FL Technics Takes Pragmatic Path To MRO Growth

FL Technics is focusing its strategy on working efficiently, using practical innovations and staying flexible as Europe’s MRO sector grows. The company has recently expanded its narrowbody maintenance services and invested in key tools and digital systems to achieve this.

With facilities in both Vilnius and Kaunas, the Lithuanian MRO concentrates on narrowbody aircraft, maintaining heavy-check capabilities including the Airbus A320 family; Boeing 737 Classic, 737NG and 737 MAX; and Bombardier CRJ 100/200. It recently added approvals for Embraer 170/190 jets.

“It’s better to focus on several core types and be the best in them rather than trying to cover everything,” Juozas Lapeika, deputy CEO for base maintenance, tells Inside MRO, adding that expanding too widely reduces efficiency. “Concentrating on A320s, 737s and Embraers allows us to serve customers effectively and maintain high standards.”

Vilius Grigas, head of sales for base maintenance, says that market dynamics shaped these decisions. “When the A320neo became the clear leader in Europe, we developed capabilities there first, and then the MAX approvals followed as demand picked up,” he notes. “The regional market was also considered, including turboprops, but the Embraer E-Jets offered a stronger long-term opportunity.”

FL Technics’ dual hubs in Vilnius and Kaunas provide flexibility. The facilities share approvals, standards and personnel, allowing labor to be shifted according to demand. “It’s really one team working across both sites,” Grigas says.

PRACTICAL INNOVATION

Realism is driving FL Technics’ technology investment strategy. “We don’t want to be the king of LinkedIn with flashy gadgets,” Lapeika explains. “Our investments are in tools that genuinely help reduce [turnaround times]. For example, we were among the first to adopt dent-mapping with 8tree, and our teams are now testing helium-based gas leak detection tools.

“I travel to see what other MROs are doing,” Lapeika adds. “Many invest in things like [radio-frequency identification] tags on tools that don’t really work and don’t necessarily add real value. We want to focus only on the technologies that truly make a difference to turnaround times and efficiency.”

Grigas stresses that FL Technics is investing in tooling that saves time, reduces cost and improves efficiency. “We’re focused on efficiency gains that matter for customers—saving time and cost while maintaining high-quality standards,” he says.

MARKET SHIFTS AND AIRLINE DEMAND

It is widely evident that the delays in new aircraft deliveries are reshaping maintenance demand. Many airlines that expected to phase out older A320ceos are instead keeping them flying longer, creating unanticipated demand for heavy checks.

“What we’re seeing is a mix of work,” Grigas says. “Roughly 30% are lighter checks on young aircraft aged between one and six years. Another share involves first structural checks on newer fleets.” Increasingly, older aircraft are returning for second 12-year checks or fifth six-year checks. These mature, 24-30-year-old aircraft are still coming into the FL Technics facility.

“We even see 36-year-old A320s that have not passed the 12-year check threshold yet, and we are already getting those requests,” Grigas notes, suggesting unusual usage patterns or deferred maintenance.

This trend ties into wider shifts across Europe’s airline industry. Low-cost carriers with access to new aircraft are introducing younger fleets that require less intensive maintenance. Meanwhile, legacy airlines are adjusting their maintenance plans as delivery delays lead them to keep older aircraft in service longer. Leasing firms, after a quieter period, are also becoming more active again.

FL Technics reports a balanced customer mix, with 25-30% of its workload coming from low-cost carriers and the rest split between legacy airlines and leasing firms. This spread helps reduce exposure to fluctuations in any single market segment.

Despite being part of the large Avia Solutions Group, FL Technics and its affiliated airlines and leasing companies operate independently and competitively. There is no guaranteed internal business—contracts are awarded based on commercial terms, not group affiliation.

According to Grigas, this independence allows FL Technics to pursue third-party deals freely. Group airlines can source MRO services externally if it is more cost-effective. He frames this as a strategic advantage because it maximizes revenue across the group while minimizing internal costs—a “dual win” for shareholders.

SUPPLY CHAIN AND LABOR CHALLENGES

The supply chain remains one of FL Technics’ biggest obstacles to efficiency. “Material delivery is one of the most critical bottlenecks,” Lapeika notes. “It is also one of the hardest things for us to control. Engines are another challenge—if Pratt & Whitney or another OEM does not deliver, we cannot influence that.

“Everyone is playing under the same conditions, but we must aim to be the best at finding solutions,” he continues. “We are constantly searching for ways to reduce downtime and improve output for our customers.”

The company positions itself as an “academy” for engineers, investing heavily in training and development. This is partly a necessity, given the global talent shortage, but also a deliberate strategy to build long-term competitiveness.

“We’ll never pay the highest salaries,” Lapeika acknowledges. “But our strength is in helping young technicians grow, gain licenses and develop into skilled professionals. Many Lithuanians who trained here are now working across Europe, and we continue to attract and develop the next generation.”

The COVID-19 pandemic exacerbated industrywide workforce gaps as many experienced engineers left the industry for other sectors. “There is still a vacuum between the younger generation just entering and the older generation retiring,” Grigas says. “We did a good job retaining our core team during COVID, but like all MROs, we must remain attractive to new talent.”

The generational shift also creates cultural challenges, Lapeika observes. “Younger technicians want to work with drones and laptops,” he says. “Aircraft may not evolve as fast as their expectations, so MROs must adapt processes and possibly regulations to make this industry appealing to them.”

EMBRACING SUSTAiNABILITY

Sustainability initiatives are increasingly shaping FL Technics’ operations as airlines push their MRO providers to align with their environmental goals.

“Our clients are very focused on sustainability, and that pushes us as well,” Grigas says. “We’re not only meeting minimum standards—we’re reviewing procurement after every check to avoid overbuying and waste.”

Lapeika highlights the generational and cultural side, too, noting the younger generation’s willingness to engage in sustainable practices, which drives positive change. “The most important thing is to be environmentally responsible in our own business,” he says. “We can’t compare ourselves with other industries, but we can ensure we are leaders within MRO.”

FUTURE FOCUS

Digitalization is increasingly shaping the direction of the MRO industry, and it is influencing everything from workflow efficiency to predictive maintenance and data-driven decision-making.

“Processes, inspections and communications are moving online,” Lapeika says. “Being fully digital will be crucial to manage bottlenecks in supply chains and communication with OEMs and airlines.” FL Technics intends to be among the leaders in this transition, he adds.

Customer expectations also are driving digital transformation, with airlines increasingly demanding digital transparency. They want real-­time visibility into maintenance progress, material status and costs, and that is certainly where the industry is heading.

Digitalization is also changing what the workforce expects. Younger technicians are eager to use modern digital tools, but aircraft systems often evolve more slowly than their expectations.

FL Technics sees its future in carefully expanding its services, applying practical innovations, building a skilled workforce and focusing on sustainability. “It’s not about having the biggest hangar or the flashiest tools,” Grigas says. “It’s about having the right people and the right solutions to deliver for airlines.”