Etihad Airways Mulls Bulk Buying Parts To Stave Off Supply Woes

Etihad Airways is exploring a novel way to get around persistent supply bottlenecks that have long bedevilled the aviation industry: buying components like seats in bulk and then storing them in a local warehouse until they’re needed.

The Abu Dhabi flag carrier is undertaking a $1bn retrofit of its existing fleet because new aircraft are delayed. But matching the delivery of seats among the most complex cabin elements with the upgrade cycle of a plane could quickly prove impossible given suppliers have been notoriously unreliable in sticking to their schedules, Etihad Chief Executive Officer Antonoaldo Neves said.

“I cannot just park five, six, seven planes and destroy my network just to retrofit the planes, it’s going to be too expensive,” Neves said in an interview in New York. “We say, look, give me all the seats to retrofit about 50 planes in three months and I store the seats, and use them when it doesn’t hurt my network to pull those planes out of service.”

Etihad’s considerations show how the aviation industry is trying to navigate one of the biggest impediments to growth: slow delivery of aircraft. Airbus SE and Boeing Co have for years struggled to get their production lines back on track, held back by component shortages and quality lapses on the factory floors. That’s forcing carriers to fly older kit for longer and requiring costly maintenance or cabin upgrades to keep the jets fresh.

Customers are still waiting for new jets like the Boeing 777X that is half a decade behind schedule. Airbus has also had trouble meeting delivery goals, while Boeing has started improving output again after years of upheaval.

Emirates is spending $5bn refurbishing existing jets like the jumbo Airbus A380 and the Boeing 777 to bridge delays with new models on order, particularly from the US manufacturer. Those overhauls have also been tied up by delayed parts availability, forcing airlines to ground a number of aircraft, cancel flights or charter short-term capacity.

Touching up the cabins with new seats has become an important marketing tool for carriers, particularly as more travellers migrate to more expensive seats like premium economy or business class. While economy class bookings are slower in some markets, Etihad is seeing continued demand for premium travel in key geographies such as the US, Europe and Middle East. That makes it harder for the airline to stand down planes, Neves said.

Neves said it’s not just supply bottlenecks holding back output. Certification requirements by authorities like the Federal Aviation Administration and its counterpart, the European Union Aviation Safety Agency, are also causing delays that are increasingly affecting growth plans.

“Certification has not improved, it’s a frustration,” Neves said. “Everything’s taking too long, we don’t have time for that, the customer cannot wait.”

The airline reported record profit of 1.1bn dirhams ($306mn) for the first half of the year, driven by both passenger and cargo demand. While state-owned Etihad is ready for an initial public offering, the decision of whether and when to go public is in the hands of the shareholder, Neves said.

As part of its plan to cash in on the continued demand for premium flying, the airline is bringing back two more Airbus A380 double decker jets, Neves said. The Etihad aircraft features the so-called Residence, a three-room layout featuring a double bed, living area and shower cubicle.

Etihad had previously planned to permanently retire the four-engined behemoth for smaller, more nimble planes but now already has seven back in service. The airline has shifted the aircraft to Toronto from New York because of capacity constraints at that location, though Neves said he’d like to return the A380 to US destinations eventually.

The national carrier expects to almost double its fleet to 200 aircraft in the next four or five years, Neves said. Still, the airline doesn’t plan on placing mega fleet orders, and will instead pursue small aircraft purchases as and when it needs them, the CEO said.

The airline doesn’t expect the exit of Wizz Air Holdings Plc from Abu Dhabi to impact traffic into its main hub. Neves said that other airlines, including its venture with Air Arabia PJSC, will add more than twice the traffic into the airport than Wizz is pulling out.