.

Key insights at a glance:

• Operational Efficiency: 72% say it defines their maintenance strategies.
• Predictive Maintenance: 65% are exploring it, yet many struggle with practical integration.
• Workforce Shortages: 62% cite technician shortages as a critical issue.
• Regulatory Compliance: 78% face complex management challenges.
• Software and AI Adoption: 70% of industry leaders see AI as crucial for boosting operational efficiency, yet only 30% are leveraging it—and just 17% have fully integrated it into their operations.

Why This Matters: This isn’t another report padded with buzzwords. Each section leads with key data points, unpacks what they really mean, and challenges assumptions. The result? Bold, actionable insights—no filler.

About the data

Over 800 aviation professionals across business and commercial aviation participated in this survey, sharing anonymous insights into their challenges, operational strategies, and technology adoption trends. Their responses were used to create a comprehensive benchmark report, highlighting best practices and emerging industry trends.

Respondent roles

Survey participants represent a diverse range of aviation roles, including:

• Maintenance technicians, Directors of Maintenance (DOMs), and A&P instructors
• Fleet operators in aerial firefighting, business aviation, and commercial airline sectors
• Training and flight school professionals

Types of operations

Responses came from professionals working in various aviation segments, including:

• Business aviation operators and fleet managers
• Aerial firefighting and special mission operations
• Flight schools and maintenance training institution

Industry-wide trends

Operational efficiency: A necessity, not a buzzword

Predictive maintenance: Beyond the hype

The Reality Check: Predictive maintenance is widely discussed—and while much of the conversation is mired in futuristic hype, the real progress is happening on the ground. Operators who are truly moving the needle are focusing on mastering the basics that drive tangible results.

Regulatory compliance: You can't afford mistakes

Workforce challenges: The shortage you can't ignore

Top software challenges: Real talk from the front lines

In aviation maintenance, software should streamline operations—not create obstacles. When a system is difficult to use, lacks key features, or fails to integrate smoothly, it directly impacts efficiency and performance.

High costs: The biggest frustration

Integration issues: A growing concern

Limited functionality or missing features

Complex or non-intuitive user interface

Lack of mobile access: A serious limitation

What Needs to Change

The results emphasize the need for:

• Cost-effective solutions tailored to different fleet sizes.
• Enhanced system integrations with third-party aviation tools.
• Mobile accessibility for real-time operational flexibility.
• Intuitive design that reduces complexity for maintenance teams.
• Ongoing feature enhancements to meet evolving industry demands.

Business aviation insights

Cost control: The balancing act

Key Challenge: Balancing cost control with high reliability.

Real-time data access: The difference between efficiency and downtime

Key Challenge: Lack of real-time, accurate data for decision-making.

Biggest threats to the business aviation maintenance industry

Key Challenge: Technician shortages, with 44% identifying it as their top concern.

Digital maintenance tools: Why small-scale fleets are falling behind

Key Challenge: 33% of small-scale fleet operators still rely on spreadsheets or homegrown systems.

Commercial aviation insights

Minimizing downtime: The pressure of the clock

Key Challenge: Reducing aircraft downtime while keeping schedules on track.

Fleet complexity: Managing scale without losing control

Key Challenge: Coordinating maintenance across large fleets and multiple locations.

Biggest threats to the commercial aviation maintenance industry

Key Challenge: A shrinking workforce and increasing operational complexity are pushing technician shortages to critical levels.

AI in aviation: Big potential, bigger hurdles

The future of aviation maintenance:** Smarter, more efficient operations

Aviation maintenance isn't getting any easier. The industry is under more pressure than ever to improve efficiency, ensure compliance, and maximize reliability. The operators that embrace digital transformation will reduce downtime, streamline workflows, and gain a competitive edge.

How Veryon helps operators stay ahead

• Real-Time Maintenance Tracking & Fleet Visibility: Veryon Tracking delivers integrated and optimized aviation maintenance, inventory management, operations, and work order software for real-time visibility into your data across departments.
• Automated Compliance & Seamless Documentation: Veryon Publications centralizes technical and regulatory documentation for quick, compliant action—no more searching through multiple systems.
• Predictive Maintenance & AI-Powered Insights: Veryon Diagnostics is the industry's only closed-loop chronic defect identification and maintenance troubleshooting solution. Powered by AI-driven insights, it enables operators to minimize delays, reduce costs, and improve fleet reliability.