(MILAN) Air India’s Milan–Delhi service, Flight AI138, was cancelled on August 16, 2025, after a maintenance issue was detected during pushback at Milan Malpensa Airport. The flight, operated by a Boeing 787 Dreamliner, became the latest disruption tied to the carrier’s ongoing reliability problems and a year of heightened oversight for the 787 fleet in India. Air India said affected travelers could receive full refunds or complimentary rescheduling, in line with its disruption policy.
The airline has not issued a detailed public statement specific to the Milan–Delhi cancellation as of August 18, 2025, though the incident has been widely reported in Indian and aviation media. According to Air India, standard rebooking and refund procedures are underway, and customer support teams have been deployed to assist stranded passengers.
This Milan cancellation follows a recent Zurich–Delhi cancellation linked to a technical snag and an aborted take-off in Kochi on August 17, 2025, underscoring strain on Air India’s Boeing 787 operations. Each case has added pressure on operations and drawn fresh attention from India’s aviation regulator.
Regulatory checks and fleet overhaul in 2025
India’s Directorate General of Civil Aviation (DGCA) ordered one-time, comprehensive safety checks on all Indian-operated Boeing 787s after a fatal Dreamliner crash in Ahmedabad in June 2025.
Key points of the DGCA directive (issued June 15, 2025):
– Inspections cover fuel parameter systems, cabin air diagnostics, electronic engine controls, hydraulic systems, and take-off parameters for 787-8 and 787-9 aircraft.
– As of mid-June, Air India had completed checks on 9 of its 33 Boeing 787s, with the remainder on a strict inspection timeline.
– The DGCA will maintain tight surveillance during this period.
The regulator’s official portal: https://dgca.gov.in/.
Alongside regulatory checks, Air India launched a $400 million retrofit and reliability enhancement program in July 2025 for its legacy 787-8 fleet.
Retrofit program highlights:
– The first aircraft in the program, VT-ANT, was ferried to Boeing’s Victorville facility in California in July 2025.
– A second airframe is set to enter the line in October 2025.
– Both are expected to return to service by December 2025.
– Upgrades include new three-class cabins, upgraded inflight entertainment, new seats, and critical avionics upgrades to reduce technical interruptions and improve onboard experience.
Maintenance schedule and capacity impacts:
– Seven of the carrier’s 26 legacy 787-8s will undergo heavy scheduled maintenance (D-checks), which take aircraft out of service for weeks.
– While this work aims to increase long-term reliability, it reduces short-term available capacity—one reason some long-haul routes are under review.
– Air India’s 787-8 fleet averages nearly 11 years in age, with the oldest delivered in September 2012.
Fleet renewal context:
– The Tata Group, which took control of Air India in January 2022, inherited an aging widebody fleet with patchy reliability.
– Under its five-year transformation plan, Vihaan.AI, the airline has committed to large investments in safety, reliability, and customer service.
– Orders include 470 new aircraft (250 Airbus, 220 Boeing), with deliveries and integration ongoing through 2025 and beyond.
Operational consequences:
– Removal of aircraft for checks and retrofits has led to route suspensions, including the Delhi–Washington nonstop from September 2025.
– Analysis by VisaVerge.com suggests the combined impact of safety checks, heavy maintenance, and cabin upgrades will likely cause more short-term schedule adjustments, but aim for a more stable long-haul network in the medium term.
Regulatory and passenger responses:
– Civil Aviation Minister Ram Mohan Naidu stressed that safety remains the top priority as investigations continue into the June crash and recurring technical issues.
– Regulators have increased audits and data reviews to track 787 performance.
– Passenger groups have urged clearer communication and faster compensation processing when flights are cancelled on short notice.
What passengers on Flight AI138 can do now
Air India says passengers affected by the Milan–Delhi cancellation can choose a refund or a complimentary rebooking. The airline also urges travelers to check flight status updates frequently, as further delays or cancellations may occur while safety checks and maintenance progress.
Practical steps for those booked on Flight AI138:
1. Contact Air India’s customer care for disruption assistance:
– +91 116 932 9333 (India)
– +91 116 932 9999 (India)
2. Use the AI.g virtual agent for 24/7 rebooking and status help.
3. Monitor airline alerts and travel advisories:
– Air India’s Newsroom and Travel Alerts page: https://www.airindia.com/in/en/news-update.html
4. If moved to a later flight, keep your updated itinerary and any messages from the airline for reference at the airport.
Important operational caveats:
– Rebooking options depend on seat availability across the network, which is under strain while multiple 787s are in maintenance or retrofit.
– Travelers with time-sensitive plans should reach out to the call center or visit the airline’s website to explore the earliest possible alternatives.
Timeline and expectations for the retrofit program
- The first two upgraded 787-8s are slated to rejoin the fleet in December 2025.
- The full 787-8 retrofit program is planned to run through mid-2027.
- Reliability upgrades will continue in parallel with D-checks, with the goal of reducing technical snags and last-minute cancellations over time.
Aviation analysts attribute the recent wave of technical incidents to:
– A mix of fleet age, intense utilization, and fewer spare aircraft while heavy maintenance is in progress.
– During such periods, even routine glitches can cause outsized network effects, particularly on long-haul sectors with tight aircraft rotations.
Air India has said it will press ahead with both safety checks and cabin upgrades, betting that short-term disruptions will yield a steadier, more comfortable product for travelers in the future.
For now, the Milan–Delhi cancellation serves as a reminder that the airline’s recovery is still in motion. Air India has apologized to affected customers and continues to process refunds and no-fee rebookings for Flight AI138. Passengers should expect customer care lines to be busy during peak hours and are encouraged to use digital channels when possible.
More details on the widebody retrofit program are available on Air India’s site: https://www.airindia.com/in/en/newsroom/articles/Air-India-commences-widebody-retrofit-programme.html.
If the planned upgrades and inspections stay on schedule, the Boeing 787 fleet that connects India with Europe may see fewer cancellations like the one in Milan as 2025 closes and more refurbished aircraft return to service.
This Article in a Nutshell
Flight AI138’s August 16 cancellation highlights Air India’s 787 reliability strain after DGCA inspections and a $400 million retrofit program aiming to restore service. Affected passengers receive refunds or complimentary rebooking; retrofit and D-checks reduce short-term capacity but target fewer disruptions by late 2025 and beyond.
