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Air India technical incidents, such as fuel spillages, hit a 14-month record

A company document shows that technical incidents, such as fuel and engine oil leaks, on Air?India flights, reached their highest rate for at least 14 month in January. This highlights the growing pressures placed on the carrier to revamp its operations. Since a fatal crash in which 260 people were killed, India's second-largest carrier has been under the scrutiny of India's safety regulator. Since then, it has reported many safety lapses, and admitted in December that there is a need for "urgent improvements in process discipline and communication as well as compliance culture".

Air India reported 1,09 incidents technical per 1,000 flights in January. This is quadrupling the 0.26 incidents that were recorded in December 2024. It did not give earlier data.

According to a document that isn't public, Air India flew more than 17500 flights in January, and 23 incidents were recorded on both its domestic and international flights. Air India investigated at least 21 of these incidents formally.

Air India's document stated that "systemic improvements are being introduced across flight operations, training, engineering, and procedural supervision to prevent a recurrence."

In a press release to, the airline stated that it had undertaken a “comprehensive program” to enhance technical reliability across its operations. It also said that its inventory of critical spares has been increased by more than 30% in order to increase aircraft availability and minimize operational disruptions.

Air India has made significant investments in the engineering infrastructure, tooling and equipment to support its technical operations.

The Indian civil aviation ministry has not responded to any of our queries.

The document only provided selective comparisons with global airline industry standards based on non-publicly available data and did not include information about the airline's low-cost subsidiary Air India Express.

CHALLENGES GALORE

Air 'India, owned by Tata Group & Singapore Airlines, is struggling to rebuild their reputation, international network and replace an ageing fleet which has been hampered by supply chain delays. The closure of Pakistani airspace for Indian carriers because of diplomatic tensions also hurt the airline financially, and it was forced to close some long-haul flights.

The Indian civil aviation ministry informed lawmakers in this month's session that 82.5% (166) of the Air India aircraft they analysed between January 2025 and now had persistent technical defects. This compares to 36.5% for IndiGo, which is market leader. The ministry did not provide any further information.

Air India's document stated that the technical incidents reported in December included engine stalls warnings, problems with flight control, hydraulics and engine oil leaks.

Five incidents of fuel or oil leakage were reported on Airbus and Boeing aircraft in a single month. On arrival, a Dubai-Mumbai aircraft found an engine with "low" oil. A Delhi-Dubai plane was forced to return after takeoff on 12 January due to "no running water in the galley and toilets", according to a document.

The document said that operational incidents, such as rejected takeoffs and flying at restricted altitudes or taking off incorrectly, amounted to 0.29 incidents per 1,000 flights. This was more than twice the level in December 2024.

It added that there had been a "decrease of operational incidents" over the past few months.

Air India currently has 191 aircraft and has ordered over?500 additional aircraft.

Air India's CEO Campbell Wilson has complained repeatedly that disruptions in the supply chain have caused delays with cabin retrofits.

Air India's February document outlined steps it is taking to "drivedown" the various technical problems.

It has implemented a program of periodic inspections for its fleet Airbus A320s and replaced all steering system hydraulic hoses in all Boeing 777s.

The document also stated that Air India has implemented a periodic air conditioning leak-check program and is taking "targeted engineering measures" to "increase aircraft reliability and decrease incident rates". Air India's problems have also attracted international regulation scrutiny. British aviation authorities asked Air India to explain why the Boeing Dreamliner that was grounded in India for safety checks, took off from London this month with a possible faulty fuel switch.

Air India responded that it reminded pilots to follow proper procedures, and that it had replaced the throttle module in the plane as a protective measure.

The UK Civil Aviation Authority didn't respond to a comment request immediately.

(source: Reuters)