Introduction: Aviation Safety in the Spotlight
On June 12, 2025, tragedy struck the Indian aviation industry when Air India Flight AI 171, a Boeing 787-8 Dreamliner, crashed shortly after takeoff from Ahmedabad’s Sardar Vallabhbhai Patel International Airport. The aircraft, bound for London Gatwick, climbed just a few hundred feet before losing altitude and crashing into a hostel building at a nearby medical college.
The incident claimed the lives of 241 of the 242 passengers and crew, along with multiple casualties on the ground. It marks the first fatal crash involving a Boeing 787 Dreamliner, a wide-body aircraft long praised for its modern safety features and fuel efficiency.
As emergency responders rushed to the scene and authorities launched a full investigation, India’s civil aviation regulator, DGCA, quickly ordered enhanced safety inspections of all similar aircraft in the fleet.
While the exact cause of the crash remains under investigation, this incident has once again raised a critical question for the aviation industry:
How prepared are we when it comes to aircraft maintenance and preventive safety measures?
This blog explores that question, not through speculation, but by focusing on what we know, what maintenance involves, and why its role in aviation safety is more vital than ever.
What We Know So Far
On the afternoon of June 12, 2025, Air India Flight AI 171, a Boeing 787-8 Dreamliner, took off from Ahmedabad’s Sardar Vallabhbhai Patel Airport en route to London Gatwick. Within 90 seconds of takeoff, the aircraft failed to gain proper altitude and ultimately crashed into a hostel building at a nearby medical college. At the time of this writing, 241 out of 242 onboard perished, along with dozens more on the ground.
The lone survivor, identified as Viswashkumar Ramesh, was seated near an emergency exit and sustained burn injuries. He is currently recovering in a hospital.
Investigation in Progress
Investigators from India’s Aircraft Accident Investigation Bureau (AAIB), supported by experts from the U.S. National Transportation Safety Board (NTSB), Federal Aviation Administration (FAA), Boeing, and GE Aerospace, are examining the flight data recorder and cockpit voice recorder (commonly known as “black boxes”).
Authorities have not confirmed the cause of the crash so far. However, they are investigating possible technical malfunctions involving engine thrust, flap deployment, or landing gear issues. There is no official statement yet on whether it was due to mechanical failure, human error, or a combination of factors.
Preventive Action
In response to the crash, the Directorate General of Civil Aviation (DGCA) ordered enhanced maintenance inspections of all Air India Boeing 787-8 and 787-9 aircraft. These checks include inspections of:
- GE GEnx engines
- Flap and slat configurations
- Landing gear systems
- Fuel, hydraulic, and electrical systems
- Critical cockpit instrumentation and warning systems
This move is intended as a preventive safety measure while investigations continue.
Understanding the Role of Aircraft Maintenance in Aviation Safety
Aviation is one of the safest modes of transport, thanks in large part to strict global standards and rigorous maintenance protocols. Behind every smooth takeoff and landing is a complex web of inspections, preventive maintenance, and system checks—many of which the public never sees but are absolutely critical to flight safety.
Routine Maintenance vs. Unscheduled Repairs
Aircraft maintenance falls into two main categories: scheduled (or preventive) maintenance and unscheduled (or corrective) maintenance.
- Scheduled maintenance includes routine inspections—daily, weekly, or based on flight hours or cycles—covering everything from engine performance to cabin systems.
- Unscheduled maintenance occurs when something goes wrong, whether it’s a warning indicator during flight or a failure detected during pre-flight checks.
The goal is to detect wear and tear, catch component fatigue, and prevent mechanical failures before they pose any risk to passengers or crew.
Critical Flight Phases Demand Extra Vigilance
Takeoff and landing are the most sensitive phases of any flight. According to global aviation safety data, over 80% of accidents happen during these stages. This makes the condition of systems such as:
- Flaps and slats
- Landing gear
- Hydraulic systems
- Thrust and engine performance even more important. A malfunction in any of these areas, especially during takeoff, leaves aircraft pilots with limited reaction time and space to recover.
Maintenance Isn’t Just a Technical Task — It’s a Safety Culture
Proper maintenance isn’t just about replacing worn-out parts. It’s also about:
- Accurate recordkeeping
- Timely inspections
- Clear communication among the ground crew, engineers, and flight staff
When any part of this system breaks down, risks increase—even if the technology on board is advanced. Maintenance errors, missed warnings, or assumptions that a previous issue was resolved can lead to catastrophic results.
Why Maintenance Isn’t Just a Checklist
Aircraft maintenance goes far beyond ticking boxes on a to-do list. It’s a layered, disciplined process where timing, communication, and consistency can literally mean the difference between a safe flight and a disaster. As aviation has become more technologically advanced, so too have the responsibilities tied to maintaining that technology.
The Pressure of High-Volume Operations
In a high-demand industry where flight schedules are tight and turnaround times are short, aircraft are expected to stay in rotation as much as possible. This constant usage puts pressure on maintenance teams to work quickly, often under time constraints and environmental stress.
When aircraft operate back-to-back long-haul flights, the wear on engines, flaps, and other flight-critical systems adds up fast. If routine inspections are rushed or postponed—even unintentionally—small issues can go unnoticed until it’s too late.
The Human Factor in Safety
Maintenance is not just mechanical—it’s also deeply human. Even with strict protocols, errors can occur due to:
- Fatigue
- Miscommunication
- Incomplete log entries
- Assumptions made under time pressure
History has shown that even one unchecked maintenance item—or one skipped step—can set off a chain reaction. While modern aircraft are built with multiple safety redundancies, they rely on correct data input, verified system checks, and clear handovers between shifts to function safely.
Red Flags Are Often Silent
One of the greatest challenges in aviation maintenance is that not all failures present symptoms right away. For example:
- A sensor might deliver inaccurate readings without setting off alarms.
- A part may appear functional under static inspection but fail under real-world stress.
This is why aviation safety experts stress predictive maintenance and deep system diagnostics—to catch what routine checks might miss.
Industry Response: Taking Action Before the Report Arrives
In the immediate aftermath of the Air India 787 crash, the aviation industry responded swiftly, not just in the investigation but in reinforcing safety and maintenance protocols across fleets. Even before the final report is released, precautionary steps are already being taken to prevent similar incidents.
Air India‘s Fleet-Wide Inspections
India’s Directorate General of Civil Aviation (DGCA) quickly ordered comprehensive inspections across all Air India Boeing 787-8 and 787-9 aircraft equipped with GE GEnx engines. These inspections include critical components such as:
- Flap and slat operation
- Landing gear deployment and retraction systems
- Engine thrust response
- Hydraulic and electrical systems
- Flight deck alerts and control settings
By proactively grounding aircraft for enhanced checks, the airline and regulator are aiming to rule out systemic issues or overlooked technical risks.
Global Eyes on the 787 Dreamliner
Although the Boeing 787 has had a strong safety record since its debut, this incident has triggered global scrutiny. Other international carriers operating the same model are reportedly reviewing their maintenance logs, sensor systems, and software updates to ensure compliance with current safety standards.
Regulatory Collaboration Across Borders
The investigation involves coordination between multiple agencies:
- India’s AAIB (Aircraft Accident Investigation Bureau)
- U.S. NTSB and FAA
- Boeing
- GE Aerospace
- UK civil aviation authorities
This level of international cooperation is standard for major incidents and signals the seriousness of this event. It emphasizes a shared understanding in the aviation world: when a system fails, learning from it must begin immediately, not just after the final report is filed.
Lessons Beyond This Crash
Aviation has long been regarded as one of the safest forms of travel, but that safety is built on constant learning, especially from incidents that shake public confidence. The crash of Air India Flight AI 171 is a tragic reminder that even with modern aircraft, safety must be earned and re-earned with every flight.
No Room for Complacency
As aircraft become more sophisticated, there’s a risk of overreliance on automation and assumptions that technology will always “catch” a problem. But aviation safety doesn’t run on luck or hardware alone—it depends on people, processes, and attention to detail.
Crashes like this one renew the urgency around:
- Thorough inspections before and after flights
- Cross-checking diagnostic data
- Listening to pilot reports or anomalies flagged in previous legs
- Training for both technical and non-technical staff
These are not just formalities—they are the foundation of operational safety.
A Culture of Transparency and Continuous Improvement
One positive trend in aviation is the increasing push for transparency. When something goes wrong, industry stakeholders are expected to:
- Report findings openly
- Share lessons learned across borders
- Update policies and procedures even before reports are finalized
This spirit of openness is what turns tragic incidents into opportunities for change and is why global aviation safety has steadily improved over the decades.
It’s About People, Not Just Planes
Behind every system check, engine reading, or inspection log are real people—engineers, technicians, flight crew, and passengers. Safety isn’t just a mechanical concept; it’s a responsibility that affects lives.
When an aircraft goes down, it’s not just a headline—it affects families, communities, and futures. That’s why every inspection matters, and every system check counts.
Conclusion: Safety Is a System, Not a Single Action
The crash of Air India‘s Boeing 787 Dreamliner near Ahmedabad Airport in Gujarat is under ongoing investigation by India’s Aircraft Accident Investigation Bureau (AAIB), with technical assistance from the National Transportation Safety Board (NTSB) and the Federal Aviation Administration (FAA).
While the exact cause has not yet been confirmed, the incident has renewed focus on the critical role of aviation safety, aircraft maintenance, and regulatory compliance.
In immediate response, India’s Directorate General of Civil Aviation (DGCA) ordered detailed aircraft maintenance checks across Air India‘s Dreamliner fleet. These checks are guided by international standards and recommended practices set by the International Civil Aviation Organization (ICAO) and supported by bodies like the European Union Aviation Safety Agency (EASA).
These inspections focus on essential systems such as the aircraft engine, landing gear, and avionics. They aim to detect issues like thermal runaway, wear and tear, and corrosion before they pose safety risks.
Modern aviation operates under an intricate web of oversight and engineering. From airspace coordination and air traffic control to fleet management, each component of a flight relies on tightly integrated systems. The use of checklists, advisory circulars, and safety management systems (SMS) ensures that aircraft meet global certification and airworthiness standards throughout their life cycle.
Preventive measures like predictive maintenance, continuous surveillance, and structured audit protocols help operators avoid failures. Maintenance teams, including licensed aircraft maintenance technicians, play a key role in applying updates, identifying hazards, and ensuring compliance with federal aviation regulations.
This incident also reminds us of how vital infrastructure and global coordination are, from civil aviation authorities to aviation law, from airport security to occupational safety and health guidelines. These aren’t just technical requirements—they’re essential safeguards that uphold the integrity of international civil aviation.
As the investigation continues, lessons from this event will be used to improve operational efficiency and maintenance services and strengthen safety across the entire industry. In aviation, safety isn’t just one person’s job or one system’s responsibility; it’s a globally shared commitment to keeping every airplane, pilot, crew, and passenger safe from takeoff to landing.
References:
Regulatory and Investigation Sources:
- Directorate General of Civil Aviation (DGCA) – Mandated enhanced inspections on Air India‘s Boeing 787‑8/‑9 fleet equipped with GE GEnx engines after the crash news.com.au+15newsonair.gov.in+15outlookbusiness.com+15
Aircraft Accident Investigation Bureau (AAIB), India – Leading the technical investigation and black box analysis,.com+6abcnews.go.com+6apnews.com+6
National Transportation Safety Board (NTSB, USA) – Dispatched investigators and are collaborating with AAIB apnews.com+5cbsnews.com+5news.com.au+5
Federal Aviation Administration (FAA, USA) – Providing technical assistance, no immediate grounding of 787s, economictimes.indiatimes.com+15reuters.com+15reuters.com+15
Industry and International Aviation Standards:
- International Civil Aviation Organization (ICAO) – Annex 8 and Annex 19 cover ongoing airworthiness and safety management systems. faa.gov+7icao.int+7sassofia.com+7
Federal Aviation Regulations (FARs, US) – Especially Part 25 and Part 43 relating to transport-category aircraft certification and maintenance wsj.com+11en. wikipedia.org+11en.org+11
Technical Coverage & Safety Reporting:
- Reuters – Reporting on probe focus areas like engines, flaps, and landing gear m.economictimes.com+15reuters.com+15theguardian com+15
CBS News / ABC News / AP News – Confirming black box recovery, casualty figures, survivor information, and crash patterns
