Why Is It Getting So Hard To Procure Military Aircraft Parts?

Perhaps a better perspective is why military aircraft parts are drying up. This is not really a new phenomenon; keeping parts in circulation for military aircraft has always been a challenge for reasons more numerous than we have room for here. But most notably, in 2024, it is the overall average age of aircraft in the inventory. Across all branches of the military in the U.S., airframes are getting older and older. Many of them have far outlasted their intended lifecycles, yet they are expected to soldier on for many more years. 

However, there are only finite numbers of any given part for any given airframe, and those eventually run out. Granted, certain parts and components can be rebuilt many times over and are intended to be, but eventually, parts just wear out. But let’s not get too far ahead. 

What Makes it So Hard to Find Parts?

Statistically, a few aircraft MDS have been much harder to procure parts for than others, which is largely due to terrible mission capability rates (MC rates). The C-5A and B-1B were both notoriously unreliable aircraft with awful MC rates that routinely dipped into the 60%- 70% range (very, very bad). 

The C-5s' problems were largely addressed and corrected when they were re-engined and avionics upgraded in the Block upgrade process. However, certain systems on the Galaxy remain problematic to this day, namely the landing gear. Aircraft that rely heavily on extremely complicated hydraulic systems always tend to have lingering problems over their lifespan, and both the Galaxy and the Bone fell victim to this. 

One key difference between these two aircraft is that the C-5 Galaxy is much older than the B-1. Yes, the B-1 is getting old; the C-5 is about two decades older. The Galaxy is a Vietnam veteran and has lasted impressively over the years. Again, it was engineered using no digital tools, which is very impressive, but the landing gear problems plagued this impressive aircraft for decades. 

Many of the B-1s' problems were related to the hydraulic system since all of the control surfaces are hydraulically actuated, and the system runs at 4,000 psi instead of the standard 3,000 psi. Long story short, these two aircraft are good representative samples of systemic supply problems in the military aviation community. Every aircraft in the inventory is complicated but to varying degrees. 

Even ultra-reliable aircraft like the C-12 are getting long in the tooth, with C-12s serving continuously since 1974. Thankfully, thousands of civilian Super King Airs are in service, so the supply chain for these is strong. However, there are tactical aircraft in service, such as the F-15 Eagle, which has served just as long as the C-12. They are getting very old (especially by fighter jet standards), and parts are much harder to come by. 

The T-38 is another great example. While it has served admirably, they have been continuously used as a secondary trainer since 1961. Yes, you read that right. They have been in service for 63 years. After six decades, there are most certainly no new parts, and none have been produced for many years. The dies are long gone for most of these parts, and the companies who made them may be long out of business. This problem was dealt with among tactical aircraft fleets, so it is certainly a universal problem. 

Challenges in Procuring Hard-to-Find Parts

Scarcity is the biggest problem with obtaining hard-to-find parts. If you need it, so do all the other organizations flying the aircraft. There are only so many units available, and they are in high demand, so getting ahold of them is challenging. 

Airframes Are Getting Old and Operating Far Beyond Their Intended Lifecycles

Again, the biggest issue with supply chains in military fleets (or at least one of the biggest issues) is the aircraft that are still operating daily and probably should have been retired two or three decades ago.  

When aircraft are manufactured, and third parties are subcontracted to build or provide certain parts and components, they are also tasked with building X quantity of spares to accompany the building contract. 

When these orders are placed, they are based on the aircraft's expected lifecycle; i.e., if the aircraft were designed for an anticipated 20-year lifecycle, then two decades' worth of anticipated spare parts are ordered with it. 

Of course, if the aircraft has serious reliability issues or problem areas (B-1B, F-111, F-14, for example), the parts supplies will run out quicker than anticipated. But then, when these aircraft are pressed into continuous service long after the expected lifecycle has passed (in a few examples, many decades beyond their expected service durations), the parts supplies will invariably dry up as well. 

One way that the U.S. military set out to combat this problem was by retiring aircraft from the fleets to boost supply chains. However, this only works in certain circumstances. 

The Problem With Supply Chain Disruptions

At the end of the day, the main problem with supply chain disruptions is reduced MC rates. When an aircraft is waiting on parts with a Red X in the forms, it is nothing more than a paperweight. The aircraft is just sitting there, getting closer and closer to hangar queen status because the part is unavailable. 

Unfortunately, a reality of parts manufacturing is single-source suppliers, which is essentially a choke point for the logistics chain. 

Strategies for Successful Procurement

While problems like single-source suppliers are certainly a reality, they are not necessarily the norm. Most parts are made or available by more than one supplier (it is generally the highly specific tactical airframes where single-source suppliers are a big problem).

Develop Long-Term Partners Over Four Decades

The first step is the hardest one, but Greenwood Aerospace has been doing it for a long time. 

You can’t fake time and effort; we have put decades of time and effort into building our reputation. We have established ourselves as industry leaders in aircraft parts procurement for the military and government agencies. Look, we have no control over the limited parts supply, but neither does anyone else. What we can control is how we go about getting them. 

GPIQ

We believe in what we do so much that we have invested heavily in upgrading our services with proprietary software known as Greenwood Parts Intelligence (GPIQ). In the past, procuring parts was challenging, time-consuming, and complex. Global supply chains have recently faced unprecedented disruptions, casting doubt on the future. Due to uncertain times and stressed supply chains, partnering with an experienced aviation supply chain and logistics provider is crucial.

Greenwood Aerospace is the trusted partner that invests in its process through Greenwood Procurement Intelligence (GPIQ). GPIQ focuses on market intelligence and value enhancement for aircraft, particularly those supporting special mission aircraft like the RC-12W, the E-11 BACN, and the T-6 Texan II. Recognizing the importance of aircraft maintenance for government programs, GPIQ adapts to changing demands.

We practice stringent onboarding and qualification to make sure our suppliers are reliable and that we can provide insights into their performance. GPIQ simplifies complex tasks, making the supply chain process efficient, quick, and accurate. We use predictive analytics with GPIQ to forecast future demand and manage supplier risk, resulting in cost savings for all parties.

As a strategic partner, GPIQ helps manage procurement expenses long-term, ensuring that you always get what you need at the best price.

Final Thoughts

The military aircraft supply chain is stressed, and it has been stressed for a very long time, since at least the beginning of OEF/OIF. In the almost quarter of a century since then, hundreds of thousands (maybe even millions) of flight hours have been racked up. Combine that with the harsh environments these aircraft have flown in, and you have a recipe for disaster. 

Thankfully, Greenwood Aerospace is here to help you find those hard-to-find parts. We are all-in on finding the best suppliers and parts so you can focus on keeping airplanes in the air. 

Greenwood Aerospace is your leader in government procurement, aircraft and parts storage, distribution, and military and defense contracting. Learn more about our services for the defense and military industries. For additional information, you can also get in touch with us here or by emailing sales@governmentprocurement.com.