If you’re like most operators and DOMs, you’ve heard throughout your careers that it’s smart to preplan for large maintenance events. People have certainly heeded this advice, as the practice is more often becoming standard operating procedure for larger flight departments and individual operators alike.

However, some have even taken this concept to the extreme by preplanning large events further and further out. While this is not a bad idea in theory, there could be a catch. The further out you plan for the major event, the more your chances increase of overlooking other events that should take advantage of that major event downtime – way down the road.

Items like interior, paint, or avionics might not be top of mind when the initial scheduling is done, but these areas often come into focus as you near the input date. And, if not included in the original scope, they may be difficult to add on at the last minute.

With demand at all-time highs, repairs and overhaul lead times have increased industry-wide, making the need for preplanning even more critical.

For example, take a look at these industry-average downtimes and lead times for larger events:

• Starlink installation: 9-16 weeks equipment lead time depending on aircraft

• New divan: 10-12 weeks lead time

• Seating upholstery: 8-10 weeks downtime depending on quantity (less if performed in conjunction with other major event)

• Monitors/cabin management system: 8-16 weeks lead time

• Custom carpet: 10-14 weeks lead time

• Lighting: 8-20 weeks lead time depending on type and style

• Woodwork: 3-6 weeks material lead time depending on type of wood; 8-10 weeks downtime if done as standalone (less if performed in conjunction with other major event)

• Paint: Slots filling up 3-6 months in advance

These are areas that can and should take advantage of major event downtime and equipment removal, and when planned in conjunction with major events, can save time and money overall.

While no one has a literal crystal ball, you can certainly plan to maximize your downtime during a maintenance event just by taking a closer look at these other areas and outlining what will need to be accomplished in the longer term.

A bit more focus and wider scope when planning these events will allow you to come out of maintenance and focus on just flying and enjoying the aircraft.

West Star Aviation is uniquely suited to help in planning to get the most out of the aircraft downtime. From “red” gear that WSA owns that is installed to facilitate aircraft movement during maintenance so painting can be accomplished without adding downtime to onsite sales and design teams that can speed up last-minute material selections, make West Star Aviation your partner in preplanning and rest assured you will be in good hands at any of our facilities when down for maintenance.