The future of the McDonnell Douglas MD-11 is looking brighter as FedEx Express is reaffirming its commitment to keep the aircraft in service. This decision comes on the heels of UPS Airlines officially retiring its MD-11 fleet, following a tragic crash in Louisville last year. Contrary to industry speculation about the aircraft’s end, FedEx is actively working to return its 29 operational MD-11s to the skies by the end of May 2024. The Memphis-based logistics giant’s actions reflect its confidence in the aircraft’s reliability and economic value.
FedEx’s strategy is driven by economic considerations. Recently, the company raised its full-year 2026 revenue growth forecast to between 5% and 6%. To achieve this growth, FedEx needs to maximize its cargo capacity. The MD-11 serves as a critical link in its fleet, providing a substantial payload capacity that bridges smaller aircraft like the Boeing 767-300F and larger models such as the Boeing 777F. Without the MD-11, FedEx would be forced to rely on costly outsourced lift, which had already cost the company $175 million during the grounding of the aircraft.
FedEx’s decision to reinstate the MD-11 involves a multi-faceted approach to ensure safety and compliance. The company is collaborating with Boeing and the Federal Aviation Administration (FAA) to conduct necessary inspections and maintenance. Recent announcements emphasized the completion of initial inspections mandated by the FAA, as well as the initiation of an advanced Non-Destructive Testing (NDT) program. This program focuses on critical components like the fuselage and wing-spar attachments, including High-Frequency Eddy Current (HFEC) scans to detect potential stress fractures that are not visible to the naked eye.
In contrast, UPS’s decision to retire its MD-11 fleet stemmed from the high costs and lengthy timelines associated with bringing its aircraft back into service. UPS opted for a one-time charge of $137 million and is transitioning to new Boeing 767 freighters instead. FedEx, on the other hand, has leveraged its proactive maintenance strategies to differentiate itself from its rival. Notably, FedEx implemented modifications to its engine pylons in response to a 2011 Boeing service bulletin related to spherical bearing assemblies in the MD-11. This precautionary measure has positioned FedEx favorably, potentially reducing costs associated with returning the aircraft to operational status.
Additionally, FedEx’s extensive MD-11 maintenance team, based in Memphis, is among the largest and most experienced in the world. This expertise will enable the company to address any further maintenance needs efficiently, keeping it on track for its May target. Furthermore, by retiring over 30 MD-11s in the past three years, FedEx has strategically stored these aircraft for spare parts, allowing it to maintain its operational fleet more cost-effectively. As UPS steps back from the MD-11 market, the availability of spare parts is expected to increase, further facilitating FedEx’s plans.
The MD-11 plays a crucial role in FedEx’s evolving international strategy. Following the loss of its air cargo contract with the USPS in 2024, the company has shifted its focus towards expanding international operations. With the demand for US-Asia flights diminishing due to tariffs and regulatory changes, FedEx is aggressively enhancing its capacity in the Asia-Europe market. The MD-11’s ability to carry 92 metric tonnes of cargo makes it an essential asset in this endeavor.
This week, FedEx announced the launch of five new weekly flights connecting Asia-Pacific and Europe through its new air transit facility at Istanbul Airport. This facility, which became operational in September 2023, can handle up to 7,000 packages per hour and serves as a strategic hub at the crossroads of Europe, Asia, and Africa. The newly inaugurated flights will include three connections from Guangzhou Baiyun International Airport and two from Shanghai Pudong International Airport, operated by FedEx’s fleet of Boeing 777F aircraft.
As FedEx navigates the complex landscape of air cargo logistics, its commitment to the MD-11 underscores a strategic approach focused on balancing operational efficiency with market demands. With its extensive maintenance capabilities and proactive strategies, FedEx is poised to keep the iconic tri-jet flying well into the future.
