Air India Sees Technical Incidents Spike Fourfold in January

Air India's rate of technical incidents surged to 1.09 per 1,000 flights in January, its highest level in at least 14 months and a sharp increase that highlights mounting operational pressures. According to a company document submitted to the Indian government, this rate represents a more than fourfold jump from 0.26 per 1,000 flights recorded in December 2024, raising concerns about the carrier's aircraft maintenance and repair programs.

The spike in Air India technical incidents comes as the carrier, now owned by Tata Group and Singapore Airlines, undertakes an ambitious international expansion and fleet modernization. The increase in maintenance issues suggests significant challenges in balancing rapid growth with operational stability. The airline is already under close watch by India's aviation regulator following a fatal crash last year.

Incident Data and Company Response

In January, Air India operated more than 17,500 flights and logged 23 technical incidents across its network, with at least 21 of those cases triggering formal investigations. The incidents involved both Airbus and Boeing aircraft and included engine-stall warnings, flight-control issues, hydraulic problems, and at least five cases of fuel or engine oil leaks. In one instance, a flight from Dubai to Mumbai landed with a low engine oil quantity.

Operational incidents, such as rejected takeoffs and departures with incorrect settings, also more than doubled, reaching 0.29 per 1,000 flights in January. The document noted, however, that there had been a decrease in such incidents in the months prior.

In response to the findings, Air India stated it has initiated a "comprehensive program to strengthen technical reliability." The airline reported it has increased its inventory of critical spares by more than 30 percent to enhance aircraft availability and has made significant capital investments in its engineering infrastructure. The document submitted to the government noted that "systemic improvements (are) being introduced across flight ops, training, engineering quality, and procedural oversight to prevent recurrence."

Regulatory Scrutiny and Fleet Condition

The rising incident rate has intensified regulatory oversight. India's Directorate General of Civil Aviation (DGCA) has been scrutinizing the airline's safety record and processes. A recent analysis presented to Indian lawmakers revealed that 82.5 percent of 166 Air India aircraft examined since January 2025 had recurring technical defects. This figure stands in stark contrast to the 36.5 percent reported for IndiGo, India's market leader.

International regulators are also taking notice. The United Kingdom Civil Aviation Authority (UK CAA) recently sought clarification from Air India regarding a Boeing 787 Dreamliner that departed London with a potentially faulty fuel switch. The aircraft was subsequently grounded in India for safety checks. A source familiar with the matter indicated that Air India responded by reminding pilots of proper procedures and replacing the aircraft's throttle control module as a precaution.

Corrective Actions and Future Outlook

To address the recurring issues, Air India has implemented several targeted engineering actions. The airline has launched a periodic inspection program for its Airbus A320 fleet to address leakage events. For its long-haul fleet, it has replaced steering-system hydraulic hoses on all its Boeing 777s. Additionally, a new periodic air-conditioning leak-check program is underway.

These maintenance initiatives are critical as Air India prepares to integrate a massive influx of new aircraft. The carrier currently operates 191 planes but has placed orders for more than 500 additional aircraft from Airbus and Boeing. The success of its turnaround strategy depends heavily on its ability to manage its existing fleet's reliability while navigating supply chain delays affecting new deliveries and upgrades.

Why This Matters

This spike in technical incidents presents a critical test for Air India's transformation under Tata Group's ownership. The airline's ability to rectify these maintenance and operational challenges will directly impact its brand reputation, passenger safety, and long-term viability. For the broader industry, Air India's situation serves as a case study on the complexities of revitalizing a legacy carrier while pursuing aggressive growth in a highly regulated environment.

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