Malaysia Airlines Pins Disruptions On Component Reliability, Workforce

KUALA LUMPUR—Malaysia Airlines says poor reliability of rotables and CFM56 engines coupled with losing maintenance technicians to rivals culminated in the recent service disruption that led the flag carrier to cut capacity by 20% until the end of the year.

Malaysia Aviation Group (MAG) Managing Director Izham Ismail says that of seven recent turnbacks and diversions, three were engine related. The other four were due to various other components on the aircraft.

Izham says the CFM56 engines that power the airline’s fleet of Boeing 737-800s are designed for around 21,000 cycles. He says the engines have started to fail after 18,000. The carrier has imposed a maximum of 17,900 cycles between overhauls for added precaution. Engine overhaul is meanwhile taking longer, he says, up to 100 days from 65-70 in the past.

Izham adds that 28% of MAG’s spares are rotables, meaning the parts could come from various operators and are serviced by the manufacturer or licensed providers before being redirected to Malaysia Airlines. By way of example, one of the Bleed Management Computers that recently failed came from a pool that originated with another airline, he says.

The company is now working to increase the level of quality checks on rotables and is collaborating with suppliers to prevent a recurrence of this problem, Izham says.

When aircraft do have issues, Malaysia Airlines does not have sufficient spare capacity to replace them—an issue made worse by delays to deliveries of its on-order 737-8s and Airbus A330neos, Izham says.

Izham also cites the departure of technicians from Malaysian MRO companies as a contributing factor to the airline’s operational difficulties.

In response to SIA Engineering Company’s announcement of future MRO operations at Kuala Lumpur Subang Airport from 2026, MAG started to engage Dviation in 2023 to train new line maintenance technicians to prepare for an expected outflow of talent from its subsidiary MAB Engineering.

While Izham acknowledges that Malaysia must attract foreign direct investment, SIA Engineering Company’s more attractive salaries have proved a drain on talent. The Malaysian Transport Ministry says 63 qualified engineers left MAB Engineering, but Izham says that only 12 went directly to SIA Engineering Company. The rest have gone to local competitors, which have also seen staff leaving for the Singaporean company.

MAG is in discussions with two overseas MRO providers to bring resources into Malaysia. The group is preparing to introduce a more attractive remuneration package to attract and retain staff.