Airline Operating Cost
Airline Operating Cost
4.1 INTRODUCTION
This section provides estimates of variable and fixed aircraft operating costs. Aircraft
variable operating costs are important factors in the evaluation of FAA investment and
regulatory programs that concern the time spent in air transportation. The variable operating
costs of aircraft affect aircraft operators directly and users of air service indirectly in the form of
higher or lower fares or taxes. Fixed aircraft costs may also be important in evaluating the effects
of FAA investment and regulatory programs that affect fleet size, cause aircraft to be more
productive, or cause aircraft to be out of service for extended periods of time.
To put airline costs in perspective, this section first shows the relationship of
aircraft operating costs to total airline operating costs and then presents another disaggregation of
total airline costs. After this, aircraft operating costs are presented in more detail. Costs in this
section are shown for air carrier, general aviation and military equipment types. Data are
presented for aircraft categories identical to those in Section 3 above.
Cost data are defined for air carrier and general aviation aircraft as variable or fixed.
Variable costs change in proportion to aircraft usage, and include fuel and oil, maintenance and
crew costs.1 Fixed costs show little or no change in proportion to changes in activity. For
example, in the short-term, a change in activity may not affect an operator’s decision about a
specific aircraft or fleet of aircraft. In the longer-term, the operator could change its fleet and
ownership costs.
There are two estimates of fixed costs provided. The first is fixed accounting charges
including depreciation, insurance, and rental charges reported by carriers in Form 41, or which
have been estimated for GA aircraft. The second is provided for commercial aircraft only. If an
FAA initiative improves system efficiency, an operator may be able to provide the same service
with fewer aircraft; alternatively, an FAA initiative may cause aircraft to be out of service or to
be removed from the fleet entirely. In either case, an estimate of the benefit or cost to the carrier
of an FAA initiative would include the carrier’s opportunity costs—the value of the aircraft in its
next best use. One immediate alternative use of an aircraft might be to lease it out to another
operator. Since there is a well-defined market for operating (short-term) leases for most aircraft
types, one can use the average monthly lease rate as a good proxy for the benefit or cost over a
defined period of time.
By necessity, the operating cost data presented in this chapter represent average costs.
Cost categories such as ownership costs are reported separately so they can be included or
excluded in a specific analysis. However, economists typically look at the concept of incremental
costs (i.e., the changes in costs from small changes in levels of activity). Incremental costs may
1
Some analysts assume that crew costs are fixed in the short run; this is especially the case for entities that operate
one or a small number of aircraft.
The U.S. airline industry has undergone considerable restructuring since the previous
Economic Values report was published in 2007. The recession of 2007-2009 resulted in
substantially reduced demand for air travel, while the price of jet fuel simultaneously increased
to near-record levels. U.S. airlines sustained billions of dollars in losses, resulting in
bankruptcies, consolidation and widespread changes in operating practices.
U.S. airlines reduced capacity, retired fuel-inefficient aircraft types and have maintained
a sharp focus on profitability. A small number of major carriers now provide the majority of
airline service in the country, although a number of ultra-low-cost carriers have developed that
focus on point to point service with fares and costs substantially less than the major carriers.
Because the Form 41 data represent aggregations across the industry, reported costs may not
accurately depict actual costs for individual carriers.
Table 4-1 shows direct and indirect operating expenses for Group III air carriers.2 As can
be seen, direct costs are about 52 percent of total costs for major passenger air carriers and about
43 percent of total costs for all-cargo air carriers. The direct costs will be examined in more
detail later in this chapter. However, this table provides a perspective on overall carrier costs and
the relative magnitudes of each category of costs. Industry costs for carriers filing Schedule P-7
of Form 41 totaled $145.3 billion for passenger air carriers and $32.9 billion for all-cargo air
carriers in 2013. Overall, the average total operating cost per block hour for passenger air
carriers was $9,099 and the average cost for all-cargo air carriers was $25,820 in 2013.
2
Group III air carriers are those with annual revenues of more than $1 billion; direct and indirect costs are
categories used on Schedule P.7 of Form 41.
Table 4-2 shows air carrier costs per block hour by operating expense grouping.3 These
data are divided into passenger and all-cargo carriers and then into air carrier groups, as defined
by DOT based on total annual operating revenue.4 In general, all-cargo carriers have higher total
block hour costs than passenger carriers. As can be seen, transport-related expenses are a large
proportion of total costs for Group III carriers.
3
The block hour data in Tables 4-1 and 4-2 are not directly comparable because Table 4-1 contains only Group III
carriers, while Table 4-2 contains Group I, II and III carriers.
4
Group III carriers have annual revenues of more than $1 billion; Group II carriers have annual revenues of more
than $100 million; Group I carriers have annual revenues of less than $100 million.
Cost data for air carriers were derived from Bureau of Transportation Statistics (BTS)
Form 41 data. The air carrier sub-groupings are based on the reporting requirements of 14 CFR
Part 241, which prescribe reporting requirements for large certificated air carriers.5 In some
years, there could be additional air carrier groups for Part 135 carriers that are required to report
financial and traffic data per 14 CFR Part 241. However, in 2013, no Part 135 carriers were
required to report.6
5
Large certificated air carriers hold Certificates of Public Convenience and Necessity issued by the U.S. Department
of Transportation authorizing the performance of air transportation with annual operating revenues of $20 million or
more.
6
One carrier that filed Schedule P-5.1 holds joint Part 121 and Part 135 operating authority.
For air carriers filing Schedule P-5.2, variable costs are categorized as fuel and oil,
maintenance, and crew. Fixed costs are categorized as depreciation, rentals, insurance, and other.
Most of the cost categories are comprised of multiple items from Form 41 Schedule P-5.2. The
composition of the cost categories is shown in Table 4-3.
7
Carrier groups II and III; large certificated air carriers with total annual operating revenues of $100 million or
more.
8
Carrier Group I: Total annual operating revenues of less than $100 million.
Air carriers filing Schedule P-5.1 are not required to report aircraft operating costs in as
much detail as air carriers filing Schedule P-5.2. Variable costs are categorized as fuel and oil,
maintenance, and crew. The only fixed cost category is depreciation, which includes rentals. The
other category includes all other costs associated with flying operations and may contain both
variable and fixed costs. Table 4-4 shows the relationship of Schedule P-5.1 cost items to the
cost categories used in this report.
Table 4-5 shows aggregate average aircraft operating cost per block hour and activity
data for air carriers filing Schedules P-5.2 and P-5.1 in 2013. Carriers that filed Schedule P-5.1
represented a very small proportion of the air carrier industry.
Block hours are the common industry measure for presenting operating cost data and are
used in this report. Tables are also provided on the APO website for costs broken down by
airborne hours. Analysts using the data need to identify the appropriate value, block or airborne
hours. (Section 6 discusses cost by phase of flight, which divides elapsed block times into
component flight segments.) Variable costs include all aircraft operating cost elements, except
rentals, depreciation and insurance. This provides an industry-wide perspective for passenger and
all-cargo operators combined.
Table 4-6 summarizes variable and fixed costs per block hour for Part 121 passenger air
carriers that filed Schedule P-5.2. Total operating costs averaged $4,289 per block hour while
variable costs averaged $3,764 per block hour. Variable costs accounted for an average of 88
percent of total costs. Narrow-body aircraft with 160 seats and accounted for nearly one-half of
activity, measured in block hours.
Table 4-6: 2013 Part 121 Passenger Air Carriers Filing Schedule P-5.2 Operating and
Fixed Costs per Block Hour
Col. 11
Cost per Block Hour
Aircraft Category Col. 1 Col. 2 Col. 3 Col. 4 Col. 5 Col. 6 Col. 7 Col. 8 Col. 9 Col. 10 Block
Fuel Total Total Hours
and Oil Maintenance Crew Variable Depreciation Rentals Insurance Other Fixed Total
Wide-body more than 300 seats $10,275 $1,687 $1,538 $13,500 $761 $318 $9 $5 $1,093 $14,592 191,834
Wide-body 300 seats and below $5,719 $1,343 $1,174 $8,236 $522 $328 $10 $6 $867 $9,103 2,006,089
Narrow-body more than 160 seats $3,102 $964 $777 $4,843 $352 $199 $6 $1 $558 $5,400 2,260,009
Narrow-body 160 seats and below $2,394 $715 $724 $3,833 $221 $325 $9 $3 $558 $4,390 8,959,309
RJ more than 60 seats $287 $444 $349 $1,080 $144 $188 $6 $5 $344 $1,424 2,156,423
RJ 60 seats and below $145 $468 $379 $993 $59 $179 $6 $3 $248 $1,240 2,596,269
Turboprop more than 60 seats NR $654 $323 $1,020 $264 $155 $3 $2 $423 $1,443 210,338
Turboprop 20-60 seats $310 $250 $258 $818 $265 $107 $0 $9 $382 $1,200 112,295
Turboprop under 20 seats (Part 23) $1,050 $175 $850 $2,075 $0 $479 $241 $167 $888 $2,962 4,605
All Aircraft $2,322 $754 $688 $3,764 $244 $270 $8 $4 $526 $4,289 18,497,171
Source: 2013 Form 41 Schedule P-5.2 financial data and Schedule T-100 traffic data
NR: Reported data not reliable
Col 1: Fuel and Oil Costs (see Table 4-3) divided by total block hours
Col 2: Maintenance Costs (see Table 4-3) divided by total block hours
Col 3: Crew Costs (see Table 4-3) divided by total block hours
Col 4: Columns 1 + 2 + 3
Col 5: Depreciation Costs (see Table 4-3) divided by total block hours
Col 6: Rental Costs (see Table 4-3) divided by total block hours
Col 7: Insurance Costs (see Table 4-3) divided by total block hours
Col 8: Other Costs (see Table 4-3) divided by total block hours
Col 9: Columns 5 + 6 + 7 + 8
Col 10: Columns 4 + 9
Col 11: Total block hours reported on Schedule T-100
Table 4-7 reports operating cost data for Part 121 all-cargo air carriers filing Schedule P-
5.2. Total operating costs averaged $11,104 per block hour while variable costs averaged $8,889
per block hour. Variable costs accounted for an average of 80 percent of total costs. Wide-body
aircraft accounted for nearly 80 percent of activity, measured in block hours.
4.2.2. Part 121 Passenger and All-Cargo Air Carriers Filing Schedule P-5.1
Cost Per Block Hour
Table 4-8 presents operating cost per block hour data for Part 121 passenger air carriers
filing Schedule P-5.1. These carriers report in a different format than the carriers that file
Schedule P-5.2. The composition of the “other” category is unknown, so it cannot be classified
as either variable or fixed costs. The average total cost per block hour was $3,111, while the
variable cost per block hour was $2,525.
Table 4-9 presents similar data for Part 121 all-cargo air carriers filing Schedule P-5.1.
The average total aircraft cost per block hour was $6,017, while the average variable cost per
block hour was $4,880. Narrow-body aircraft with the equivalent of 160 seats and below
comprised nearly one-half of the total block hours.
The source for the variable and fixed operating costs for general aviation aircraft was The
Aircraft Cost Evaluator, published by Conklin & de Decker.9 Costs assume an operator of one or
two aircraft of a given model, and do not reflect lower prices which may be available through
bulk purchases. The following variable cost categories were obtained from The Aircraft Cost
Evaluator for use in this study:
9
Conklin & de Decker, The Aircraft Cost Evaluator (Orleans, MA, 2014. Version 14.2.0).
10
Aviation fuel prices have shown unusual volatility during the past few years. The fuel price survey was conducted
near the peak of prices in early 2014. Users may wish to adjust the Fuel & Oil cost element to match prices observed
at another time. For example, if a user wanted to base operating costs on avgas at $6 per gallon, he could multiply
the Fuel & Oil cost element for a piston Economic Values Category by ($6 / $8.01) = 0.749.
Maintenance labor costs represent the average cost of routine, scheduled, and
unscheduled maintenance labor. Labor hours are based on data from operator experience,
manufacturer's data and surveys. Crew salaries are derived for each aircraft type from a
recognized pilot salary survey, and benefits are typically an additional 30 percent of wages.
Salaries are counted for the entire crew, which depending on the aircraft type can consist of a
captain, copilot and flight engineer. Crew salaries and benefits are divided by Conklin & de
Decker’s estimated annual flight hours for that model in order to obtain hourly crew costs. The
Aircraft Cost Evaluator also provided the following fixed costs:
Hangar Rental
Insurance
Hull
Single Limit Liability
Miscellaneous Overhead
Recurrent Training
Aircraft Modernization
Navigation Chart Services
Refurbishing
Computerized Maintenance Management Program
Weather Service
Other Fixed Cost
Fractional Cost/Year + Tax
The Aircraft Cost Evaluator provides different cost categories based on the type
of operation for which an aircraft is used. It was assumed that piston and turboprops (categories
1-8) are used in business operations; turbojets (categories 9-11) are used in corporate operations;
piston engine rotorcraft (categories 12 and 14) are used in utility operations; and turbine
rotorcraft engine (categories 13 and 15) are used in commercial operations. Business operating
11
Conklin & de Decker classify crew costs as fixed in The Aircraft Cost Evaluator. As noted earlier in this section,
whether crew costs are best considered fixed or variable depends on the nature of the operation and the employment
arrangements. GRA converted annual salary and benefit costs to an hourly rate by dividing them by C & D’s
utilization rate (annual hours flown), on a per-model basis.
All piston engine and turboprop airplanes for which air taxi hours are a small percentage
of total hours flown (i.e., all piston and turboprop airplanes with fewer than 10 seats—see Table
3-13) use an hourly crew cost equal to the value of Intercity Business air travel time, or $60.0012
per hour. Air taxi hours are also a small percentage of total hours flown for piston rotorcraft.
Therefore, it was assumed that the crew cost per hour equals the value of time ($60.00).
4.3.2. Depreciation
Jets: 4%
Rotorcraft: 5%
Turboprops and Pistons: 6%
Table 4-10 summarizes general aviation aircraft operating cost per flight hour by each of
the economic values categories. While the average total cost per hour is about $1,600, it ranges
from about $300 per hour to over $10,000 per hour, depending on the size, complexity and age
of the aircraft within each group. Average variable costs per hour including flight crews are
$1,098, while they are $903 per hour if crew costs are not counted.
12
DOT, Office of Economic and Strategic Analysis, Revised Departmental Guidance on Valuation of Travel Time
in Economic Analysis (Washington, DC, July 9, 2014).
For each aircraft, multiply its operating cost elements (Columns 1, 2, 3, 6, 7 and 10 in
Table 4-10) by the number of hours it operated under uses corresponding to each of the
operating rule parts.
Sum these products by Economic Values Category, producing a single value for each cost
element, for each operating rule part.
Divide these sums by the total hours flown by aircraft in that Economic Values Category
under that operating rule part.
That is, for each operating rule part, the mean of a cost element is calculated reflecting only the
hours flown under that rule part, not all hours flown by all aircraft. If flights under an operating
rule part are conducted disproportionately by aircraft with higher operating costs within an
Economic Values Category, the costs under that rule part in Table 4-11 will be higher than the
overall costs for that Category shown in Table 4-10.
Table 4-12 presents operating costs for fractionally owned aircraft. The General Aviation
Survey results for 2013 were used to identify the fractionally owned aircraft. The Aircraft Cost
Evaluator from Conklin & de Decker was then used as a source of operating cost data for aircraft
types identified as fractionally owned through the GA Survey. Operating costs for fractional
aircraft were weighted by the number of fractional aircraft in order to arrive at average operating
costs by economic values category as well as for all fractionally owned aircraft.
Operating costs for fractionally owned aircraft are not directly comparable to those of
other general aviation aircraft because the Conklin & de Decker data, as can be seen in Table 4-
12, do not include the operating cost components (i.e., fuel, maintenance, etc.,) only the total
hourly variable operating costs. In addition, costs in Aircraft Cost Evaluator are reported by
fractional ownership provider and fractional ownership share. A single fractional ownership
provider was chosen to represent all aircraft in those aircraft types offered by more than one
provider because costs do not differ significantly between the different providers of services of
the same aircraft type. The hourly operating costs reported in Table 4-12 assume quarter share
ownership and no depreciation. Average total operating costs per hour for all fractionally owned
aircraft are higher than those of general aviation aircraft.
Data on military aircraft operating costs were developed in consultation with the various
branches of the armed services. Available data were obtained both from public websites as well
as telephone interviews with appropriate DOD and FAA personnel. In general, the values were
applied on an aircraft-type-by-aircraft type basis where there were cost observations from at least
one military air service. In cases where there were no observed costs for a specific aircraft type,
the group average was applied. In the table below, the average weighted total is based on the
hourly weighted operating costs of each aircraft type.
The cost data were taken from data on aircraft reimbursement rates for various types of
aircraft.13 Reimbursement rates are reported for four categories of users: DOD, Federal Agency,
Foreign Military Sales Users, and All Other Users. This report uses the all other category
because it is the most complete cost metric. The aircraft operating costs include crews and reflect
the varying sizes of crews for a specific aircraft. For example, most military rotary wing aircraft
operate with a pilot, co-pilot and one or two other crew members. Some of the larger turbojet
aircraft with three or more engines conduct electronic surveillance operations and have large on-
board crews. The crew costs reported in Table 4-13 reflect this. In addition to crew cost, the
reimbursement costs include operations and maintenance costs and an asset utilization factor.14
The asset utilization factor includes an allocation of healthcare costs for military personnel.
DOD does not include an element of ownership costs in the reimbursement rates. Asset
valuation for DOD aircraft is extremely complex because the assets are long lived and have had
many major upgrades over the useful life. For example the Boeing B-52 has been in operation by
the military service since 1954, approximately 60 years. It has had upgrades to its engines,
avionics, weapons systems and offensive and defensive electronic systems.15 Aircraft
replacement costs are described in Section 5.
13
DOD, Office of the Undersecretary of Defense, Fiscal Year (FY) 2014 Department of Defense (DoD) Fixed Wing
and Helicopter Reimbursement Rates. Accessed February 12, 2015,
http://comptroller.defense.gov/Portals/45/documents/rates/fy2014/2014_f_h.pdf; DOD, Office of the Undersecretary
of Defense, Comptroller, “Collections for Reimbursements of DoD-Owned Aircraft (Rotary Wing),” in Financial
Management Regulation, Volume 11A: Reimbursable Operations Policy. DoD 7000.14-R, Chapter 6, Appendix G.
Accessed February 12, 2015, http://comptroller.defense.gov/Portals/45/documents/fmr/Volume_11a.pdf.
14
The asset utilization factor is 4 percent times the sum of costs for: fuel, depot level repairables, depot
maintenance, other and crew salary for each specific aircraft.
15
Boeing B-52. Accessed March 23, 2015, http://www.boeing.com/defense/b-52-bomber/.