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Storing Boeing's grounded jets: A costly logistical challenge

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Storing Boeing's grounded jets: A costly logistical challenge
Policy
Webp b737max
Boeing 737 MAX | Boeing

In 2019, the grounding of Boeing 737 MAX aircraft affected nearly 500 jets, including around 100 new ones that could not be delivered after two fatal crashes within five months. This crisis significantly impacted Boeing's market value, reducing it by $41.5 billion and incurring a cost of almost $1.5 billion for canceled flights.

A significant financial burden during this period was the storage cost for these grounded planes. The Los Angeles Times reported on Southwest Airlines storing 34 of its 737s in the Mojave Desert but did not disclose specific costs. An "industry veteran" estimated these expenses at $2,000 per month per aircraft.

Determining exact storage costs is challenging as airlines and manufacturers often do not share this data due to its high variability. Estimates differ widely; while the LA Times cited a monthly cost of $2,000, a San Diego Union-Tribune article suggested $0.40 per day per 1,000 lbs of aircraft weight, which translates to approximately $3,100 monthly for storing a 737-800 model.

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The weight differences among various 737 models also affect storage costs. For example, the base model 737 Classic (737-300) weighs about 72,360 lbs empty, whereas the newer Boeing 737 MAX weighs around 138,699 lbs empty.

Economies of scale in aircraft storage might have allowed airlines to negotiate bulk deals for storing large numbers of aircraft like the heavier MAX variant at prices similar to lighter versions.

Tim Zemanovic, a former owner of an Arizona-based aircraft storage facility told the LA Times: "Planes are meant to be flying and being used... You've got to keep them that way even when they're in storage." Maintenance tasks such as running turbofans weekly and ensuring control surfaces function add to costs. Environmental factors like desert sand and wildlife also contribute to maintenance challenges.

Despite these expenses, keeping planes ready for return was necessary once regulatory approvals were granted. Each jet required extensive checks before returning to service after prolonged grounding.

Production issues compounded Boeing's challenges as it suspended new 737 MAX construction from January 2020 due to space constraints and ongoing evaluations amid continued groundings. Bloomberg Intelligence analyst George Ferguson remarked: “They can’t keep building and parking planes indefinitely.”

By March 2021, global regulators began approving the return of the MAX fleet with Boeing starting deliveries from long-term storage facilities soon after. As of April 2025 estimates indicated there were still some undelivered but completed MAX units awaiting dispatch.

Looking ahead post-grounding era sees typical seasonal or end-of-life-related storage patterns resuming although past experiences likely remain vivid reminders prompting careful future planning by both airlines and manufacturers alike.

Boeing has sought extensions related FAA exemptions highlighting ongoing regulatory hurdles potentially affecting operational timelines suggesting further efforts needed avoiding repeat disruptions seen previously with massive associated costs incurred during earlier crises.

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