UPS says its grounded fleet of McDonnell Douglas MD-11 cargo planes will remain out of service for several months following a deadly November 4 crash in Louisville, delaying the aircraft’s return well beyond the peak holiday shipping season.
In an internal memo to employees, UPS Airlines President Bill Moore said inspections and potential repairs required under Federal Aviation Administration (FAA) oversight are “more extensive than initially expected.” UPS initially projected a weeks-long process but now expects months of work before the MD-11 fleet can return to service.
Crash Prompted Immediate Grounding
The MD-11 grounding began shortly after the November 4 crash at Louisville International Airport, when the aircraft’s left engine detached during takeoff and ignited a fire. Fourteen people were killed, and at least 23 were injured.
Cargo carriers grounded their MD-11 fleets even before the FAA issued a directive. Investigators later found cracks in the aircraft’s engine mount, raising new concerns about the aging airframe.
Inspections Now Expected To Take Months
According to Moore, Boeing’s ongoing evaluation shows the maintenance and inspection requirements will exceed early estimates. The FAA has directed operators to wait for Boeing to develop FAA-approved inspection procedures and any necessary corrective actions.
UPS stated it “will take the time needed to ensure that every aircraft is safe.”
Company Says Deliveries Will Continue Through Contingency Plans
With a significant portion of its wide-body cargo fleet grounded, UPS said it will rely on contingency strategies to meet customer demand during the holiday season. The company did not specify whether those plans include aircraft substitutions, added flight hours, or increased use of ground logistics.
Aging MD-11 Fleet Under Increased Scrutiny
Roughly 109 MD-11s remain in operation worldwide. The aircraft averages more than 30 years in age and is used exclusively for cargo.
MD-11s account for about 9% of UPS’s fleet and 4% of FedEx’s. Boeing, which took over production following its 1997 merger with McDonnell Douglas, said it is providing technical support to operators as they work to meet FAA requirements.
The FAA said Boeing must finalize and submit all inspection and repair procedures for approval before MD-11 flights can resume.