With Over 7,700 Suspect Parts, EASA Faces Uphill Battle to Regulate the Aviation Supply Chain

Comments by Steven Bentley FRAeS CEO of Sofema Aviation Services www.sassofia.com

Facing The Aviation Supply Chain Challenge

The aviation industry’s safety and operational reliability depend heavily on rigorous supply chain oversight, yet the growing influx of suspected unapproved parts (SUPs) poses a significant challenge to regulators.

The European Union Aviation Safety Agency (EASA) has flagged over 7,700 suspect parts, signalling a persistent issue within the global supply chain that demands immediate action. These unapproved, forged, or counterfeit parts threaten the integrity of aircraft systems and, ultimately, passenger and crew safety.

The Scope of the Problem

The aviation supply chain is vast, with components often sourced through a complex network of suppliers, brokers, and distributors. The 7,700 suspect parts reflect a troubling trend of inadequate controls, exploited loopholes, and malicious actors seeking financial gain.

Cases documented by EASA and partner authorities highlight systemic vulnerabilities:

• Forged EASA Form 1 Documentation: A recent case involved forged EASA Form 1 certificates accompanying SPRING (Fuel Pump) parts for Leonardo aircraft. The fraudulent documentation misled operators and maintenance providers, creating a risk of non-compliant parts being installed.
• Lost/Stolen Identification Plates: In another alarming incident, identification plates for Airbus A330 and ATR 72 aircraft were reported lost or stolen. These plates are critical to tracing parts to their approved sources, and their absence opens pathways for counterfeit replacements.
• Counterfeit Thrust Reverser Actuators: Counterfeit components, including thrust reverser actuators, were discovered during maintenance inspections. These parts, falsely certified, pose critical safety risks, as thrust reversers are essential for decelerating aircraft upon landing.
• Hydraulic System Failures: Suspected unapproved hydraulic valves and bolts installed in Boeing aircraft further underscore how critical systems are vulnerable to unapproved part infiltration.

Such incidents are not isolated; rather, they reflect a broader pattern of counterfeit components penetrating maintenance networks, often through brokers or unauthorized distributors.

Regulatory Challenges

EASA’s ability to regulate this complex supply chain faces numerous obstacles:

• Globalized Markets: Many parts originate from regions outside the EU, where regulatory oversight is inconsistent. Fraudulent actors exploit this gap to introduce counterfeit or unapproved components.
• Complex Distribution Channels: Parts frequently change hands multiple times, obscuring their origins and making it difficult to verify authenticity.
• Forged Documentation: Counterfeit parts are often accompanied by falsified certificates like FAA Form 8130-3 or EASA Form 1, undermining the credibility of regulatory frameworks.
• Resource Limitations: Regulatory bodies face limitations in manpower and technology to inspect every part or investigate every case.

High-Profile Examples

The documented cases provide clear evidence of the scale and seriousness of this issue:

• Pump Fuel Booster – DUKES Inc.: Forged FAA Form 8130-3 documents accompanied critical components, raising concerns about how counterfeit documentation can bypass quality assurance processes.
• CFM56 Turbine Blade Assembly: Lost or stolen components for the widely used CFM56 engine pose a major risk to commercial aircraft operations.
• Counterfeit Landing Gear Components: These components, discovered in critical systems, highlight the life-threatening consequences of counterfeit parts infiltrating essential aircraft structures.

Addressing the Crisis

To combat the spread of unapproved parts, EASA and global regulators must enhance their oversight strategies:

• Improved Traceability: Implementing advanced digital solutions such as blockchain technology to trace the origin and movement of parts.
• Stricter Penalties: Enforcing harsher penalties for suppliers and brokers found guilty of distributing counterfeit components.
• Global Collaboration: Strengthening partnerships between EASA, FAA, and other authorities to share intelligence and coordinate inspections.
• Audits and Inspections: Increasing the frequency of audits at approved organizations and enhancing surveillance of supply chain intermediaries.
• Industry Awareness: Educating airlines, MROs (Maintenance, Repair, and Overhaul organizations), and manufacturers to identify red flags and improve verification processes.

Conclusion

The proliferation of unapproved parts presents a clear and present danger to aviation safety, and with over 7,700 suspect parts already flagged, the urgency for action cannot be overstated. EASA’s challenge lies not only in identifying and removing these parts but also in fortifying the supply chain against future infiltration. By leveraging technology, enhancing global cooperation, and holding bad actors accountable, regulators can begin to stem the tide of counterfeit and unapproved components, safeguarding the integrity of the aviation industry for years to come.

As the aviation sector continues to recover and grow, ensuring the airworthiness of every part must remain a top priority—because safety, after all, is non-negotiable.

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Sofema Aviation Services (SAS) and Sofema Online (SOL) provide regulatory training for suspect parts FAA & EASA. For comments & questions, please email team@sassofia.com.