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1.2014 January/FebruaryThe Lufthansa Technik Group Magazine
Component loan, exchange and sale
Availability around the clockNew aircraft services
Spot landing for 787 services
Lufthansa Technical Training
Hands-on MRO experience
Regional markets
Reliable partner in the Middle East
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2 | Content
Lufthansa Technik Connection is a complimentary information
service for Lufthansa Techniks family and friends. Published every
two months. This and earlier issues can be downloaded from our
websitewww.lufthansa-technik.com/connection
Publisher Lufthansa Technik AG Tilman Tesseraux Marketing &
Sales HAM TS/M Weg beim Jger 193 22335 Hamburg, Germany Infoline
+49-40-5070-5553 Fax +49-40-5070-8860 [email protected]
www.lufthansa-technik.com
Editorial Production Editorial office: Flightlines,
HamburgDesign: Art Works! Werbeagentur, HamburgPhotos: Lufthansa
Technik AG, Lufthansa AG Printing: Beisner Druck GmbH & Co.
KG
Lufthansa Technik Connection 1.2014
Technical Training Erfurt training center: 4 Hands-on MRO
experience InterviewwithAndreasKaden: 6 A fantastic training
environment
eServices manage/m: Plug & Play 7
Component Services SingleComponentAvailability: 8 Fast, flexible
and available worldwide! InterviewwithIsabellAmann: 10 Quality and
reliabilityRepairTechnology: 21 The meaning of SMART
Aircraft Services StarFlyer: 11 Lease return and more
Maintenance & Engineering: 20 15 years of cooperation with
MIATAircraftEngineeringServices: 25 Strong focus on SCAMT
Employee Portrait Jana Ludwig: 12 Taking off into the world of
MRO
New AircraftBoeing787: 16 Spot landing for the Dreamliner
Technology & Innovation Landing gear components: 14
Precision coupled with reliability Integratedbushingproduction
18
Engine ServicesAcousticpanels: 24 Quiet,
please!LaboratoryServices: 25 Oil filter analysis for CFM56
Events & Exhibitions Dubai Airshow: Reliable partner in the
Middle East 26
Categories News 3, 4 Events & Exhibitions 26 Products &
Services 28 Contacts 30
21
Hands-on MRO experiencePractical experience in an approved EASA
Part-145 training environment is now on offer at the Erfurt
training center of Lufthansa Technical Training.
4
The meaning of SMARTSRU Manufacturing and Repair Technology is
dedicated
to developing andperforming new repairs.
Availability around the clockSingle Component Availability (SCA)
is Lufthansa Technik redesigned
portfolio for the loan, exchange and sale of components.
8Spot landing for 787 servicesLufthansa Techniks expanded
portfolio of Boeing 787 services is valued by more and more
customers.
16
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Lufthansa Technik Connection 1.2014 News | 3
Boeing 777F phase-inLufthansa Technik Maintenance International
// At the end of 2013, Luft-hansa Technik Maintenance International
(LTMI) together with its customer, Lufthansa Cargo (LCAG),
officially welcomed the first member of the new Boeing 777F fleet,
which has been named Good Day, USA, in Frankfurt. To ensure that
the phase-in proceeds smoothly, the LTMI colleagues have been
working on the entry into service of the new fleet, which will
number five aircraft, since October 2012 on a joint project
involving several different de-partments. Thus, for example, the
dock has been remodelled, em-ployees trained and over a million
euros has been invested in tool-ing and operating resources. //
Support for 787 nacellesContract with UTC Aerospace Systems //
Lufthansa Technik and UTC Aero-space Systems have signed a
long-term contract to provide rotable provisioning and MRO services
for Boeing 787 nacelle components designed and manufac-tured by UTC
Aerospace Systems Aerostructures business. Heike Hartmann, Director
of Lufthansa Techniks Airframe Related Component (ARC) business
unit (photo left), said: This agreement is a further milestone for
our roadmap to estab-lish Lufthansa Technik as one of the leading
MRO providers for the new Boeing 787 program. Lufthansa Technik now
offers its customers the full spectrum of life cycle support
services for Boeing 787 nacelles on both General Electric and
Rolls-Royce engine nacelles. Such services include sophisticated
high-tech repairs and modifications, lease and exchange of nacelle
components and on-site repairs around the world to quickly resolve
aircraft on ground situations. //
Boeing 767 fleet overhaul Ameco Beijing // Ameco Beijing and
Business Air have signed a three-year contract for the airlines
entire Boeing 767 fleet overhaul. The first layover starts in
January 2014. The cooperation between Ameco and Business Air
started in September 2012. Ameco has provided Business Air with
Boeing 767 airframe overhaul and PW4000 engine leasing and overhaul
services. //
Support and training for Arik AirPartnership // Lufthansa
Technik and Nigerias Arik Air, the largest airline in western
Africa, are expanding their partnership in the technical care of
the airlines fleet. The cooperation between the two companies,
which has existed since the airline began operations in 2006, has
now been expanded as part of a Total Operational Management (TOM)
contract and extended by six years. By this extended and expanded
contract, we signal to both our travelling customers and the
aviation community at large our resolute determination to continue
underpinning our operations with world-leading serviceability
protocols available only through a select cadre of maintenance
providers. Lufthansa Technik enjoys a place of prominence within
this distinguished group and, as such, Arik Air is proud to
continue building upon our successful partnership, said Dr. Michael
Arumemi-Ikhide, Group CEO and President at Arik Air. //
Norwegian Air Shuttle extends contractBoeing 737 // Norwegian
Air Shuttle and Lufthansa Technik have extended the current wheels
& brakes services contract for the airlines Boeing 737 fleet.
The new contract also covers pooling and home-base lease services
for the carriers growing Boeing 737-800 fleet currently comprising
69 aircraft. In the past we have made good experi-ence with
Lufthansa Techniks support and they facilitate Norwegians sustained
growth. Thats the reason why we have decided to continue and even
expand the contract for wheels & brakes services with Lufthansa
Technik, said Asgeir Nyseth, Chief Operating Officer of Norwegian
Air Shuttle. Wolfgang Weynell, Vice President Marketing & Sales
at Lufthansa Technik, commented: Over the past years our two
companies have established a very close relationship. This latest
contract is a great proof that our success story will continue. We
will do our best to remain Norwegian Air Shuttles preferred
technical partner. //
Contract signing (from left): CEO Dr. Michael Arumemi- Ikhide
and Chairman Sir Joseph Arumemi-Johnson of Arik Air, Senior Vice
President Marketing & Sales of Lufthansa Technik Walter Heerdt
and Altfried Nessel, CCO of Lufthansa Technik Maintenance
International.
Paul Snyder, Vice President of Customer Service for UTC
Aerospace Systems Aircraft Systems segment (center), with Heike
Hartmann and Dr. Gunther Kruse from Lufthansa Technik.
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Lufthansa Technik Connection 1.20144 | News
The only thing we cant do is fly, says Andreas Kaden, Managing
Director of Lufthansa Technical Training (LTT), and sums up the
unique offering of the com-panys training center in Erfurt,
Germany. Here, a Boeing 737 is available to the course participants
as a real-life learning object, with all the associated manuals,
jobcards, tools and resources. Customers work in pro-fessionally
equipped workshops with specialist tools and materials for the
aerospace indus-try. Maintenance and repair tasks specially
designed for the trainees and individual supervision ensure the
acquisition of practical skills. Experts with appropriate EASA
Part-66 CAT B licenses supervise the course partici-pants during
their practical assignments.
EASA Part-145 environment in Erfurt.
SAA continues cooperationTES for CFM56-7B engines // South
African Airways (SAA) and Lufthansa Technik are continuing their
cooperation in the area of engine overhaul. A contract to provide
support services for the 23 CFM56-7B engines in SAAs Boeing 737-800
fleet that has been in place since 2001 has been extended and will
now continue until the aircraft are taken out of service. Under the
terms of the Total Engine Support (TES) contract Lufthansa Technik
not only overhauls the engines. The company also guarantees the
continuous availability of the highly flexible Airline Support
Teams AST. //
Engine support for Pakistan InternationalPW4000, PW127 //
Lufthansa Technik and Pakistan International Airlines (PIA) signed
a comprehensive engine support contract. The German company will
look after the Pratt & Whitney PW4000 engines of the six Airbus
A310s in PIAs fleet. Signed at the Dubai Airshow by Samin Uddin
Naqvi, PIAs Director Engi-neering and Maintenance (left), and
Walter Heerdt,
Senior Vice President Marketing & Sales Lufthansa Technik,
the contract covers spare engine support, engineering services,
logistics and repair and overhaul. The new partner-ship follows the
recent signing of a three-year contract covering technical services
for the Pratt & Whitney Canada PW127 engines in PIAs fleet of
six ATR42 turboprop aircraft, to be provided by Lufthansa Techniks
subsidiary Lufthansa Technik AERO Alzey. The first engine is
currently undergoing overhaul. //
Lufthansa honors Father of the 747Joe Sutter // Boeing engineer
Joe Sutter (92) changed aviation history when he spearheaded the
design and development of the worlds first Jumbo Jet, the Boeing
747, more than 40 years ago. In honor of his dedication to aviation
and long-stand-ing partnership with Lufthansa, the airline
presented him with the Lufthansa Lifetime Achievement in Excellence
Award and an honorary certificate signed by the Executive Board of
the Lufthansa Group. Sutter is the first person ever to receive
this award.
Joe Sutter is a true pioneer in our industry and his ingenuity
has been integral to Lufthansas successful 50-plus year partnership
with Boeing, said Nico Buchholz, Lufthansas Executive Vice
President Fleet Management, who presented the award on behalf of
the Lufthansa Executive Board. //
Cooperation with Spirit AeroSystemsThrust reverser services //
Lufthansa Technik and Spirit AeroSystems, Inc. have entered into a
cooperation agreement related to the joint provision of repair,
overhaul and supply services for the CFM56-7B and GE90-94/-115
thrust reversers and cowl-ings. Under this agreement, Lufthansa
Technik and Spirit AeroSystems will utilize each others repair
facilities and capabilities in the Europe, Middle east and Africa
(EMEA) region as well as other support elements for each companys
respective repair and overhaul services. We are looking forward to
working closely together with one of the worlds largest designers
and manufacturers of thrust reversers and cowlings, said Heike
Hartmann, Director of Lufthansa Techniks Airframe Related Component
(ARC) business unit. //
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Lufthansa Technik Connection 1.2014 New Aircraft | 5
Just recently, the German Federal Aviation Office (LBA) approved
the Erfurt training center as a learning environment in accor-dance
with EASA Part-145. As a result, Lufthansa Technical Training can
now offer customers a practical program lasting up to three months
(minimum participation period is one month and the courses start at
the beginning of each month), which is sub-sequently certified as
counting towards the practical experience requirements of the
European Aviation Safety Agency.
In Erfurt Lufthansa Technical Training provides students with
high-quality training for their future activities as approved
air-craft mechanics in a fault-tolerant working environment: from
simple maintenance tasks such as a brake or wheel change to
more complex jobs such as working on control mechanisms or fault
rectification. The practical experience gained is certified on LBA
form 19.2, which has to be submit-ted to the LBA by the aircraft
mechanic or avionics technician when applying for a Category A or
Category B Aircraft Mainte-nance License (AML).
As Andreas Kaden points out: Lufthansa Technical Training is the
only training pro-vider in Germany that offers participants their
own EASA Part-145 training environ-ment and is now also able to
certify practical experience of up to three months according to
statutory requirements. In the near future we would like to
gradually expand our capa-bilities to allow the entire practical
experience section to be carried out at our own training
Hands-on MRO experience Practical experience in a German Federal
Aviation Office (LBA) approved EASA Part-145
environment is now on offer at the Erfurt training center of the
Lufthansa Technik Groups
training specialist for the MRO industry.
center. International customers in particular can benefit
greatly from this because often they dont have an employment
agreement with maintenance organizations.
Jens Lange, Product Manager of Basic Training at Lufthansa
Technical Training, says: We very often have customers requesting
that their staff gain maintenance experience according to EASA
regulations, so we have set the relevant training in motion in
Erfurt. This training now allows us to offer them extraordinary
flexibility as to how they gain the practical experience necessary
for obtaining an AML.
Lufthansa Technical Training Phone
[email protected]
Scan the QR code for more information.
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invested more strongly in distance learning products to enable
blended learning, which is the optimum mix of classroom
instruc-tion, distance learning and the use of new media. Were also
looking at virtual class-rooms again with the goal of minimizing
the necessity of travel for our customers.
What highlights do you see in Lufthansa Technical Trainings
portfolio, today and in the future?One important highlight is our
training cen-ter at Erfurt Airport in Germany, where weve been
offering hands-on training since 2008. Weve got a fantastic
training environment there that youll find nowhere else. In
addition to classrooms with the usual media, we have an
instructional workshop and in particular an aircraft hangar with
genuine, living aircraft and all of that at a single site. The
aircraft in particular a Boeing 737 and the tools in the hangar and
workshop are the same as you would find in a fully equipped Part
145 operation. In other words, the entire environment, the IT
landscape and the procedures are organized exactly as they would be
in a genuine maintenance organization. The only thing we cant do is
fly. And theres more: the German Federal Aviation Office
The market for technical training is fairly dynamic at the
moment. What is Lufthansa Technical Trainings current
situation?Andreas Kaden: Lufthansa Technical Training has already
undergone a transfor-mation over the last few years. We posi-tioned
ourselves to be even more up-to-date, including our training media
and content. Our portfolio of web-based train-ing courses, our
media concept for aircraft types such as the A330, A320 or A380,
and our training with 360 interactive spherical panoramas are proof
of this. Beyond that, the latest example of our ongoing adaptation
to current and future market requirements is our array of EASA
EU1149/2011-compliant training courses. Lufthansa Technical
Training provides its customers a total of 400 practical and
the-oretical EASA-approved type training courses for 17 aircraft
types as well as 50 basic courses in compliance with the new
regulations that have been in effect since August 2013. As a matter
of fact, all the relevant type training courses offered by
Lufthansa Technical Training were approved well in advance of the
statutory deadline, allowing us to offer customers a timely change
to training concepts and content in accordance with the new
regulations.
How have your customers benefited from this?One positive
secondary effect of our approach is that some courses have been
shortened and that means our custom-ers employees spend less time
away from work. That alone offers a significant eco-nomic
advantage: from the overall cost perspective of the customer, the
absence of a productive employee is much more expensive than the
mere costs of a train-ing course. Beyond that, we have also
A fantastic training environmentTraining in a realistic Part-145
environment, managed training solutions
and the development of customized training: Andreas Kaden,
Managing
Director of Lufthansa Technical Training, explains how the
company
positions itself for the future.
has approved the Erfurt training center as an EASA Part-145
environment. As a result, we are the only training provider in
Germany that can offer customers an in-house EASA Part-145
environment and can now also certify practical experience of up to
three months according to statutory require-ments. We plan to
gradually expand our capabilities in the near future to allow the
entire practical experience section to be carried out at our own
training center. International customers in particular benefit
greatly from this, because often they dont have an employment
agreement with maintenance organizations.
What support can you offer customers beyond the actual training
courses?In the future we want to offer our large cus-tomers in
particular the option of having us administer their training. That
is, we would take on all the organization, including par-ticipant
registration, travel arrangements, lodging, all the way to
documenting the results which is where there are legal requirements
to consider. This would ide-ally be managed using a web-based tool.
We already have the software environment we need to take over the
complete admin-istration of participants, including record-keeping.
Im firmly convinced that managed training solutions like these
offer custom-ers genuine added value, and we hope to be able to
offer them as of mid-2014.
But they apply primarily to regular training, the kind that
appears in course catalogs. What about customized training for
individual training needs?Its true that there is always a need for
training whose content and structure is based on very individual,
customer-specific requirements. This is why we want to immerse
ourselves more strongly this year
Lufthansa Technik Connection 1.20146 | Technical Training
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eServices | 7
in training development. We want to use our methodical and
didactic know-how to advise customers on questions regarding the
right mix of media of all kinds whether printed or web-based that
they need in their training to reach a certain level of
qualification.
What about offers for basic vocational training?To date we have
always provided basic vocational training exclusively to Lufthansa
Technik and other Lufthansa Aviation Group companies, but in the
future we also want to make this or a similar product available to
the third-party market. The German dual-study system with its mix
of vocational school and workplace is very well known beyond our
national borders, and it enables better, more practice-orient-ed
training.We have been approached increasingly by interested foreign
training providers and even foreign governments about mapping this
training model in other countries, too, and we are in a position to
do that. An example is Lufthansa Technik Philippines in Manila,
where we already do something similar. We offer basic vocational
training there in a way that is closely tied to on-site
production.
Why does it make sense for a customer to commission the training
of its own technical personnel from a specialist like Lufthansa
Technical Training?As an independent subsidiary of Lufthansa
Technik, we are well positioned to offer training in the third
party market. But the reality in the rest of the industry is often
very different. Many MRO operations train their aircraft mechanics
in-house. And because its usually the operations own productive
employees who serve as train-ers, the costs associated with
providing training are frequently not accurately assessed. If you
pull a productive employee away from his work for a week or two, he
cant earn any money for the company during that time, and the
probability is high that these losses are greater than the costs of
training procured outside the organization.
Using the mini PDL-Pad, jointly developed by Lufthansa Technik
and mbs electronic systems, data loads can be performed unattended
and up to 60 percent faster. In addition, thanks to the secure
aircraft software stor-age inside the mini PDL-Pad, the reliability
of data loads is increased. As ground times are reduced as well,
this device is a great relief for line maintenance oper-ations. The
aircraft software in question includes the navigation database,
which has to be updated in the aircraft every 28 days, i.e. at
least 13 times a year. With the new mini PDL-Pad other aircraft
software can be loaded, as well.
Similar to a tablet PC in size and shape, the handy mini PDL-Pad
is a lot smaller and lighter than the previously used carrying
case-like portable data loaders, which weigh about twelve
kilograms. Complementing features such as its handy size and
integrated capability to communicate over Ethernet, WLAN or UMTS, a
separate power cable is no longer required for operation, as the
mini PDL-Pad uses the aircraft as its power source. All these
advantages, together with the Secure USB feature, make the mini
PDL-Pad a superior portable data loader, says Matthias Fliegner,
Lufthansa Technik IT project manager, in charge of developing the
new device. The above mentioned Secure USB feature patented by
Lufthansa Technik makes the mini PDL-Pad particularly unique. This
enables us to eliminate even USB media. As a result, we save a lot
of valuable time and pro-cess costs while at the same time data
security is significantly increased, under-lines Fliegner who is
optimistic about the products future: Right now the interest in the
new mini PDL Pad is constantly rising and we hope we will be adding
many customers as users in the near future.
Lufthansa Techniks manage/m module m/modification/software is a
com-prehensive application for tracking aircraft software
configurations. The applica-tion can be used for planning aircraft
software updates as well as for reporting the software
configuration of any aircraft at any point of time. In addition to
the traditional creation and distribution of software,
m/modification provides a seam-less integration of portable data
loaders, making the use of any physical media unnecessary.
Erik Abels Phone +49-69-696-91628 [email protected]
Plug & PlayThe brand new portable data loader mini
PDL-Pad
enables any aircraft software to be transferred wirelessly
from the manage/m module m/modification/software to
the aircraft, eliminating any need for physical media.
Lufthansa Technik Connection 1.2014
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8 | Component Services Lufthansa Technik Connection 1.2014
Fast, flexible and available worldwide!
Lufthansa Technik has redesigned its portfolio for the loan,
exchange and sale of aircraft components and consolidated
these availability products into its new Single Component
Availability (SCA) product. SCA features fast availability
from
one of the biggest component pools in the world.
SCA customers can tailor Lufthansa Techniks service according to
their needs. Some customers require logistics services along with
the actual aircraft component, while others prefer to arrange their
own transport.
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Component Services | 9 Lufthansa Technik Connection 1.2014
As one of the worlds leading MRO providers, Lufthansa Technik is
ideally placed to offer component loans, exchanges and sales.
Lufthansa Techniks material pool and warehouse locations in Europe,
USA and Asia give customers access to one of the biggest
inventories of aircraft components in the world irrespective of
whether they already have a contract with Lufthansa Technik.
Lufthansa Technik is known for its high quality standards and
in-depth under-standing of the airline business, which is why our
customers are always approach-ing us for component loans and sales,
saysIsabellAmann,whoheadsuptheLufthansa Technik team dedicated to
the new product. But Single Component Availability is more than
just a new brand name; it represents our commitment to the needs of
our customers as well as to the market demand for ad-hoc component
availability. We acknowledge that aircraft operators require fast,
simple and trans-parent access to aircraft components around the
clock to and from every desti-nation around the globe.
Dedicated Sales and Loan Team
Single Component Availability (SCA) is the logical extension of
Lufthansa Techniks established portfolio of services and cus-tomer
solutions. However, a large number of SCA inquiries are triggered
by un-planned events such as AOG situations. Hence, SCA inquiries
often arrive at Lufthansa Techniks AOG Desk, where a dedicated
Sales and Loan Team manages component loans, exchanges and sales
around the clock.
Please continue on page 10
Single Component Availability SCA
// With Single Component Availability (SCA), Lufthansa Technik
makes loans, exchanges and sales of aircraft compo-nents available
on a case-by-case and non-contractual basis to every customer. The
component portfolio includes line replaceable units (LRUs) and
engine-related components for all Airbus and Boeing commercial
aircraft as well as selected regional platforms such as the
Bombardier Q400 and CRJ. //
Hot
line
+49-40-5070-4308 SCA
Hotline24/7
For more infor-mation about SCA please scan the QR code
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Lufthansa Technik Connection 1.201410 | Component Services
Isabell Amann, Team Manager Loan & Exchange, talks about the
customer benefits of Lufthansa Techniks Single Component
Availability (SCA).
Quality and reliability
Why is Lufthansa Technik so well qualified for the loan,
exchange and sale of aircraft components?Isabell Amann: To start
with, we have a material inven-tory worth more than a billion
euros, which enables us to provide non-routine components rapidly.
Were locat-ed at the heart of the operations of over 230 airlines
with more than 2,500 aircraft. This means were familiar with the
problems operators face, especially in AOG situa-tions, and were
not restricted to a single aircraft type.
What warranties does Lufthansa Technik offer for components?Were
renowned for our high level of repair and com-ponent logistics
expertise. We can offer the quality and reliability that customers
expect of components pur-chased or borrowed from us. Thats one
reason why we offer SCA components with a six months or 1,000
flight hours warranty.
Which sales channels offer operators access to SCA?In our
experience, most inquiries arrive via e-mail or phone. We
established a dedicated Sales and Loan Team number and e-mail
address, which is manned around the clock. The Sales and Loan Team
is located on the same floor as Lufthansa Technik's AOG Desk. This
ensures that inquiries are handled right away.
How is SCA represented on the online marketplace?We are already
very active on the ILS platform and we also sell components through
AeroXchange. Our inventory of components is listed on both ILS and
AeroXchange. Currently we are also testing five addi-tional online
platforms to expand our customer chan-nels. And if a part doesnt
appear online, its always worth calling or e-mailing the Sales and
Loan Team.
Isabell AmannPhone
[email protected]
Hot
line
+49-40-5070-4308 SCA
Hotline24/7
SCA customers can tailor Lufthansa Techniks service according to
their needs. Some customers require logistics services along with
the actual aircraft component, while others prefer to arrange their
own trans-port. Lufthansa Technik has an extended logistics network
and the necessary capabili-ties at its disposal to provide global
com-ponent support for every fleet size. Lufthansa Technik is
ideally positioned to add further value to Single Component
Availability through the logistics supply chain. The same applies
to the repair of unserviceable components, which customers can send
to Lufthansa Technik for repair under a Single Component
Maintenance (SCM) agreement.
Strong customer orientation
Single Component Availability benefits from more than just a
dedicated team, with the possibility of additional logistics or
component repair services. When Lufthansa Technik established the
SCA product, the internal loan, exchange and sales processes were
restructured to reflect a stronger customer orientation.
This enables Single Component Availabil-ity to deliver the
quality and responsiveness that Lufthansa Technik Component
Services isknownfor,saysIsabellAmann.
SCA Hotline
[email protected]: HAMAOLH
Customer advantages
Worldwide access to vast global component inventory Fast 24/7
availability 6 months/1,000 FH warranty occurs first High Lufthansa
Technik quality
standards Expert staffing Material listed on various
online platforms Logistic services if requested
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Lufthansa Technik Connection 1.2014 Aircraft Services | 11
Lease return and more
Japanese airline StarFlyer has expanded and extended its support
agreement with
Lufthansa Technik. The contract comprises the complete execution
of the customers
lease returns, among others.
Lufthansa Technik has been providing technical support to
StarFlyer since the airline began operating in 2006. Now StarFlyer,
which is currently operating a fleet of eleven Airbus A320
aircraft, has extended the Total Technical Support (TTS) agreement.
The integrated technical sup-port we receive from Lufthansa Technik
allows us to focus optimally on flight opera-tions, emphasized
Tatsuji Fukuro, a mem-ber of the board of StarFlyer. We are very
pleased to continue to support the growth of this successful
airline so extensively, said Dr. Johannes Bussmann, Chief
Exec-utive Human Resources, Engine & VIP Services of Lufthansa
Technik.
Total Technical Support TTS
Within the frame of the TTS contract Luft-hansa Technik provides
a wide range of technical services to Starflyer. Covered are for
example services for the engines and landing gears, an AMOS MRO
software package support as well as Lufthansa Techniks Aircraft
Production Inspection Program (APIP). As part of the contract,
for
the first time Lufthansa Technik also takes over the complete
execution and integrated support of a customers lease returns.
Early November the first aircraft had already been ferried to
Lufthansa Technik Philippines in Manila. The Airbus A320 with the
call-sign D-AAAL the aircraft has a temporary Ger-man registration
was put through a care-ful lease return check. Already at the first
day of the return work, a specialist com-posites repair (ARC) team
from Lufthansa Technik Shenzhen was in Manila to check the thrust
reversers and inlet cowls in order to avoid possible surprises
prior to the return. Ralf Schulze, Senior Sales Execu-tive, points
to a current trend in lease con-
tracts: Today, at lessors choice, most of the leasing contracts
do oblige the lessee to return an aircraft in accordance with
either EASA or FAA requirements. This means, that an operator not
flying under EASA regulations definitely requires the support of a
CAMO organization for a lease return. Luft hansa Technik is
perfectly prepared to take on such responsibilities.
The on-site presence of StarFlyer during the lease return could
be limited as the entire work is managed and performed by Lufthansa
Technik. As this issue of Connec-tion goes to print, the aircraft
will be in the hands of its owner. Two more aircraft are scheduled
for lease returns during the coming months and one more aircraft in
early 2015. Founded seven years ago with initially three Airbus
A320s, StarFlyer offers domestic service to destinations in
Japan.
Ralf SchulzePhone [email protected]
Performing a careful check, the Airbus twin jet is prepared for
return to its owner.
For the lease return work, the aircraft was ferried to Lufthansa
Technik Philippines.
For more information about ALTS please scan the QR code
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Right from the start of my studies I wanted to join Lufthansa
Technik, as I am fascinated by aviation, aircraft technology and
travel. Here I work close to the aircraft and the product, says
Jana Ludwig, explaining her decision to apply for a place as a
StartTechnik trainee. Her dream came true: she has been working at
Lufthansa Technik as a trainee for over a year now, and in this
time she has gained many impressions and contributed to the
suc-cess of projects.
On graduating from high school Jana Lud-wig studied Transport
Engineering at Dresden University of Technol-ogy. After the
interme-diate diploma she decided to specialize inAir Transport
Technology and Logistics. Her first direct contact with Lufthansa
came dur-ing an internship in Revenue Management for the Lufthansa
long-haul fleet. During a second internship she worked in process
optimization for the A380 produc-tion at aircraft manufacturer
Airbus. I real-ized during my studies and the internships that
working merely in systems engineering would not be my goal for a
later employ-ment, says Jana Ludwig. Im more inter-ested in
projects and interfaces. And I wanted to obtain a deeper
understanding of other departments.
Off to a good start with StartTechnik
On completing her diploma thesis she therefore applied for the
StartTechnik trai-nee program at Lufthansa Technik. I was attracted
by the flexibility of this program, and as a result I am seeing a
lot of the
company and, as they say, Im becoming a Lufthansa Technik
specialist, she says. During their program trainees choose four
assignments in different parts of Lufthansa Technik, which do not
necessarily all have to be connected to their former studies. I
didnt know exactly what I wanted to do career-wise. So for me its a
great opportu-nity to get to know many people, see how things are
interconnected within the com-
pany and work in different areas.
After a long selec-tion process Jana Ludwig received her
acceptance, and finally started at the company in October 2012. The
first three
weeks were spent on an introduction course involving lectures,
tours and workshop vis-its that was attended by all trainees
starting their program in 2012, with activities in Frankfurt and
Hamburg. The trainees them-selves choose where their four
assignments over the next two years will take place, receiving
support from Human Resources.
From logistics to strategy
After a theoretical thesis Jana Ludwig wanted to do something
tangible, so her first assignment was with Operations Engi-neering
at Lufthansa Technik Logistik Ser-vices, where she worked on a
project in the Aircraft Components Services depart-ment. Lufthansa
Techniks component pool warehouse was relocated to Frankfurt. This
involved a complete change to the component admission and issue
process-es, with the aim of serving customers more quickly and more
effectively in the future, Jana Ludwig explains. In a series of
pilot phases the processes were reviewed and optimized. I was
involved in the planning, preparation and implementation and as a
result I was also able to witness the results. Together with the
colleagues from the pro-duction and the project team we were able
to find the best solutions, she says enthu-siastically. It wasnt
plain sailing, but we found our way to overcome the obstacles.
On her second assignment she came to see a quite different side
of Lufthansa Technik, working in Strategy and Product
I got to know a lot of fantastic colleagues who are very
enthusiastic and totally committed to their products. Jana
Ludwig
A lot of self-initiative, mobility and flexibility is expected
of the Lufthansa Technik trainees.
12 | Employee Portrait Lufthansa Technik Connection 1.2014
Taking off into the world of MRO
Working in different departments and learning at the same time:
as a trainee at Lufthansa
Technik, Jana Ludwig is acquainting herself with different areas
and projects in the company
and is working on making the services even more attractive for
customers.
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Employee Portrait | 13 Lufthansa Technik Connection 1.2014
On graduating from high school Jana Ludwig studied Transport
Engineer-
ing at Dresden University of Technology. After the intermediate
diploma she decided to specialize in Air Transport Technology and
Logistics.
Jana Ludwig
Management in Aircraft Engineering, at Line Maintenance in
Frankfurt. I definitely want-ed to take a look at strategic
processes, as this was something I hadnt touched on at all during
my university studies, she explains. One task was to reform the way
the business units products are presented and to high-light the
benefits for customers. During my research I got to know a lot of
fantastic col-leagues who are very enthusiastic and totally
committed to their products, she says. She also carried out a
preliminary study on the IT systems in Aircraft Maintenance and
market expectations, with a view on how customers using different
IT systems can be cared for at the same service level.
Self-initiative and dedication
As well as their assignments, trainees also get involved in
other areas. They organize introduction weeks with lectures from
the senior management for specialists and engineers at Lufthansa
Technik, who by this
means get better acquainted with parts of the company outside
their immediate areas of responsibility. In this connection we meet
a lot of interesting colleagues and find out more about other areas
and products, says Jana Ludwig. The trainees also contribute with
their own experiences to the program and thus develop it further.
To date around 50 trainees have already completed the StartTechnik
program and an active alumni network has developed.
A lot of self-initiative is expected of the trainees, along with
mobility and flexibility. The subjects in the assignments are very
complex, but can be managed, says Jana Ludwig. And you get a lot in
return. In this connection she has the support of a bud-dy, a
former trainee, and a mentor from the management of Lufthansa
Technik. I meet my mentor regularly. She assists me by giv-ing
advice and she helps me with decisions and her own experience. As
far as the future is concerned, Jana Ludwig can well imagine
working in the project environment, as she
did during her first assignment. I like the exchange of
information and ideas and working closely with other people, she
says. But perhaps I will surprise myself. At the moment I have the
luxury of being able to see so many different departments and
projects. Jana Ludwig started her third assignment just recently.
This time her work took her a long way away to Lufthansa Technik
Philippines in Manila.
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14 | Technology & Innovation Lufthansa Technik Connection
1.2014
grinding machines. The accuracy required of these large
components is to a tolerance of a few hundredths of a
millimeter.
Local overheating
This grinding process poses major demands on man and machine. To
start with, it is imperative that the accuracy and surface quality
requirements are adhered to. As grinding is a very time-consuming
process, the technicians try to increase productivity
Landing gears, the legs of commer-cial aircraft, are highly
stressed during operation and are therefore built to be extremely
robust. But even they have to go into the shop to be overhauled,
normally after an operating period of around ten years. This is the
point at which, amongst other things, the anti-friction coating of
the sliding tubes is renewed. These surfaces, which are generally
implemented as a hard chrome layer, are electroplated and then
finished to the required size using special
by stepping up the rate at which metal is removed. But this
introduces the danger of local overheating, which can damage the
component. To assure the quality of the grinding process, Lufthansa
Technik has therefore set itself the goal of increasing the process
reliability during the grinding of these landing gear components.
The techno-logical groundwork for this was laid by the development
of a grinding process with inte-grated quality assurance that could
be mon-itored online. Under the Grinding project,
Precision coupled with reliability
Enhanced process reliability in connection with the grinding of
landing gear components
such was the goal of the Grinding innovation project tackled by
Lufthansa Technik
with the support of the Federal Ministry of Education and
Research (BMBF).
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Lufthansa Technik Connection 1.2014 Engine Services | 15
which was supported by the Federal Min-istry of Education and
Research (BMBF), a number of new techniques were devel-oped that
will help to systematically elimi-nate damage to work pieces during
the grinding process.
Sensor technology
To avoid overheating the component that is being ground, first
of all a suitable tem-perature sensor was developed. This sus-pends
the grinding process as soon as a critical threshold is reached,
thus avoiding damage to the landing gear component. As the
component is covered by the grinding wheel and the cooling
lubricant throughout the grinding operation, a spe-cial fiber optic
cable that measures the surface temperature of the component in
real time is used here. This technology eliminates the possibility
of the expensive landing gear parts sustaining grinding burn, which
can result in uncontrolled loss of strength.
Laser measurement system
In a further step the parameters of the grinding process were
optimized. The aim was to avoid damaging vibration during the
grinding process, which could result in surface blemishes. This
optimization made it possible to guarantee a stable and virtually
vibration-free grinding process.
The fiber optic cable is embedded in the grinding wheel.
A further outcome of the Grinding project is a laser-based
measurement system that measures the component throughout
machining. This system pre-vents the grinding disk from colliding
with the component in case the machine operator has made an error
in entering the machining parameters. Once again the effect of this
will be to improve pro-cess reliability.
Optimization of process reliability
Under the Grinding research project, which ran from January 2011
through November 2013, not only was a large volume of special
proprietary data gath-ered, but machining of the landing gear parts
was improved through optimization of the grinding parameters and
process reliability was raised. At the same time a lot of time was
saved, yet the quality of the workmanship was higher. As the
results obtained constitute unique char-acteristics, the rights to
these have been protected through several patent filings. In this
way in collaboration with the Institute of Production Management
and Technology of the Technical University of Hamburg-Harburg
Lufthansa Technik has succeeded in extending its expertise in the
grinding of landing gear compo-nents and in widening its
technological edge in the area of landing gears.
CF34-10E MRO for Air Astana
Lufthansa Technik AERO Alzey // Kazakhstan national carrier Air
Astana (KZR) has signed an exclusive-agree-ment with Lufthansa
Technik AERO Alzey (LTAA) for the provision of MRO services for the
carriers fleet of CF34-10E powered Embraer 190 aircraft. Air Astana
introduced the first of twelve planned Embraer 190 into the
regional operation in May 2011. Under the new contract Lufthansa
Technik AERO Alzey will provide maintenance, repair and overhaul
services as well as spare engine support. Following the positive
experience with our previous PW125B MRO support agreement, we
decided earlier in 2013 to extend the relationship by entering into
an exclusive engine service agree-ment for our new E-Jet fleet with
Luft-hansa Technik AERO Alzey. We have worked with the Alzey shop
since the airline started operating PW125B powered Fokker 50 in
2002 and we have found that Lufthansa Technik AERO Alzey is
delivering the service we require at very competitive prices, says
John Wainwright, Senior Vice President Engineering Group, Air
Astana. We are very pleased to continue our partnership with Air
Astana and are looking forward to supporting the airlines future
growth says Martin Hach, COO of Lufthansa Technik AERO Alzey. We
believe the achievement of this agree-ment is a result of LTAA
commitment to the regional aircraft engine market to provide the
most flexible and compre-hensive services to our customers. //
Signing ceremony (from left): Peter Foster, President Air
Astana, Martin Hach, COO, LTAA, Andreas Kehl, VP Sales &
Marketing, LTAA, and John Wainwright, SVP Engineering Group, Air
Astana.
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16 | New Aircraft Lufthansa Technik Connection 1.2014
Spot landing for the Dreamliner
Lufthansa Techniks further expanded and deepened portfolio of
Boeing 787 services
is valued by more and more customers. New services have been
added and cooperative
agreements are in place to support the entire life cycle of the
Dreamliner.
While an increasing number of air-lines are taking delivery of
their first Boeing 787s, the long sought-after aircraft that will
usher in an innovative new aircraft era, Lufthansa Technik is
further expanding the range of services it offers for the composite
airliner.
As the fleet numbers rise and operation of the 787 ceases to
have a niche status, the airlines are clearly going to need 787 MRO
services that go beyond the success-ful Total Component Support
(TCS) that Lufthansa Technik already provides to Japan Airlines and
Ethiopian Airlines. In addition to component support, one of the
most important cornerstones of reliable flight operations,
Lufthansa Technik has now added a new element to its broad spectrum
of life cycle services for the 787 the Air-craft Production
Inspection Program which supplements services such as start-up
support, line maintenance, engine change
teams, engineering support and VIP com-pletions. Meanwhile
Lufthansa Technik recently acquired two more 787 operator customers
for its TCS offering: Air Canada and TUI Travel have both signed
support contracts tailored to their individual needs. Whereas
Lufthansa Technik is set to pro-vide full component support for Air
Cana-das 787 fleet, the contract with TUI Travel focuses on the 787
engine-related compo-nents of the GEnX. These two new agree-ments
are a good example of how Lufthansa Technik has the flexibility to
adapt its com-prehensive material support services to the varying
needs of different airlines.
Customized component support
Air Canada has signed a Total Component Support contract that is
due to take effect when Boeing delivers the first 787 to Air Canada
in the first quarter of 2014. Under
the agreement, Lufthansa Technik will pro-vide Air Canada with a
wide-ranging service portfolio, including the supply of serviceable
parts from Lufthansa Techniks extensive 787 component pool, the
maintenance, re-pair and overhaul of removed components, home base
lease, transportation logistics, reliability reporting and seamless
IT inte-gration. The largest Canadian airline has placed firm
orders for 37 Boeing 787s, with a further 23 options.
Air Canada is the newest TCS customer.
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Lufthansa Technik Connection 1.2014 New Aircraft | 17
Please continue on page 10
The selection of a component support provider for our 787 fleet
is an extremely important decision, said Alan Butterfield, Vice
President Engineering and Mainte-nance of Air Canada, on the
occasion of the contract signing. Lufthansa Technik clearly
demonstrated their commitment and ability to ensure the integrity
of our 787 long-haul operation from day one. An on-site program
manager at Air Canadas head office in Montreal and expansion of
the component pool in Miami, Florida, will ensure that Air
Canada receives the best possible level of service.
For the four airlines Thomson Airways, Arkefly, TUIfly Nordic
and Jetairfly, which all are part of TUI Travel and have taken
delivery of their first 787s, Lufthansa Technik will provide full
coverage for all engine-related components of the 787s GEnx-1B
engines. In this case Total Component Support covers a subset of
the 787 com-
ponents but still incorporates all services, including MRO,
pooling and provisioning of home bases tailored to each airlines
particular requirements. Now that these two new customers have
joined Lufthansa Techniks service network, the MRO pro-vider
handles a significant share of the material support requirements of
current and future 787 fleets.
Japan Airlines, Ethiopian Airlines and several TUI Travel
airlines are among the continuously increasing customer base for
comprehensive material support.
Pho
to: B
erni
e Le
ight
on
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Lufthansa Technik Connection 1.201418 | New Aircraft
From phase-in to line maintenance
To ensure that the integration of the Boeing 787 into an
airlines fleet proceeds without a hitch, Lufthansa Technik is the
first MRO provider in the world to also now offer its acclaimed and
extremely popular Aircraft Production Inspection Program (APIP) for
this aircraft type. With experienced inspec-tors stationed directly
at the assembly line, Lufthansa Technik performs individual
inspections on-site to ensure the optimal production quality and a
high degree of reliability in sub-sequent aircraf t operation. 50
Boeing 787 production in-spections have al-ready been com-missioned
and the first 787 to have been quality checked by Lufthansa Technik
has been delivered. Once the aircraft is in service, the technical
support coverage that Lufthansa Technik provides to 787 operators
goes further: the company is also fully prepared to offer
comprehensive engineering support for the latest Boeing
aircraft, from start-up support to all engineering services during
the air-craft life. In Munich and Frankfurt Lufthansa Technik is
already performing line mainte-nance for the 787 aircraft of
international customers.
Together with UTC Aerospace Systems, a key supplier in the
Boeing 787 Dreamliner program, Lufthansa Technik now also pro-vides
rotable provisioning and MRO servic-es for Boeing 787 nacelle
components,
offering the full spec-trum of life cycle sup-port services on
both General Electric and Rolls-Royce engine na-celles. Services on
offer include the lease and exchange of nacelle components,
on-site
repairs around the world to quickly resolve aircraft on ground
situations and high-tech shop repairs and modifications of these
components, making full use of Lufthansa Techniks many years
experience of com-posite materials in the aviation industry.
Last but not least, the services offered in the premium segment
VIP completions illustrate just how well-prepared Lufthansa Technik
is for the Dreamliner with its modern composite structures. Even
before the first Boeing 787 VIP for private or government customers
is delivered at the end of the year, Lufthansa Technik has finished
all its prep-arations for the completion and technical care of this
state-of-the-art aircraft type. With the development of a new
process for cabin installations in the new aircraft types with
composite airframes, the company has also laid the foundation for
customized cabin solutions for its VIP customers. In short, with
services to cover every aspect of the expanding life cycle of the
Boeing 787, the specialists of Lufthansa Technik are passing on
unique expertise and experience to operators around the globe
Lufthansa Technik is the partner of choice for industry-leading
independent and tailor-made services for the Dreamliner.
Dirk WinklerPhone [email protected]
Lufthansa Technik clearly demon-strated their commitment and
ability to ensure the integrity of our 787 long-haul operation from
day one. Alan Butterfield
Integrated bushing production
A mobile system for the measurement of landing gear components
is the heart of a Lufthansa
Technik proprietary development aimed at increasing the
efficiency of the landing gear overhaul
process, eliminating potential faults and improving
precision.
Aircraft landing gears are not only subjected to enormous loads
dur-ing a hard landing the forces can exceed the weight of the
aircraft by a sub-stantial factor the harsh operating condi-tions
of landing gears often cause corrosion in the drilled holes and on
the flange sur-faces of the bushings. Regular maintenance of the
landing gear is therefore a must to satisfy the safety requirements
and ensure a long service life. Whereas the corrosion on the
components can be removed by machining, the bushings can no longer
be used. In the course of a typical landing
gear overhaul bushing replacement is there-fore mandatory. The
manufacture of the replacement bushings made of bronze, aluminum or
steel alloys however is a challenge. As each component repair
requires a different cutting depth to remove the surface damage,
the bushing holes on every component have different diameters. This
means that a new bushing with individ-ual dimensions has to be
fabricated for each bore. After replacement, the component with the
new bushings installed must pre-cisely match the dimensions
prescribed by the original equipment manufacturer (OEM).
In the past both the measurement and the manual calculation of
the bushing dimensions required a large amount of labor. After
machining the landing gear components were first measured to an
accuracy of a hundredth of a millimeter with hand-held instruments
(caliper gauges, measurement guns, micrometer calipers and three
point internal micrometers). The data was noted down by hand and
entered into the SAP system. The new bushing dimensions (length,
flange thickness and diameter) were then calculated based on the
measured data. Then the new dimen-
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sions and the corresponding order infor-mation had to be entered
into the bushing drawings again manually before being passed on to
the workers in the machine group, who would then once more
manu-ally enter them into the CNC machine tool.
Automatic data transfer
Working with the Department of Informatics of Hamburg University
and Lufthansa Systems, Lufthansa Technik has developed a software
that puts an end to the tedious process. It enables the bushing
dimensions to be calculated automatically and the automatic
transfer to the relevant technical drawings. By using a
semi-automatic mea-suring arm, a lot of time can be saved,
component measurement can be signifi-cantly improved and the error
rate reduced. The measuring arm automatically transfers the
component dimensions to the SAP system. The SAP system calculates
the necessary dimensions of the new bushings and controls the
printing of all necessary order documents and drawings. As a
result, the effort required to manually trans-fer the data and
perform the associated administrative tasks is drastically reduced.
Only the data for the new bushing dimen-sions must still be entered
into the CNC machine manually, but in the future this too will be
automated.
Reduced process time
Within this research project, which was funded by the Federal
Ministry of Education and Research, the work steps component
measurement, calculation of bushing dimensions and bushing
production have been combined into a coherent, inte-grated system.
As a result only a few, opti-mally interconnected interfaces are
now required. Linking the measurement meth-ods and automating the
work processes has not only made it possible to reduce process
times by up to 30 percent, but the quality level has been further
improved.
To ensure that the research results are put to best use, an
intensive information exchange has taken place with all
subsid-iaries and affiliates of the Lufthansa Technik Group that
are involved in landing gear overhauls. A patent application for a
mobile measurement system that incor-porates the results of the
Software Devel-opment Bushings research project, has already been
filed.
Technology & Innovation | 19 Lufthansa Technik Connection
1.2014
Bushing manufactured on lathe.
The bushing is inserted into the landing gear component.
Semi-automatic measuring arm in use.
Measuring a bushing diameter with an outside micrometer.
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Lufthansa Technik Connection 1.201420 | Aircraft Services
ation Safety Agency and the airline received its first approval
for line maintenance of Airbus A310 and Boeing 737NG aircraftin
accordance with EASA Part-145 rules and regulations. Yet before the
end of the same year the scope of approval was expanded to cover
performance of C-checks. In 2006 MIAT successfully performed its
first in-house C-checks on Boeing 737 and A310 aircraft.
As MIATs M&E Organization continued with line and base
maintenance of the Boeing 737NG fleet, Lufthansa Technik won a
contract for Total Component Sup-port (TCS) of the aircraft type.
The same applied to the Boeing 767aircraft that was integrated into
the fleet in 2013. For this type too Lufthansa Technik has taken on
the provision of component support. In the same year the European
Aviation Safety Agency expanded MIATs scope of approv-al for
performance of the 767-300ER line and base maintenance.
Gaining independence
Last year Lufthansa Technik and MIAT cel-ebrated 15 years of
successful cooperation. At an event held to mark the
anniversary,
Walter Heerdt, Senior Vice President of Lufthansa Technik for
Marketing and Sales, handed over a voucher for an aircraft painting
training course for partners employees.
All through the years of cooperation with Lufthansa Technik,
MIAT Mongolian Airlines has thus benefited from the support of its
partner: it has been always able to rely on the high quality
technical services it required and has also enjoyed hands- on
assistance, know-how transfer and training of the MRO provider as
it moved towards self-sufficiency. Today MIATs Maintenance &
Engineering Organization performs all kinds of aircraft maintenance
work independently, down to the D-check, while Lufthansa Technik
provides Total Component Support and a variety of MRO services for
the aircraft operated by the airline. As such, this partnership
incarnates the success of the cooperative approach of Lufthansa
Technik.
Dmitri ZaitsevPhone
[email protected]
Over this time the engineering arm of Mongolian Airlines has
steadily developed into an independent and multi-faceted MRO
company while Lufthansa Technik remained reliable part-ner and
supplier of MRO services on the side of the airline from the Far
East. All beginnings are difficult, so they say. In case of an
airline, Total Technical Support (TTS) from Lufthansa Technik will
usually be the solution. When Mongolian Airlines acquired its first
Airbus A310 back in 1998, the logical next step was therefore to
put this support solution in place. This univer-sal service
program, ranging from compo-nent to engine support and from
aircraft maintenance to on-the-job training for Mongolian
technicians and engineers, which was carried out on-site by
Lufthansa Technik personnel, was essential for the success of the
technical operation and the formation of MIATs own M&E
Organization.
Over the years MIAT developed with a sense of purpose,
systematically acquiring and expanding its own maintenance
com-petencies. The real breakthrough happened in March 2005 when
the quality of prepara-tions was recognized by the European
Avi-
15 years of cooperation with MIAT
MIAT Mongolian Airlines and its Maintenance & Engineering
Organization and Lufthansa
Technik can proudly look back at 15 years of successful
cooperation.
MIAT Vice President Mr. Khurelbaatar S. (right) takes the
training voucher from the hands of Walter Heerdt, Senior Vice
President Marketing and Sales of Lufthansa Technik.
Pho
to: m
iat.c
om
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Lufthansa Technik Connection 1.2014 Component Services | 21
The meaning of SMART
SRU Manufacturing and Repair Technology is a Lufthansa Technik
specialty engineering,
production and process team dedicated to developing new repairs
and performing them
series production of components included. Ten engineers work
mainly on developing new
processes to save parts that would otherwise have to be
scrapped.
Lufthansa Techniks SRU Manufacturing and Repair Technology
(SMART) prides itself on its conviction that a better solution can
always be found. SRUs or shop replaceable units are sub-components
or piece parts that can be quickly replaced at a shop. Whereas
today the term smart sometimes appears hackneyed in connec-tion
with products, at Lufthansa Technik the name is spot-on. The SMART
team of Component Services is staffed by a group of experienced
engineers focused on im-
proving SRUs. They have already handled components from a wide
range of aircraft subassemblies. These include engines, landing
gears and structural parts and are not limited to components of all
aircraft systems. The aim of their development work is always to
improve the reliability and service life of a component and
specifically to avoid the need to scrap parts.
This service, a highly flexible combination of development and
production, is possible thanks to Lufthansa Techniks status as
a
Design and Maintenance Organization. Today airlines, MRO
companies and even OEMs benefit from the expertise of this team
that is able to cover the full service spectrum from damage
analysis to the development of an improvement or the certification
and implementation of a large-volume repair. These days even the
contract production of parts in large unit numbers is nothing
unusual for the team.
Please continue on page 22
Preparing a Main Fuel Pump Housing for machining.
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22 | Component Services Lufthansa Technik Connection 1.2014
Engineering Services
The service portfolio of SMART is based on two pillars. The
first of these is Engineering Services, which covers the
development of the product, the production process and the
necessary tools and equipment. The spectrum of work handled here
extends from the analysis of operating principles and mechanisms of
action to construction model analysis and definition of the actual
requirements for every individual compo-nent and their systematic
classification. The final outcome is a new design with improved
durability, longer service life and often even lighter weight.
Production Services and Repair
Production Services then covers the pro-duction of individual
parts in the facilities of Lufthansa Technik. The instruments used
in this connection extend across all the strands of technology
avail-able in the SRU and Manufac-turing Center, from machining to
surface technology and beyond. In this way the cus-tomer receives a
certified
part from a one-stop shop ready for installa-tion. The
development of a special repair for an air-oil IDG cooler assembly
is a good example of the wide-ranging capability of the SMART team.
During operation, heavy wear occurs on the oil cooler cascade,
which directs the out-let air of the cooler to the bypass flow of
the engine. As typical re-pairs such as replac-ing individual vanes
using TIG welding proved to be of limit-ed value, Lufthansa
Techniks engineersdeveloped a new cascade using a casting
technique. The new cascade is welded to the cooler assembly. This
repair returns the air-oil cooler to its original operating
condi-tion, with form, fit, function and fatigue equivalent to an
OEM part. The big differ-
ence is the dramatically lower cost, which easily justifies the
investment in
developing the cascade assembly as casting.
A different approach was chosen by the engineers when a toilet
bracket came under scrutiny. The original part was made of an
aluminum alloy, which didnt hold up well under the highly corrosive
conditions found in an aircraft toilet. The parts often simply wore
out. The SMART engineers changed the material from aluminum to a
plastic material saving weight and eliminating the possibility of
future failures due to cor-rosion. The replacement parts
manufac-tured by Lufthansa Technik are the equiva-lent of OEM parts
in terms of form, fit, func-tion and fatigue, and brought only half
of the cost with them.
The handling of a Service Bulletin con-cerning Boeing 777
aircraft is a typical case of a component repair performed by
SMART. SB 777-55A0018 requires the replacement
of existing horizontal stabilizer pivot pins with new or
reworked pivot pins, as micro cracks have been found in the chrome
plating, sometimes extending into the base metal. As the pins join
the horizon-
tal stabilizer to the stabilizer support bulk-head, a fractured
pin could result in loss of control of the airplane. Lufthansa
Technik decided to offer the rework of the pins. The chrome plating
on the pins is removed, the base structure is checked for defects
and a new chrome plating is applied. After grinding the pins to the
final dimension, a careful check ensures that the pins are in
opera-tional condition again. This process cuts
The close connection to Lufthansa Groups airlines gives us
highly detailed knowledge of the requirements of every single
aircraft component. Sabrina Hornig
A mechanic carefully performs a visual check before plating.
IDG oil cooler after repair. A new cascade the grey casting has
been welded to its core.
The plating shop offers a comprehensive portfolio of processes.
These pins are chrome-plated.
-
Lufthansa Technik Connection 1.2014 Aircraft Services | 23
the cost of a new pivot pin kit set in half.
When it comes to the development of improvements to SRUs,
customers bene-fit not just from the technical competence of the
MRO market leader. As Sabrina Hornig of Product Engineering and
Plan-ning points out: The close connection to Lufthansa Groups
airlines gives us highly detailed knowledge of the require-ments of
every single aircraft component. This gives us a distinct edge. On
top of this, in addition to the repairs ready for production that
have already been devel-oped, working with the customer we can also
develop and implement new repair solutions.
The result of each individual repair speaks for itself.
Depending on the indi-vidual part more than half of the cost can be
saved. But at the same time these highly efficient repairs, once
carried out, have the effect of significantly lengthen-ing the
service life of the components. In this way Lufthansa Techniks
customers benefit twice over a solution that truly deserves the
name SMART.
Sabrina Hornig Phone +49-40-5070-68167
[email protected]
Customer advantages
Proprietary developments Cost reduction Extended service life
Reduced scrap rate Availability improved Increased reliability
Participants at the Lufthansa Technik Maintenance International
Custom-er Forum attended a concentrated program of informative
presentations and discussions covering every aspect of the
maintenance world. Topics ranged from the A320 extended service
goal to various maintenance program models and inno-vation topics,
to the 787 engineering. There was also a briefing on the latest
developments in manage/m. The attend-ees were particularly
interested in two contributions on the subject of quality, which
stimulated animated discussion among the airline representatives.
It was exactly the right choice of topics, said John Fields,
Engineering Manager Aer Lingus, praising the agenda. Andy Beck,
Line Maintenance Manager EasyJet, con-curred: The conference is
very well struc-tured and focused on problem solving.
Opportunity for improvement requests
One of the high points of the Forum every year is the Airline
Caucus, at which all the representatives get the opportunity to put
their improvement requests to the Luft-hansa Technik Maintenance
International management. The session was kicked off by Altfried
Nessel, CCO of Lufthansa
Technik Maintenance International, who recapped on the
suggestions for im-provement that had been voiced the previous year
and outlined the progress made in those areas since then. After
that the floor was opened up for discus-sion and the exchange of
experiences. Participants were particularly complimen-tary about
the speed with which Lufthansa Technik Maintenance International
always comes up with solutions for different cus-tomer problems.
One topic that has not yet been entirely resolved is the desire on
the part of customers to deal with a single point of contact within
Lufthansa Technik for all operational matters.
Mario Hess, in charge of Maintenance at Eurowings and a veteran
participant of LTMI Customer Forums, values highly the good
exchange of information and pleasant atmosphere. Wolfgang Urich,
Manager Line Maintenance Stations TUI-fly, who had come directly
from the Inter-national Airlines Technical Pool (IATP) in Abu
Dhabi, said that he had accepted the invitation because every year
there is something new to make attending the Forum worthwhile.
Alexander Heilmann, CEO of Lufthansa Technik Maintenance
International, commented: We are very grateful for the open
discussion and the direct, honest feedback of our customers. And it
is a great delight to be able to welcome a number of delegates to
the event year after year. //
Altfried Nessel Phone
[email protected]
Replacing the aluminum brackets with plastic eliminated failures
due to corrosion.
LTMI Customer Forum
Representatives of twelve airlines attended Lufthansa
Technik
Maintenance International (LTMI)s recent Customer Forum
in Frankfurt. As well as German airlines, delegates came
from
England, Ireland, Norway, Turkey and Abu Dhabi and their
feedback on the event was extremely positive.
-
Lufthansa Technik Connection 1.201424 | Engine Services
Quiet, please!In partnership with the German Aerospace Center,
Lufthansa and
Lufthansa Technik are looking for new possibilities for
noise
suppression. Under a project which is led by the Lufthansa
Group
acoustic panels have been modified.
The noise produced by turbofans is one of the limiting factors
in air transport. Engineers therefore fight for every decibel by
which the noise emis-sions can be reduced. There are a number of
angles from which the level of sound produced during operation can
be tackled. For example, it is well known that acoustic panels
located in the engine inlets play an important role in the overall
acoustics of an aircraft engine. They consist of annular-shaped
sandwich segments covered with wire mesh that extend up to the fan.
As previous findings reveal these panels to have some acoustic
shortcomings, the acoustic engineers have been looking for
alternatives to the classic configuration.
During an extensive series of tests con-ducted in collaboration
with the German Aerospace Center (DLR) and supported by the Federal
Ministry of Economics and Technology (BMWi), two hard wall
acous-tic panel variants for CF6-80C2 have been developed and
tested. The acoustic mea-surement took place at Lufthansa Techniks
engine test cell in Hamburg using DLRs unique microphone array that
has been developed especially for indoor measure-ments. The array
consists of some 60 microphones placed in the bottom right corner
of the test cell covering different sound emission angles. Three
days of measurements have lead to an enormous amount of data that
currently is analyzed by DLR.
Thus the so-called MODAL project (German: Modelle und Daten zur
Entwick-lungaktiverSchallschutzmanahmenimLuftverkehr) is an
excellent example of how Lufthansa Technik not only vigorously
pursues cost-effective efficiencies, but also goes to great lengths
to achieve the best solutions for the environment that are
technically feasible today. Lufthansa works permanently with
partners in industry, pub-lic administrations, academic
institutions and research to develop perceptible noise-reduction
measures. This manifests itself in concrete efforts, such as the
con-tinuous modernization of the aircraft fleet, the ongoing
optimization of the existing fleet and the use of noise-reducing
proce-dures in daily flight operations.
Dr. Gerd Saueressig Phone
[email protected]
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Lufthansa Technik Connection 1.2014 Aircraft Services | 25
Oil filter analysis for CFM56
Lufthansa Techniks Laboratory Services unit has been
licensed to examine oil filters of CFM56 engines. Adding
this
special competence means another big step towards
becoming the one-stop-shop for all MRO-related laboratory
demands.
As well as lubricating and cooling the highly stressed bearings
in turbine engines, the oil also serves the important additional
function of wash-ing out wear debris and small particles and
trapping them in the filter. The analy-sis of these particles
caught in the filter is an important way of evaluating the
technical health of an engine, which is
why the engine manufacturer requires that regular examinations
are carried out. Lufthansa Techniks Laboratory Services is now
licensed to conduct oil filter analy-sis for the CFM56 engine
series. This kind of examination is required, among others, by the
following Service Bulletins: CMF56-5B SB72-0670, SB72-0671,
SB72-0808 and SB72-0833.
Training and audit
The first step in analyzing the filters is to carry out a
predefined filter-washing process to gather all debris for
analysis. In a second step the debris collected is
Aircraft Engineering Services // A new name for the acclaimed
think-tank of Lufthansa Technik Engineering: By renaming its
renowned Maintenance Manage-ment Services Aircraft Engineering
Services (AES), Lufthansa Technik is stepping up the focus on SCAMT
services for its customers from the branding and visibility in the
market perspectives. Under the new designation of Aircraft
Engi-neering Services, the MRO providers maintenance specialists
will continue the success of what hitherto have been its
Mainte-nance Management Services, offering the same content.The
focus of activities will in future be increasingly on aviation-law
related tasks. Maintenance Management Services has already provided
support to operators in the past in managing airworthiness tasks.
EASA regulations allow operators to subcontract the performance of
Subcontracted Continuing Airworthiness Manage-ment Tasks (SCAMT),
while the operator remains ultimately responsible vis-a-vis the
aviation authority. The Aircraft Engineering Services department,
rebranded as of 1 January 2014, will continue to be the
organization within Luft-hansa Technik that is responsible for
SCAMT.
Philipp KrusemeyerPhone
[email protected]
Strong focus on SCAMT
For more information: www.lufthansa-technik.com/aes
classified and described by size, mate-rial class, condition and
total quantity, supported by the appropriate images. Because
Laboratory Services already has the necessary equipment, including
the scanning electron microscope required for the analysis,
obtaining the approval was a logical next step. To meet the
requirements for obtaining
the approval, special trainings were performed, including the
analysis of test filters and discussion of the results. The final
audit was conducted by an expert from GE. Armed with this new
approval, Lufthansa Techniks Laboratory Services has expanded its
capabilities by an important element, underlining its approach to
offering its customers the most comprehensive capability
spectrum.
Dirk SchulenburgPhone
[email protected]
CFM56 oil filter analysis has been added to the capability
spectrum of Lufthansa Techniks Laboratory Services.
Using the electron microscope the tiniest particles become
visible.
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Lufthansa Technik Connection 1.201426 | Events &
Exhibitions
Reliable partner in the Middle East
The Middle Eastern aviation market is strongly growing.
At Lufthansa Technik Middle East Services (LTMES), head-
quartered in Dubai, Lufthansa Technik is continuously
expanding
its range of technical services for the regions customers.
The Dubai Airshow at the end of 2013 visibly underlined
Lufthansa Techniks role as reliable partner for the Middle East and
Africa region, provid-ing high-quality technical solutions for both
private and commercial aircraft oper-ators. Lufthansa Technik
Middle East Ser-vices (LTMES) bundles all the contact part-ners for
sales, logistics, technical training
and the component business, and makes them available in Dubai.
Lufthansa Technik Middle East Services Managing Director Ziad al
Hazmi outlines the development: We have already added local
employees to strengthen both our customer service in the area of
component support and the sales office for our regional VIP
custom-ers. Now we are considering expanding
Cabin solutions for America
Lufthansa Technik presented its two latest products for the
aircraft cabin the GuideU floor path marking system and the
HelioJet cabin lighting system at the recent Aircraft Interiors
Expo Americas show.
// American carriers are increasingly backing new, efficient
aircraft. To save fuel, more and more attention is being paid to
aircraft weight. American airlines are therefore particularly
interested in cabin furnishings that improve passen-ger comfort,
require little maintenance and at the same time save weight. These
requirements are satisfied by Lufthansa Techniks new GuideU
1000-series and HelioJet cabin products. When present-ed at
Aircraft Interiors Expo Americas, they met with a lot of interest
from American aircraft manufacturers and airlines alike.
Together with SCHOTT Lighting and Imaging Lufthansa Technik
presented HelioJet, a new LED lighting technology for the aircraft
cabin that uses approxi-mately one fifth of the LEDs required by
conventional LED lights. A special pro-cedure ensures that the
light is evenly distributed. HelioJet also has the advan-tage of
requiring very little in the way of maintenance.
GuideU 1000-series, the latest version of the Lufthansa Technik
non-electric floor path marking system, was also on show. Designed
to fit every common cabin floor material GuideU provides for a very
easy installation, a broad choice of colors and a lifetime without
mainte-nance. The patented GuideU system features a most efficient
and light-weight design, saving more than 15 percent weight versus
competing products.
The product sales team in America. The Lufthansa Technik booth
at the Dubai Airshow with ample lounge space for business
meetings.
With Dubai as one of the worlds booming hubs, Lufthansa Technik
is expanding its offering here.
Pho
to: S
ven
de B
ever
e
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Lufthansa Technik Connection 1.2014
Meet us at...
For more information: www.lufthansa-technik.com/events
16 18 January 2014 | Bahrain
Bahrain AirshowThe Bahrain International Airshow has established
itself as one of the most elite business-to-business events.
05 06 February 2014 | Dubai
MRO Middle EastThe MRO Middle East Conference and Exhibition
brings together decision- makers from airliness and suppliers.
11 14 February 2014 | Singapore
Singapore AirshowAsias largest aerospace and defence event
ranges among the most renowned air shows in the world.
25 26 February 2014 | Moscow
Aircraft Maintenance RussiaThe annual platform in Russian and
the CIS for discussing the main issues of aircraft maintenance and
repair.
18 21 March 2014 | Johannesburg
MRO AfricaThe next MRO Africa will again be a place to network
with leading players from Africa and around the world.
PreviewHighlights from the next
issue:InnovationManagementAircraftrecoveryFleetmanagerportrait
Events & Exhibitions | 27
our material support services, deploying specialized personnel
for our customers in the region and providing line maintenance
services for customers outside Lufthansa.
Composite repairs ARC
Owing to rising demand for on-site techni-cal services for
nacelle components, repair operations for Airframe Related
Com-ponents (ARC) will be expanded in early 2014. With a local
facility in place, spare part provision and repairs can be offered
more efficiently to customers in the region. Depending on the
required service, repairs can be undertaken either at the customer
site or in Dubai without creating additional transport expenses, or
be organized within the Lufthansa network.
Catering for the rapid growth of the avi-ation industry in the
Middle East and the
continual increase in aircraft movements in the region,
Lufthansa Technik Middle East Services will also begin to offer the
highly efficient service Cyclean Engine Wash at its facility in
Dubai as well as at the regions airports. There have already been a
lot of definite enquiries from airlines interested in using the
service.
Cyclean Engine Wash
The Cyclean process frees the engines, in particular the fan and
compressor blades, from dirt such as sand, mud, dust and pol-len.
Once cleaned, the engines are more thermally efficient in operation
and use up to one percent less kerosene for the same level of
performance. This reduces costs and is better for the
environment.
For us and our customers, the perfor-mance of the engines,
protecting the envi-ronment by reducing CO2 emissions, and cost
savings from extended on-wing time are foremost considerations,
says Oliver C. Winter, Program Manager Cyclean Engine Wash at
Lufthansa Technik. Ziad al Hazmi: Our new services in Dubai will
help us fulfill the wishes of our airline and VIP customers even
better.
Ziad al HazmiPhone +971-440-57-550 [email protected]
5-6
Februa
ry 2014
Dubai
MRO
Middle Eas
t
Booth 316
On site: Ziad al Hazmi is Managing Director of Lufthansa Technik
Middle East Services.
Cyclean is now offered on site in the region.
-
Lufthansa Technik Connection 1.201428 | Products &
Services
No matter if you are a regional start-up, a small or mid-sized
carrier, a private or governmental operation, or a legacy airline:
Our range of products and services can be tailored for commercial
and private fleets of every mix, kind and age.
Total Support ServicesTotal Support Services are the first
choice for any customer wanting to enjoy cost-efficient and
reliable flight operations and focus on his core business at the
same time. Total Operational Support (TOS) Total Technical Support
(TTS) Total Base Maintenance Support (TBS) Total Material
Operations (TMO) Total Component Support (TCS) Total Engine Support
(TES) Total Landing Gear Support (TLS)
Single Services Single services and shop load events such as
letter checks, engine overhauls or repairs of single components are
at the core of a unique assembly of products and services. Aircraft
Services Component Services Engine Services Landing Gear Services
VIP & Executive Jet Solutions Logistics & Training
Special Services The worlds leading manufacturer-indepenent MRO
provider offers a product portfolio reaching beyond traditional MRO
services from the manual. Composite Repairs (ARC) Engine Parts
& Accessories Repair (EPAR) Maintenance Management Services
(MMS) Aircraft Leasing & Trading Support (ALTS) AOG Services
Surface treatment
Cabin & IFE Products Lufthansa Technik has successfully
established a line of cabin products. Cabin Management & IFE
Systems Aircraft & Cabin Equipment Connectivity Patient
Transport Solutions
eServicesLufthansa Techniks Technical Operations Websuite
manage/m allows operators to manage their technical operations via
a web-based system.
A380
A380
A319
A330
A340-300
A310
A318
A320
A321
A340
A330
A310
A300
A318
A319
A321
A320
World of services Airbus
For more information: www.lufthansa-technik.com/services
A300
Airbus A300 Line Maintenance Base Maintenance Component Services
Engine Services: P&W JT9D, PW4000-94, GE CF6-80C2
Airbus A310
Line Maintenance Base Maintenance Component Services Engine
Services: JT9D, PW4000-94, CF6-80C2
Airbus A318
Line MaintenanceBase MaintenanceComponent ServicesEngine
Services: CFM56
Airbus A319 Line MaintenanceBase MaintenanceComponent
ServicesEngine Services: CFM56-5, V2500-A5
Airbus A320 Line MaintenanceBase MaintenanceComponent
ServicesEngine Services: CFM56-5, V2500-A5
Airbus A321 Line MaintenanceBase MaintenanceComponent
ServicesEngine Services: CFM56-5, V2500-A5
Airbus A330
Line MaintenanceBase MaintenanceComponent ServicesEngine
Services: CF6-80, PW4000-100, Trent 700
Airbus A340
Line MaintenanceBase MaintenanceComponent ServicesEngine
Services: CFM56-5, Trent 500
Airbus A380
Line MaintenanceBase MaintenanceComponent ServicesEngine
Services: Trent 900
Hot
line
+49-40-5070-4308Hotline24/7
AOG desk
-
Lufthansa Technik Connection 1.2014 Products & Services |
29
737
737
737NG/MAX
737 NG
747-8
757
777
MD11
MD80
767
787
787
777
747-8
757
767
MD-11
MD-80
RegionalsBoeing
CRJ 700
CRJ
E-Jets
Q-Series
Q-Series
ERJ 190
Boeing Business Jet (BBJ)
Airbus Corporate Jetliner
Challenger Family
Embrear Executive Jets
Embraer
Boeing Business Jet
Airbus Corporate Jets
Bombardier
Boeing 737
Line MaintenanceBase MaintenanceComponent ServicesEngine
Services: CFM56-3
Boeing 737NG
Line MaintenanceBase MaintenanceComponent ServicesEngine
Services: CFM56-7B
Boeing 747
Line MaintenanceBase MaintenanceComponent ServicesEngine
Services: JT-9D, PW4000, CF6-80C2
Boeing 757 Line MaintenanceBase MaintenanceComponent
ServicesEngine Services: RB211-535
Boeing 767
Line MaintenanceBase MaintenanceComponent ServicesEngine
Services: PW4000-94, CF6-80C2
Boeing 777
Line MaintenanceBase MaintenanceComponent Services
Boeing 787
Line MaintenanceComponent ServicesEngine Services**schedule to
be defined
MD-11
Line MaintenanceBase MaintenanceComponent ServicesEngine
Services: CF6-80C2,PW4000-94
MD-80
Line MaintenanceBase MaintenanceComponent Services
Business Jets
ACJ
Line MaintenanceBase MaintenanceComponent ServicesEngine
Services:CFM56, V2500-A5
BBJ
Line MaintenanceBase MaintenanceComponent Services Engine
Services:CFM56-7B
Bombardier
Challenger, Learjet,Global Express.Line MaintenanceComponent
ServicesEngine Services:CF34
Embraer
Legacy, Lineage.Line MaintenanceBase MaintenanceComponent
ServicesEngine Services: CF34
Bombardier CRJ
Line MaintenanceBase MaintenanceComponent ServicesEngine
Services: GE CF34
Bombardier Q400
Line MaintenanceBase MaintenanceComponent ServicesEngine
Services: PW100, PW150
Embraer
E-Jets 170/175, 190/195, Line MaintenanceBase
MaintenanceComponent ServicesEngine Services: GE CF34
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Lufthansa Technik Connection 1.201430 | Contacts
Key Account VIP & Executive JetsJoachim von Holtzapfelp
+49-40-5070-3514f
[email protected]
Lets talk about solutions
Local representatives
Senior Vice President Marketing & SalesWalter Heerdtp
+49-40-5070-2524f +49-40-5070-2101hamtssek