SHANGHAI- Tata Group-owned Air India (AI) has expanded its Boeing 787-8 retrofit programme by adding Boeing’s Maintenance, Repair and Overhaul (MRO) facility in Shanghai, China, alongside its existing facility in the United States. The move is aimed at accelerating the modernization of the airline’s Dreamliner fleet by the end of 2027.
The Tata Group-owned carrier currently operates 26 Boeing 787-8 Dreamliners. The first aircraft, registered VT-ANZ, has been sent to Boeing’s Shanghai facility, while future aircraft will continue to undergo upgrades in the United States. The retrofit programme supports Air India’s broader fleet transformation strategy.
Air India Expands 787 Upgrade Programme
Air India is increasing the pace of its Boeing 787-8 refurbishment by operating two overseas retrofit lines simultaneously.
Until now, the airline relied on Boeing’s facility in the United States for the extensive cabin and maintenance upgrades. The addition of the Shanghai MRO facility is expected to reduce waiting times and improve the overall completion schedule.
The first aircraft assigned to the new facility is VT-ANZ, marking the beginning of retrofit work in Shanghai. Another Boeing 787-8, registered VT-ANR, is scheduled to undergo refurbishment at Victorville in the United States.
According to industry sources, Air India is also evaluating additional global retrofit locations. Any further expansion will depend on maintenance slot availability and operational capacity at Boeing’s partner facilities, FE reported.
Modern Cabin Upgrades Across the Fleet
The retrofit programme is designed to completely modernize Air India’s legacy Boeing 787-8 fleet.
Each refurbished aircraft receives:
- A redesigned three-class cabin
- New seats across all cabins
- Upgraded interiors
- A refreshed passenger experience
- Air India’s latest branding and exterior livery
Three Boeing 787-8 aircraft have already completed the full refurbishment programme and returned to commercial service with the airline’s new cabin products.
The upgrades are part of Air India’s ongoing fleet transformation following its acquisition by the Tata Group, which includes improvements across both narrowbody and widebody aircraft.
Maintenance Work Determines Retrofit Duration
A standard Boeing 787-8 retrofit typically requires around 30 days. However, the actual time can vary significantly depending on scheduled maintenance requirements.
The recently upgraded aircraft VT-NAC remained out of service for more than 90 days because the airline combined heavy maintenance inspections with the cabin refurbishment and repainting process.
By completing both maintenance and interior upgrades during the same visit, Air India aims to reduce future aircraft downtime after they return to service.
Airline Targets Completion by End of 2027
With retrofit work now taking place in both Shanghai and the United States, Air India expects the programme to accelerate considerably over the coming months.
The airline plans to have approximately 10 to 12 Boeing 787-8 aircraft upgraded by April 2027. Operating multiple retrofit lines allows several aircraft to undergo refurbishment simultaneously, improving the pace compared to relying on a single maintenance location.
Air India is also taking advantage of its temporarily reduced international network operations to send more aircraft for upgrades without significantly affecting flight schedules.
The carrier continues to target completion of all 26 legacy Boeing 787-8 retrofits by the end of 2027, bringing a consistent onboard product across its long-haul Dreamliner fleet.
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