AOG logistics costs reflect the premium nature of emergency services in aviation, where speed takes priority over economy. Understanding these costs helps explain why airlines invest heavily in inventory management and predictive maintenance to avoid AOG situations whenever possible.

Next Flight Out (NFO) services typically cost 5-10 times more than standard air freight, with prices ranging from $15-50 per kilogram depending on the destination, urgency, and size of the shipment. A small electronic component weighing 2 kilograms might cost $100-300 to ship via NFO within Europe, while the same shipment to Asia could cost $500-1,500. These prices include expedited handling fees, priority booking charges, and 24/7 service premiums.

On Board Courier (OBC) services command much higher rates, often costing $5,000-15,000 for European deliveries and $10,000-30,000 for intercontinental shipments. These costs cover the courier’s salary, flight tickets, accommodation if overnight stays are required, customs handling fees, and insurance for high-value parts. While expensive, OBC becomes cost-effective when considering that a grounded wide-body aircraft can cost an airline $50,000-100,000 per day in lost revenue and operational expenses.

Emergency road transport within Europe offers a middle ground, typically costing $3-8 per kilometer plus time-based charges for the driver and vehicle. A Frankfurt to Munich delivery (approximately 400 kilometers) might cost $2,000-4,000 including fuel, tolls, driver costs, and expedited service premiums. Road transport becomes particularly attractive for heavy or oversized parts that would be extremely expensive to ship by air.

Cost perspective: While AOG logistics appears expensive, it’s important to compare these costs against the alternative. A single cancelled long-haul flight can cost an airline $100,000-500,000 in lost revenue, passenger compensation, rebooking costs, and reputation damage. From this perspective, spending $10,000-20,000 on emergency parts delivery often represents significant savings.