The aircraft maintenance industry is currently facing an alarming shortage of skilled engineers. This crisis has been brewing for years, and it’s now more evident than ever.
In the past, becoming an aircraft mechanic was a structured, methodical process, involving apprenticeships, formal education, and hands-on training.
Today, the industry is facing such high demand that it seems eager to hire anyone with basic skills, even if they’re still learning. The focus now seems to be more on filling vacancies quickly, sometimes at the expense of thorough training and safety standards.
The result? A significant risk to aircraft safety and operational integrity.
What’s Changed in Aircraft Maintenance?
Historically, there were three primary routes to becoming an aircraft mechanic:
- Apprenticeships: The most common pathway, where individuals would attend a recognised training school, complete a multi-year apprenticeship, and then earn their "apprenticeship deeds."
- Military Training: Another route involved military service, where personnel received technical training on aircraft and could then transitioned into the civilian sector if/when they left the military.
- Degree Programmes: Finally, some individuals pursued a degree in aerospace engineering or aviation maintenance, which would lead to attaining a licence and employment.
A Glimpse into the Present
In today’s climate, it’s increasingly common for companies to hire workers with minimal experience, often with just a basic understanding of mechanics. While these "zero to hero" programs aim to address workforce shortages quickly, they can also lead to a decline in standards.
As a result, less experienced or undertrained individuals may be tasked with important maintenance duties, sometimes with limited supervision.
The concern moving forward is how this will affect the industry long term, as the risk of safety issues may grow due to gaps in training and experience.
Root Causes of the Skilled Engineer Shortage
1. The Brexit Effect
Ah, Brexit. The gift that keeps on giving.
Brexit has had a profound impact on the UK’s ability to recruit skilled aircraft maintenance workers from Europe. The restrictions on working permits, coupled with complications around certifications (such as the the growing wedge between EASA and the CAA), have severely limited the availability of European workers in the UK aviation sector. Many companies that previously relied on this pool of talent are now facing a stark shortage, struggling to find local replacements.
2. Apprenticeship schemes going under
Flybe, Monarch Airlines, and Thomas Cook were all major players in the aviation and travel sectors, and their collapses, which occurred in close succession, signalled a dramatic shift in the landscape of the industry. These companies were renowned not only for their services but also for their strong commitment to nurturing talent through well-established apprenticeship programmes. Each of these airlines trained a significant number of apprentices annually, particularly in technical and engineering roles.
For instance, Flybe, Monarch, and Thomas Cook each graduated approximately 40 engineering apprentices per year between them, who would then go on to become skilled aircraft mechanics in the aviation industry. These apprenticeship programmes were designed to provide a comprehensive blend of theoretical knowledge and hands-on experience, ensuring that the next generation of engineers was not only proficient in the latest technologies but also well-versed in the operational demands of a busy airline. The companies' apprenticeship initiatives played a vital role in ensuring a steady supply of qualified personnel capable of filling the critical roles required to maintain safe and efficient aircraft operations.
While other companies in the aviation sector have begun to introduce apprenticeship programmes in recent years, replicating the scale, quality, and consistency of those run by Flybe, Monarch, and Thomas Cook is no simple feat. Establishing a strong, effective apprenticeship scheme demands time, effort, and significant investment.
It often takes decades for such programmes to become deeply embedded within a company and develop a reputation for producing highly skilled engineers who meet the industry’s high standards. Newer apprenticeship schemes, while growing, remain in the early stages of development, and face challenges such as limited resources, fewer opportunities, and the difficulty of matching the standards set by long-established programmes.
The closure of these airlines and their associated apprenticeship schemes has had a ripple effect on the aviation industry, particularly in the UK, where there continues to be a significant demand for skilled engineers. Rebuilding a robust talent pipeline will take years and require sustained investment from both airlines and training institutions to ensure that the next generation of aviation professionals is well-trained and ready to meet industry demands.
Another key contributor to the training of aircraft engineering apprenticeships is QinetiQ, an MOD company based in Amesbury. QinetiQ used to produce around 15 aircraft engineers annually through its long-standing training school, which has now been discontinued following the company’s shift in focus. This further underscores the growing challenge the industry faces in replacing the vital apprenticeship programmes that have been lost in recent years.
3. The Ageing Workforce
Over the years, the aircraft maintenance workforce has steadily aged. Many experienced engineers are retiring, but recruitment efforts to backfill these positions have not kept pace. Traditionally, the apprenticeship system would allow younger technicians to be mentored by seasoned professionals, gaining vital on-the-job experience. However, with the recent disruptions caused by Brexit and COVID-19, the pool of experienced mentors is shrinking, leaving newly qualified engineers without sufficient guidance.
4. Rush to becoming licenced
Another growing problem is the rush to acquire an aircraft maintenance licence. The Civil Aviation Authority (CAA) requires five years of experience to apply for your licence. However, this time frame alone doesn’t guarantee that the candidate has received adequate foundational training. Many technicians are fast-tracked through zero-to-hero courses, which often lack the depth required for them to truly grasp the complexities of aircraft maintenance. This poses serious risks, as an individual with limited hands-on experience is more likely to overlook critical safety issues.
5. Higher Demand Since COVID-19
The COVID-19 pandemic significantly disrupted the aviation industry, forcing many airlines to furlough or lay off employees, including skilled maintenance personnel. While business aviation remained somewhat unaffected, the broader aviation industry came to a halt. As the industry begins to recover, many workers have either retrained or left the sector entirely, further compounding the shortage of skilled engineers. The current shortage in the workforce is now coupled with a lack of new entrants, as potential apprentices are hesitant to join an industry still struggling to regain stability.
The Impact of the Skills Deficit
The most concerning impact of this skills shortage is the direct threat it poses to safety. In the past, an aircraft mechanic would typically follow a structured career path: starting with apprenticeship or degree training, then progressing through on-the-job shadowing, followed by probationary periods before receiving full authorisation to work independently.
However, this structured approach is breaking down. It won't be long before many unqualified individuals are being allowed to work unsupervised on live aircraft within days of starting their jobs, without the safety nets that once provided critical oversight. This will accelerates the risk of accidents and incidents in aviation.
The Civil Aviation Authority (CAA) regulations dictate that a licenced aircraft engineer should provide full supervision over mechanics as they work on an aircraft. However, in practice, achieving this level of oversight is incredibly difficult, particularly when managing a team of up to ten mechanics.
The trust between mechanics and licenced engineers becomes absolutely vital in this scenario, as the engineer is expected to rely on the mechanics to carry out tasks properly.
Yet, with insufficient training, many mechanics may not even recognise when they’ve made a mistake, and without the experience to address it, those errors can go unnoticed or cause significant damage.
This lack of hands-on experience and the inability to spot mistakes without the guidance of a licenced engineer only heightens the risks.
The traditional apprenticeship system once ensured that mechanics gained the necessary expertise to work with confidence and accuracy, but without it, the trust needed between mechanics and engineers to ensure safety is being dangerously compromised.
The Lost Learning Opportunities
Apprenticeships used to serve as a vital learning environment where future engineers could make mistakes and learn from them. This experiential knowledge—gaining an understanding of the consequences of actions like overtightening bolts or damaging delicate systems —was invaluable. Without this kind of training, new mechanics may not fully grasp the long-term impact of their actions, leading to undetected damage to aircraft.
Technological Challenges and Their Impact on Skill Requirements
1. Advanced Systems Requiring Higher Skillsets
As aircraft become more technologically advanced, so too must the engineers who maintain them. Today’s aircraft rely heavily on complex avionics and autopilot systems, which reduce pilot input but introduce new challenges for maintenance. These systems, although lighter and more efficient, are also more delicate. An untrained technician might not know how to properly handle advanced components like fibre optic cables, which could lead to costly or even catastrophic damage if mishandled.
2. Emerging Materials and Methods
Another challenge is the increasing use of composite materials in aircraft construction. These materials, which offer greater strength and weight savings, require specialised knowledge and skills to repair. The old saying “hush hush double flush” doesn’t cut it anymore!
Improper handling can easily result in permanent damage, compromising the aircraft’s structural integrity. Training the next generation of engineers to work with these materials is crucial to ensuring the continued safety of the aviation industry.
Evolving Regulations and Certification Processes
Regulations in aviation are constantly evolving to meet new challenges. While this is essential for maintaining high safety standards, it also creates pressure on companies to comply with changing certification processes. The divergence of regulations between bodies like the European Aviation Safety Agency (EASA) and the Civil Aviation Authority (CAA) has made it difficult for companies to keep up. Without proper alignment, these changes can lead to confusion and gaps in training and certification.
Potential Solutions
To address the skills shortage, aviation companies may need to reconsider their approach to licencing and training. One potential solution is to extend the probation period for newly licenced engineers, ensuring that they work under the close supervision of an experienced mentor for at least a year. This would allow companies to assess their progress and ensure they are ready to take on more responsibility.
Another approach would involve revisiting the way apprenticeships and degrees are structured, ensuring that there is more on-the-job training and mentorship built into the curriculum.
The Future Outlook: A Call for Change
The aviation industry cannot afford to continue down its current path. The shortage of skilled engineers is not only a threat to the industry’s ability to function efficiently but, more importantly, to the safety of passengers and crew.
Without immediate action, this crisis will only worsen. Investing in training, revising licencing processes, and bringing back structured mentorship programmes will be essential in bridging the gap.
The aircraft maintenance industry is facing an unprecedented crisis in the form of a skills shortage that is jeopardising safety and efficiency. Immediate attention is needed to address the root causes, from Brexit and companies going under to evolving technology and regulation.
Only through thoughtful solutions can we ensure that the next generation of engineers is adequately trained and prepared to maintain the aircraft of tomorrow, safely and reliably. The stakes are too high for anything less.
