Fiery UPS plane crash could spell the end for MD-11 fleet if the repairs prove too costly

A recent fiery crash involving a UPS MD-11 cargo plane shortly after takeoff from Muhammad Ali International Airport in Louisville, Kentucky, has prompted the US Federal Aviation Administration (FAA) to ground all remaining MD-11 and related DC-10 aircraft. This critical incident, which resulted in 14 fatalities, including the three-person crew, occurred when the aircraft's left engine detached, sparking a massive fire. The grounding signals a serious reevaluation of the aging trijet fleet, raising questions about its future in commercial cargo operations.

Investigators from the US National Transportation Safety Board (NTSB) quickly identified cracks in key parts responsible for securing the engine to the wing of the crashed UPS MD-11. This finding draws parallels to a catastrophic 1979 DC-10 crash in Chicago, which also involved an engine separation and led to a worldwide grounding of DC-10s. While the specific components differ, the NTSB is now scrutinizing whether a common design flaw or maintenance issue could be at play across the MD-11 and DC-10 fleets. The FAA is collaborating with the NTSB and Boeing, the current owner of the MD-11's original manufacturer, to determine necessary actions.

The potential cost of mandated repairs, coupled with the MD-11 fleet's average age exceeding 30 years, could accelerate the retirement plans of major cargo operators like UPS, FedEx, and Western Global. Industry experts suggest that investing heavily in repairs for these older aircraft may not be economically viable, especially with newer, more efficient models available from manufacturers such as Boeing and Airbus, despite current production backlogs. The MD-11 and its predecessor, the DC-10, have historically shown higher accident rates compared to other commercial planes, further fueling the debate over their continued operational lifespan.

The NTSB is also closely examining the maintenance history of the crashed UPS MD-11, noting that a detailed engine inspection was last performed in 2021, with the aircraft not due for another until thousands more flights. This raises critical questions about the adequacy of current maintenance schedules for these legacy aircraft. While some aviation experts argue that age is less critical than rigorous maintenance, the FAA and Boeing must now determine if the existing protocols are sufficient to ensure the safety of the remaining MD-11 fleet, which constitutes a significant portion of the cargo operations for companies like UPS and FedEx.