Lufthansa Technik | Technik Connection

Transcription

The Lufthansa Technik Group Magazine
4.2016 July/August
Lufthansa Technik at ZAL TechCenter
New aircraft services
A350 VIP interior
Support for Ural Airlines
A350 capabilities
expanded
Welcome
home
A decade of
partnership
Photo: Michael Lindner
Future created in Hamburg
2 | Content
Lufthansa Technik Connection 4.2016
Innovation and technology
• ZAL TechCenter:
• Fourth industrial revolution:
On the road to MRO 4.0
• Predictive maintenance:
The talking aircraft
Lufthansa Technik has commenced research
operations at the ZAL TechCenter in the
south of Hamburg.
Photo: Trilux
6
12
Customer portrait
• Ural Airlines:
A decade of growing partnership
• Interview with Igor Poddubniy: “A reliable partner”
The partnership with customer Ural Airlines goes
far beyond mere component supply.
15
eServices
• Guided tour:
manage/m® update
New aircraft services
• Agreement: All-round support for the A350 nacelle system
• Airbus A350:
Discover the web app
Welcome home
The Airbus A350 VIP interior concept is a comprehensive
approach towards health and well-being on board.
Employee portrait
• Matthias Berg:
“A win-win situation”
22
18
12
14
11
20
21
26
27
22
25
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Categories
• News
3– 5
• Events 27
• Products and services
28
• Contacts
30
A350 capabilities expanded
Lufthansa Technik is a licensed service provider to ensure
all-round nacelle support for A350 operators.
10
VIP & Special Mission Aircraft Services
• A350 VIP:
15
Welcome home
Engine Services
• Air Cycle Machine (ACM):
A350 capability progress
• Repair and overhaul:
Engine teardown yields quality parts
• APU Services:
2,500 overhauls and counting
• Cutting-edge system:
For perfect surfaces
A decade of growing partnership
6
Lufthansa Technik Connection
is a complimentary information service for Lufthansa Technik’s
family and friends. Published every two months.
This and earlier issues can be downloaded from our website
www.lufthansa-technik.com/connection
Publisher
Lufthansa Technik AG
Kai Raudzus · Corporate Marketing · HAM TS1/M
Weg beim Jaeger 193 · 22335 Hamburg, Germany
Infoline +49-40-5070-5553 · Fax +49-40-5070-8860
[email protected] · www.lufthansa-technik.com
Angela Huber-Saffer · Database management
Editorial production
Editorial office: Flightlines, Hamburg
Design: Art Works!, Hamburg
Photos: Lufthansa Technik AG, Deutsche Lufthansa AG
Printing: Beisner Druck GmbH & Co. KG
News | 3
Maintenance partnership with easyJet
easyJet and Lufthansa Technik Maintenance International have signed a contract
for extensive collaboration at London Gatwick Airport (LGW).
W
ith a fleet of 55 aircraft, Gatwick
is the largest base for the lowcost airline. As part of this fiveyear collaboration, Lufthansa Technik (as
the Part 145 maintenance organization)
will handle Light Base Maintenance (LBM)
inputs and AOG hangar support for the
Airbus A319 and A320 aircraft fleet as well
as the A320neo in the future.
Brendan McConnellogue, easyJet’s
Head of Maintenance, comments: “In addition to the hangar build itself, a tender was
run to select a suitable partner to provide
the maintenance services. easyJet’s existing partner in Milan Malpensa and Berlin
Schoenefeld, Lufthansa Technik, was
selected and a ground-breaking five-year
contract has been signed which sees
Lufthansa Technik opening their first UK
hangar-based operation. The on-site team
will deliver two inputs every night, seven
days a week and provide AOG hangar
support as required.”
Ulrich Hollerbach, Chief Executive
Officer of Lufthansa Technik Maintenance
International, comments: “This partnership
project builds on and continues the successful cooperation between easyJet and
Lufthansa Technik over the past years.
We are extremely proud that our offer was
able to fulfill the service and business
model expectations of one of Europe’s
leading airlines. We are absolutely sure
that we will deliver the same high quality
at London Gatwick which easyJet already
knows from our common activities in Milan
Malpensa and Berlin Schoenefeld.”
Work for easyJet under the new contract commenced recently. Lufthansa
Technik has a staff of about 60 mechanics
on site who executes two checks per
night, seven days a week.
4 | News
Lufthansa Technik Connection 4. 2016
Kuala Lumpur
Dubai
Cooperation project
with Malaysia Airlines
Hamburg
Cooperation with
DC Aviation Group
Cooperation with
Starburst Accelerator
Innovation // Lufthansa Technik
has chosen Starburst to develop and strengthen ties with
innovative start-ups in the aerospace sector. Having access to
a start-up pool with aerospace
focus of at least 150 start-ups
in Europe as well as 100 startups in the US, Starburst covers
a wide range of potential future
collaborations with start-ups.
In addition to its established
partnerships with universities,
research institutes, Small and
Medium-sized Enterprises
(SMEs), OEMs and aircraft
manufacturers, Lufthansa
Technik is working toward a
strong presence in the start-up
arena in several predefined
technical search fields as part
of its Open Innovation Network.
Those collaborations can take
all forms imaginable: from a
simple inspiration by new
technologies (market watch)
to a complete buy-in.
Dr. Helge Sachs, Vice President
Corporate Innovation Management and Product Development
of Lufthansa Technik: “Starburst helps Lufthansa Technik
as well as the Lufthansa Group
to cooperate with start-ups in
the aviation industry in the
local, European and global
innovation ecosystems.” //
VIP & Special Mission Aircraft
Services // Lufthansa Technik
has concluded a cooperation
agreement with DC Aviation
Group, a leading operator of
business jets in Europe. As
part of the agreement, the two
companies plan to offer their
VIP customers a first-class
package of services at Al
Maktoum International Airport
(Dubai World Central Airport).
An experienced, highly qualified team of engineers and
mechanics will ensure cost
efficiency and quality that are
“made in Germany”. Just like
Lufthansa Technik, DC Aviation
Group is headquartered in Germany, in this case in Stuttgart.
The contract services will be
provided in the hangars and
VIP facilities of DC Aviation AlFuttaim LLC, a joint venture of
DC Aviation and the Al-Futtaim
Group. They will consist of regular checks as well as maintenance services, including
unplanned repairs for example
in the case of an AOG. The
portfolio also features services
for aircraft cabins, including
small modifications. Moreover,
plans call for a mobile aircraft
and cabin service to serve the
region.
The offer is rounded off by
extensive FBO services (fixedbase operator) for ground
operations at the airport, such
as fueling, catering for passengers and pilots, and transport
services. //
Melbourne
Qantas extends A380
support contract
Spairliners // Qantas Airways
has renewed its Integrated
Component Care contract with
Spairliners, a joint venture of
Lufthansa Technik with Air
France, who have been providing services since the A380
Entry Into Service in 2008. The
contract covers component
pooling and repair solutions of
all Line Replaceable Units
(LRUs) for Qantas’ Airbus A380
aircraft fleet. As a result of the
new agreement, the contract
provides an additional transportation service to and from
Qantas’ homebase in Sydney
and all line stations.
The contracted services include
the scope of about 1,000 part
numbers (P/N) in total. Qantas
offers A380 passenger transport
services with 14 daily flights
connecting Sydney and Melbourne to Dubai, London, Hong
Kong, Los Angeles and Dallas.
Since operation of Qantas’ first
A380 in 2008, the component
provider has served the airline
for over 350,000 flight hours.
“Spairliners is our preferred
component provider thanks to
the successful partnership and
improving high service levels
through the time of the existing
contract,” says Mike Legrand,
Head of Procurement, Engineering at Qantas Airways. //
MRO business for Boeing and
Airbus // Lufthansa Technik and
Malaysia Aviation Group Berhad
have signed a Terms of Reference in Kuala Lumpur on a strategic partnership framework for
a Joint Venture (JV) to establish a
regional Maintenance, Repair and
Overhaul (MRO) facility. The facility
would be based at Malaysia
Airlines’ existing facilities at
Kuala Lumpur International Airport and service the Boeing 737
and Airbus A320 family of aircraft. It is expected to introduce
state-of-the-art technical capabilities for base maintenance
services, creating a centre of
excellence for the region.
“We are excited about the tangible benefits of the JV. Lufthansa
Technik is one of the global leaders in MRO services, and the
level of skill, expertise and technological transfer will be invaluable, both for us and for Malaysia”,
said Christoph Mueller, Group
Chief Executive Officer of Malaysia Aviation Group Berhad and
Malaysia Airlines Berhad.
“Once this new Joint Venture
becomes true, we will extend
significantly our MRO capabilities
in one of the most emerging
markets worldwide,” explained
Dr. Johannes Bussmann, Chief
Executive Officer of Lufthansa
Technik. “With Malaysia Airlines
at our side we will have a strong
regional partner to create a
real success story with this new
business.”
The formation of the JV will be
subject to, inter alia, approvals
from the competent regulatory
authorities and the signing of
definitive agreements. //
News | 5
Hamburg
Hamburg
Alzey
Hamburg
Comprehensive BBJ
787 cabin modification
Services // Lufthansa Technik
will start a comprehensive
cabin modification program on a
Boeing BBJ 787-8 for an undisclosed customer. The green
aircraft will arrive at Lufthansa
Technik’s completion center in
Hamburg, Germany, in early
autumn. The modification is
based on a service bulletin
from the aircraft manufacturer
and is adapted to the specific
customer needs. It comprises
a special cabin layout and the
adjustment of both the inflight
entertainment system and the
communication system.
“The modification of this 787
is another milestone in further
strengthening our expertise on
this aircraft type,” said Walter
Heerdt, Senior Vice President
Services, Lufthansa Technik. “In
addition to our already existing
MRO services for different 787
commercial operators we are
now also extending our port
folio for this aircraft model to
our VIP business. This makes
Lufthansa Technik the leading
provider of technical services
for the 787.”
Subsequent to the modification,
Lufthansa Technik will further
support the aircraft with technical services. So far Lufthansa
Technik supports more than
180 Boeing 787. The product
portfolio comprises Maintenance, Repair and Overhaul
services for commercial and VIP
aircraft of this type, including
engineering, spare part supply,
modifications and completions.//
Multitype approval
for new exit signs
PW150A contract from
Biman Bangladesh
Lufthansa Technik AERO
Alzey // Biman Bangladesh
Airlines and Lufthansa Technik
AERO Alzey have signed an
exclusive five-year agreement
for the Maintenance, Repair and
Overhaul services of the PW150A
engines powering Biman’s two
Dash8-Q400 aircraft. Biman,
the flag carrier of Bangladesh,
serves major international and
regional destinations. Additionally, Biman serves connectivity
to its domestic destinations in
Bangladesh and selected
regional routes to neighboring
countries with these recently
introduced two airplanes.
“For Lufthansa Technik AERO
Alzey this long-term agreement
with Biman is a milestone in the
development of our worldwide
customer base and in particular
in Bangladesh. With Biman, a
very experienced flag carrier
entrusts his fleet of engines in
Lufthansa Technik AERO Alzey,”
says Mark Johnson, CEO of
Lufthansa Technik AERO Alzey.
“During the negotiations for this
contract we valued Biman as a
fair and competent partner and
highly appreciate now that the
decision was finally in our favor.
It is our intention that with this
new cooperation we will be
able to build up a long-lasting
relationship and further extend
the scope of partnership.” //
Internet connectivity
on short-haul flights
Lufthansa // In October of this
year, the first Lufthansa shortand medium-haul aircraft will
take off with broadband internet on board. Lufthansa’s entire
A320 family fleet is expected to
have the innovative technology
installed by mid-2018. One key
milestone has already been
reached: Lufthansa Technik is
the first MRO company in
Europe to have received the
Supplemental Type Certificate
(STC) from EASA to install a
Ka-band antenna on the A320
family, i.e. the A319, A320, and
A321 models. The STC serves
to verify that the modifications
to the aircraft (hardware or
software) conform to the design
specifications stipulated by
EASA.
With its many years of experience in the aircraft modification
sector, Lufthansa Technik is
responsible for installing all
systems and components as
well as for the works required
to comply with aeronautical
and statutory regulations. In
Europe, this was the first successful installation involving the
GX communications network
and the Honeywell-designed
Ka-band antenna. To install the
system, electrical and structural
modifications were required
both inside and outside the aircraft cabin. All modifications
were developed and approved
by Lufthansa Technik’s licensed
development unit. //
GuideU // Lufthansa Technik
has received approval across all
aircraft types for a new generation of photoluminescent signs.
With immediate effect the existing maintenance-intensive and
non-environmentally-friendly exit
signs at the flexible curtains in
the cabin can be replaced by the
Lufthansa Technik GuideU material, which is already used for
emergency floor path marking.
Regular replacement of signs
for reasons of aging as has been
the case to date is now history
thanks to a so-called Multitype
STC, an aircraft manufacturer
and type-spanning approval.
The exit sign made from the
completely maintenance-free
GuideU material simply has to
be installed once directly at the
aircraft manufacturer or as part
of routine maintenance work. //
Stay up to date!
Customer Newsletter //
Lufthansa Technik’s online customer newsletter Connection
Flash supplements our popular
bi-monthly Lufthansa Technik
Group Magazine Connection
with first-hand news on innovative technologies and developments, new services and offers,
and future events. //
www.lufthansa-
technik.com/
customer-newsletter
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6 | Innovation and technology
a Te c
The “ZAL – Center of Applied Aeronautical Research” is setting out to enhance
the networking of the civil aviation industry in Hamburg. As one of the major
shareholders, Lufthansa Technik has already commenced research operations
at the ZAL TechCenter in the south of Hamburg.
h
Innovation and technology | 7
Photos: Michael Lindner
T
he central idea espoused by the
ZAL (Zentrum für Angewandte Luftfahrtforschung – Center of Applied
Aeronautical Research) is to promote joint
research by industry and science on future
topics of importance in the field of aviation.
Its objective is to continuously expand the
world’s third-largest civil aviation location
in Hamburg, which currently employs more
than 40,000 people. This idea is now a
ZAL TechCenter opening with Brigitte Zypries,
Federal Government Coordinator of German Aerospace Policy (3rd from left), and Lufthansa Technik
CEO Dr. Johannes Bussmann (2nd from left).
reality at the ZAL TechCenter. In addition to
Airbus and the City of Hamburg, Lufthansa
Technik is one of the main shareholders in
the forward-looking research facility.
Following the official opening of the ZAL
TechCenter in Hamburg’s Finkenwerder
district in spring, the participants now have
a home where they can work together and
carry out research directly and collaboratively with the partners under one roof. With
a working area of just under 26,000
square meters, the ZAL TechCenter provides space for around 600 workplaces in
offices, laboratories and hangars.
Equipped with a sophisticated research
and test infrastructure for selected aspects
of aviation, the center will promote the
industrialization of new technologies.
�
Please continue on page 8
powder sprayed is accelerated in a speOther Lufthansa Technik facilities are
cial nozzle to reach supersonic speeds.
also part of the TechCenter. These include,
The sprayed particles create a very dense
for example, the large autoclave in the
and strongly adhering overlay. Due to hitARC® shop (Airframe Related Compoting the surface at that high velocities in a
nents, ARC®), an indispensable tool for
solid state the particles get cold welded
developing fiber reinforced composite
by micro friction processes. As the partitechnologies, as well as some facilities of
cles stay at relatively moderate temperathe Original Equipment Innovation (OEI)
tures there is no risk for any chemical
business unit.
reaction with the environment which leads
The TechCenter is used in a variety of
to outstanding mechanical properties of
ways. While Airbus has consolidated its
the coating. New powder materials are
Research and Technology division fully at
now being investigated and parameter
ZAL, Lufthansa Technik is
studies carried out
focusing on coopto also qualify the
eration projects,
new procedure for
which can be carWhat makes the ZAL TechCenter
repairs on a variety
ried out with partso special is the fact that the
of components.
ners locally. The first
partners are all equal and work
Several projects
dedicated projects
together without hierarchical
undertaken by
have already startissues. Creative potential has
Lufthansa Technik
ed, one example of
free rein here.
at ZAL examine the
which is 3D printing.
repair of fiber-reinLufthansa Technik
Dr. Johannes Bussmann
forced composite
has installed a highstructures. This is an important task for the
performance printer locally, which is suitfuture, since the load-bearing structures of
able for printing metal alloys. The first test
modern commercial aircraft are made
pieces have been produced to check the
predominantly of carbon-fiber-reinforced
system stability and metallurgical quality.
polymers (CFRP). The patch repairs that
So far it looks promising and Lufthansa
have been available to date are limited in
Technik will soon be ready to ramp up the
the allowed repair size.
repair development. The primary goal of
the tests is initially to repair engine parts
Automatic repair process
using this procedure. While 3D printing is
already used in the production of engine
parts, the corresponding technology should The objective is to allow composite structures to be repaired directly using custom
now also allow damaged components to
CFRP layers. The repair process should
be repaired in the printer. A metallography
also be carried out automatically in order
laboratory is available for supporting the
to ensure the quality. A robot for preparing
practical tests.
scarf joints already exists and is currently
Another technology that is also being
transferred into standard procedures. A
examined for Engine Services is the souniversal testing machine is being used to
called cold gas spraying process. This is
examine the mechanical properties of the
essentially a coating process, where the
“
Initial test series of the 3D printer: The first specimen show up.
specimen produced during the tests and
to ultimately enable approval. A 39 months
long research project is being supported
by the German government in the framework of the German Federal Aeronautical
Research Program (LuFo) and conducted
with many of ZAL’s shareholders. The
examples show that Lufthansa Technik is
optimally positioned to make best possible
use of the opportunities offered by the ZAL
for safeguarding technical and economic
development as an MRO provider.
Sven Taubert
Phone +49-40-5070-67177
[email protected]
ZAL – Center of Applied
Aeronautical Research
// The Center of Applied Aeronautical
Research is the technological research
and development network of the civil
aviation industry in the metropolitan
region of Hamburg, Germany. It is the
interface between science, industry
and the city of Hamburg with the aim
to continuously secure and expand the
world’s third largest site of civil aviation.
In close coordination with Hamburg
Aviation, ZAL brings together the city’s
technological skills at one central facility
(ZAL TechCenter), thus creating synergies. ZAL was established by nine partners. The shareholders are the Free
and Hanseatic City of Hamburg, Airbus
Operations GmbH and Lufthansa
Technik AG, each with a 20 percent
stake; the Association for the Promotion of Applied Aeronautical Research,
with an 18 percent stake; the German
Aerospace Center (DLR), with a 10
percent stake; and four Hamburg Universities, each holding 3 percent. //
Photo: Paul Milbrod
www.zal.aero/
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On the road to MRO 4.0
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Many industries are facing the challenge of a new, fourth industrial revolution (Industry 4.0) –
the merging of the real and the virtual world to form the Internet of Things. Lufthansa Technik has
identified the potential of the development and has started looking at introducing Industry 4.0
technologies in its shops.
I
ndustry 4.0 implies a host of individual
measures. Companies have to increase
the level of their automation in production, examine the use of human-machine
support systems and ensure their value
chain and especially physical production
processes are smoothly linked into the
digital world. The objective is to further
increase productivity in order to remain
competitive in the long term.
To achieve the new goals, old ways of
thinking will have to be thrown overboard.
All-encompassing integrated systems will
have to be developed instead of isolated
local solutions and processes as well as
interfaces will be more standardized.
Since October 2015 Lufthansa Technik
has performed preliminary investigations
concerning these goals in the landing
gear, engines and maintenance divisions.
Partners in these investigations include
the Helmut Schmidt University, Hamburg’s
Center of Applied Aeronautical Research
(Zentrum für Angewandte Luftfahrtforschung, ZAL), the start-up Synergeticon
and the Technical University of Hamburg-
Harburg. Potential application scenarios
with high implementation potential will first
be identified, analyzed and preselected.
These will then be prioritized based on
specific economic and technical implementation criteria. The results will be used
as a basis for further production planning
and for making decisions in relation to the
interdisciplinary project cluster “MRO 4.0”.
The objective here is to implement Industry 4.0 applications by migrating to the
Lufthansa Technik process landscape in
all product divisions.
Among other things, Lufthansa Technik
is developing a concept for transmission
of measured values to mobile devices, a
tracking system with visualization feature
for internal logistics and a mobile phone
application for visualizing order-related
data. These demonstrators focus on providing data on mobile terminals in relation
to location and findings in order to sup-
eServices | 11
manage/m® update
A new version of the guided tour and the recent
phase-in at another customer airline are two news
from Lufthansa Technik’s WebSuite manage/m®.
port employees and avoid media interrupts between
different IT systems. This will ultimately lead to improved
networking of all the relevant stakeholders within production. These support systems are ideal for helping
employees carry out their tasks in a meaningful and
structured manner.
Support can either be virtual, for example with collection of information or with documentation, physical, for
instance in the case of component measurement or installation, or a combination of the two. All supporting systems
aim to reduce errors in manual work processes, thus
ensuring a consistently high quality of work. The full and
real-time networking of all entities involved (humans,
machine, component) allows the development of new
knowledge-based services through the exchange of data.
Securing the company’s future
Intelligently networked production where employees are
integrated optimally in the workflow delivers benefits in
terms of productivity. The challenge lies in identifying the
best possible combination of all of the strengths of
employees (flexibility and creativity) and the strengths of
automation (reproducibility and process reliability). The
“quick wins” identified, i.e. topics that allow profits to be
earned without significant further effort, will be implemented following the preliminary investigations. These quick
wins will also act as precursor for further introduction of
Industry 4.0 technologies. In addition, the identified topics
with potential are to be transferred to the main “MRO 4.0”
program from the middle of 2016. One objective will be to
elaborate cross-discipline concepts and solutions that can
be exchanged between the divisions.
With its efforts in line with the MRO 4.0 vision, Lufthansa
Technik intends to safeguard its industry-leading position,
securing the company’s future in the highly dynamic world
of aircraft MRO.
Gerrit Rexhausen
Phone +49-40-5070-65496
[email protected]
www.lufthansa-technik.
com/mro-4.0
T
he manage/m® guided tour gives customers an overview of
the 15 manage/m® modules of Lufthansa Technik’s Technical
Operations WebSuite and their performance. Short introductory
films reflect the world of manage/m® from a user’s point of view,
showing the main functions of each module and application.
Guided tour update now online
As the world of manage/m® is always evolving, so is the guided tour.
“We have a lot of customers who ask us about the additional usage
of specific applications after they have seen the guided tour,”
explains product manager Jamila Jadran, who was responsible for
the current modifications. Lufthansa Technik therefore introduces
updates on new functions within manage/m® every other year, giving
users the possibility to gain a first impression of the benefits they
have to offer. The new version of the guided tour contains updated
films on m/material and its online material offer function, the new
“customer work instruction” within m/jobcard and gives an exclusive
insight into the newly designed module m/compliance. The guided
tour can be accessed via the services section within the manage/m®
WebSuite.
Phase-in for Surinam Airways
Lufthansa Technik has successfully phased in manage/m® at Surinam
Airways. Starting in mid-March, the introduction commenced with
two phase-in trainings at the airline’s headquarter in Paramaribo.
A total of 15 staff, including production planning, engineering and
quality management, participated in the training, with one official
from the Civil Aviation Authority also joining in.
Peter Grulich, manage/m® customer integration manager, introduced the participants to Lufthansa Technik’s Technical Operations
WebSuite, giving an overview of the system, explaining the general
usage of the different modules and how they are connected.
Surinam Airways uses the full range of manage/m® for its A340-300
aircraft, having contracted Lufthansa Technik to perform line maintenance checks including A-checks.
Jamila Jadran
Phone +49-69-696-37386
[email protected]
www.manage-m.com
12 | Customer portrait
A decade of
growing partnership
The partnership between Lufthansa Technik and its
customer Ural Airlines goes far beyond mere component
supply. For ten years now, Lufthansa Technik has closely
supported the development of the airline and its fleet of
Airbus aircraft.
T
he Russian carrier Ural Airlines is a
successful airline, and one on a
course for growth. Lufthansa Technik
has supported the carrier with customized
technical services since it added the first
A320 to its fleet ten years ago. In addition,
Lufthansa Technik accompanies Ural
Airlines as the carrier moves toward its
goal of building up and expanding
maintenance capabilities for its own and
for customer fleets.
Growth from the Urals
This longstanding customer of Lufthansa
Technik can look back on a long history
that began when United Air Squadron was
founded in 1943 at Koltsovo Airport in
Ekaterinburg, which was then known as
Sverdlovsk. Later, the squadron was part
of Aeroflot, and in 1993, after the split-off
of Aeroflot, the company, then known as
Sverdlovsk Aviation, was divided into an
airport and an airline. The latter became
Ural Airlines.
Today, this private carrier is one of the
largest in Russia with its home base in the
heart of the Ural region at Koltsovo (Ekaterinburg International Airport) and Moscow’s Domodedovo Airport as one of its
most important hubs. The airline is grow-
ing and continuously expanding its network in Russia, the CIS and around the
world, while the number of passengers is
strongly increasing every year.
Support from the very beginning
The cooperation between the carrier and
Lufthansa Technik goes back to 2006,
when Ural Airlines added its first Airbus
aircraft to its fleet. “Ten years ago, Lufthansa Technik had already been well
established in the Russian MRO market
and had earned a reputation for supporting airlines just starting operations of
Western aircraft,” says Dmitri Zaitsev, Vice
President Corporate Sales Eastern Europe
& CIS of Lufthansa Technik. “And we were
hopefully a natural choice of Ural Airlines
to ensure safe and reliable flight operations
of their new Airbus fleet. Nevertheless,
we also had to learn and understand the
challenges that our partner was facing
and tailor our services to address these
requirements.”
Total Technical Support (TTS®) for Ural
Airlines currently comprises component
MRO and pool access and services for
Aircraft Related Components (ARC®) as
well as engine and APU overhauls as
individual events. “We adjust our scope of
services regularly to Ural Airlines’ current
needs. For instance, in the past we have
performed base maintenance layovers for
the airline,” explains Ralf Zimdars, Sales
Executive Eastern Europe & CIS. The
carrier’s initial inventory of two aircraft has
meanwhile grown into a homogeneous
fleet of 37 aircraft from the A320 family.
Lufthansa Technik ensures reliable spares
logistics for Ural Airlines, including material
supply, from its home bases in Hamburg
and Frankfurt.
�
Customer portrait | 13
About Ural Airlines
// Ural Airlines is one of the largest rapidly developing Russian airlines. The airline’s base airports are first-rate Russian aviation hubs:
Moscow Domodedovo and Ekaterinburg. Ural Airlines operates
scheduled and charter flights to Russian, CIS and international
destinations. Every year, new destinations are added to the airlines’
route map. Ural Airlines’ fleet consists of modern and comfortable
European aircraft of the Airbus A320 family. The key priorities of the
airline are international quality and safety standards. In 2012, Ural
Airlines obtained its EASA Part 145 approval for line maintenance,
which was expanded to base maintenance in 2015. //
14 | Customer portrait
“A reliable partner”
Connection talked to Igor Poddubniy, Technical
Director of Ural Airlines, about the partnership
of the airline with Lufthansa Technik and their
expectations in the long term.
Lufthansa Technik has been
supporting Ural Airlines with
components and other technical
services for almost a decade.
What are the most important
cornerstones in this partnership?
Igor Poddubniy: From the start of
our partnership, the most important
things for us were technical ser
vices and component support, of
course. When we performed line
maintenance only, several C-checks
for our A320 aircraft were performed at the facilities of Lufthansa
Technik. Now we perform base
maintenance under our own
approval, but Lufthansa Technik’s
component support still remains
essential for us.
What were the decisive
arguments for contracting
Lufthansa Technik?
Back then it was crucial for us to
get access to Lufthansa Technik’s
vast experience in engineering
and maintenance of Western
aircraft, and to benefit from its wellorganized production, variety of
services and strong quality system.
Our first agreement covered a lot of
aspects of maintenance, engineering and component support, which
helped us during the start of A320
operations.
How did Lufthansa Technik fulfill
the expectations of Ural Airlines?
In my opinion Lufthansa Technik is,
first of all, a reliable partner. All of
our agreements are honored and
the support is very effective.
How would you describe the
relationship of Ural Airlines and
Lufthansa Technik in general?
The cooperation with Lufthansa
Technik meant a hard learning
curve for us, as Ural Airlines had to
understand Western maintenance
practices, learn how to communicate with a large foreign partner,
distribute responsibilities between
our departments, build optimum
cross-border logistics and solve a
lot of organizational issues. The
good spirit of our relationship helps
us solve problems quickly and with
high quality, of course. I hope this
is mutual and that Lufthansa Technik
can say the same about us.
What do you expect from
Lufthansa Technik in the long
term?
With the successful groundwork that
we have laid together, we expect our
partner to support the growth of Ural
Airlines with high-quality and costeffective maintenance solutions.
At the same time, we are striving to
further expand our maintenance
capabilities, whenever economically feasible, to ensure the growth
of our fleet to fifty aircraft in the
coming years.
Teamwork among partners
Over the course of the past decade, the partnership between Lufthansa Technik and Ural
Airlines has clearly developed beyond pure
technical support. “At the beginning, nearly
all the technical services were provided by us
or partners such as Aeroflot,” explains Ralf
Zimdars. But as it gained more experience
with aircraft from the A320 family, Ural Airlines,
which has a large number of technical
employees, began to carry out some of the
technical work itself, starting with line maintenance, engineering and adding aircraft overhauls in early 2015.
“We recognize a continuously growing
professionalism of our partner’s technical
staff. We have always supported Ural Airlines
in this process, because ultimately we understand ourselves as a partner to our customers,”
explains Dmitri Zaitsev. Lufthansa Technik
shares its experience with Ural Airlines on
optimizing base maintenance in the airline’s
new hangar, and provides support for developing the back shop capability. “Our cooperation is very close. We pay a lot of attention
to ensuring that both companies benefit from
our partnership.”
The close cooperation between the MRO
company and its airline customer is also
strengthened by many personal ties. In the
meantime, the customer support of Ural Airlines is mostly provided by the Russian speaking staff of Lufthansa Technik in Hamburg and
Moscow, ensuring that there are no linguistic
barriers.
After all, services that are adapted to suit
the carrier’s needs will ensure that Lufthansa
Technik can continue to be a technical partner to Ural Airlines as it pursues the growth
of its fleet – and plans call for its fleet size to
grow again over the next five years to fifty
aircraft.
www.uralairlines.com
VIP & Special Mission Aircraft Services | 15
Welcome home
At this year’s EBACE in Geneva, Lufthansa Technik unveiled its brand-new Airbus A350 VIP
interior concept. With a comprehensive approach towards health and well-being on board, the new
concept promotes flexible areas for privacy or valuable family time and provides super connectivity.
Entering the A350 VIP, passengers are
greeted by a friendly ambiance that
meets their personal taste and lets
them rediscover flying. Free from any
constraints, they can simply enjoy the
company of family and friends.
�
16 | VIP & Special Mission Aircraft Services
com/a350-vip
Featuring a personal spa above
the clouds, the A350 VIP interior
literally invites travelers to take a
deep breath and unwind.
Traveling a lot sometimes feels like
the aircraft is a second home.
Lufthansa Technik’s approach to
well-being on board makes sure
that passengers have everything
they need to relax.
VIP & Special Mission Aircraft Services | 17
T
he A350 »Welcome Home« VIP interior is a masterpiece from front to
back. The first design priority was to
create flexible areas that can be opened
and combined for better social interaction
and closed for full privacy if so desired.
“The idea is much more than just a healthy
surrounding in an aircraft. We strive to create
a flying experience that lets you arrive
more relaxed and strengthened than when
you started the journey,” explains Lufthansa
Technik interior architect Michael Reichenecker, who designed the »Welcome Home«
cabin.
The guest lounge entertains with a cinema size screen and offers a new lighting
approach. An exclusive feature is the large
spa area which is equipped with a relaxing
steam bath, a massage shower, and a
massage table that may also double as a
Patient Transport Unit (PTU) if so required.
Top sound quality and individual lighting
let guests immerse fully in a deeply relaxing
surrounding. With Lufthansa Technik’s
patent-pending new illumination concept,
ceilings and walls themselves turn into
lighting elements. For healthy on-board
food preparation, Lufthansa Technik’s new
induction platform has been integrated into
the galley. “This unique VIP cabin concept
not only addresses our customers’ requirements, but is also a clear proof of Lufthansa
Technik’s design and engineering competency. Many of our own products, like the
»chair« VIP seat, the steam shower or our
inductive cooking plate have been integrated in this cabin,” said Wieland Timm,
Vice President Sales VIP & Special Mission
Aircraft at Lufthansa Technik.
The whole cabin comprises about 270
square meters (about 2,900 sq ft). The concept is flexible and allows the adaption to
other widebody aircraft, too. In addition to
its VIP cabin completion capabilities for the
Airbus A350, Lufthansa Technik is already
offering a broad portfolio of Maintenance,
Repair and Overhaul services to various
commercial carriers for this aircraft type.
Family flex area
Crew VIP VIP bathroom bedroom Main entrance
VIP VIP lounge office Guest lounge
Dining Galley Guest rooms Spa and workout
The talking aircraft
On the road to predictive maintenance: Sometime in the near future, aircraft will be able to
report during flight that “a component will soon fail, please replace it as soon as possible”. This
is a dream of every aircraft maintenance team. Dr. Helge Sachs, Vice President Corporate
Innovation Management and Product Development, explains Lufthansa Technik’s leading role
in making this dream come true.
C
ars talk to us. We take it for granted that they will warn us if the tank
is running out of gas or if we have
forgotten to switch the lights off before getting out. Aircraft can also communicate,
but the technology they use is a lot more
complex and the number of components
much larger – as is the amount of data
they produce.
In an ideal world, airplanes would evaluate and pass on these data so that maintenance engineers know when a component
is about to fail, because the consequences
are much more serious than in cars. An
aircraft that is grounded – deemed unairworthy due to malfunctions – takes up a lot
of time and costs a lot of money, in particular
when the Maintenance, Repair and Overhaul (MRO) company, such as Lufthansa
Technik, has to send specialists and spare
parts to distant countries.
This is why making aircraft “talk” is currently one of the most exciting topics in the
MRO industry. At the “MRO Americas”
conference in Dallas, Texas, in early April
this year, aircraft equipment manufacturers, maintenance companies and airlines from all over
the world discussed the
use of Big Data in aviation. Good progress
has already been
made in the
field of data
collection. For example, an Airbus A350
can accumulate three gigabytes of data
over the course of several flights. The biggest challenge is evaluating this data and
allowing conclusions to be drawn. When is
a component likely to need replacing? Can
maintenance intervals be extended?
Predictive maintenance is the future
This type of analysis is not entirely new, but
it currently involves assessing a few specific
data sets on the ground. The everyday
routines are corrective maintenance –
replacing certain components when they
stop working – and preventive maintenance – maintaining components at specific intervals despite the fact that their
service life is not finished.
The future lies in predictive maintenance.
This means that the technicians will have
much more data available when carrying
out checks and will be able to identify
when a component needs maintenance
earlier than planned. In the future, aircraft
could send data at very short intervals
even during flights, which would mean that
they could “talk” to the MRO engineers.
During the next maintenance event, the
engineers would know in advance exactly
which faults they had to deal with.
Lufthansa Technik is playing a leading
role in this area. The company set up a
corporate analytics office in Hamburg
at the end of 2015. Its role is to collect
data and identify patterns using powerful
“
Dr. Helge Sachs, Vice
President Corporate
Innovation Management
and Product Development
Our experience is our differentiator. Flying more than 700 aircraft
in the Lufthansa Group and
servicing about 3,800 aircraft at
Lufthansa Technik lets us see not
only the performance of parts,
but the impacts of the processes
around them.
algorithms. Working together with the MRO
engineers, the data analysts in the office
generate large numbers of sample cases
that allow clear conclusions to be drawn.
For example, how does a component in a
specific aircraft type behave under certain
conditions? If an airline mainly deploys its
aircraft in wet and cold regions, they will be
subject to different stresses than those that
fly over deserts.
One unique feature of the new office is
the large quantity of data that it has available. Lufthansa Technik maintains almost
3,800 aircraft of different types. This has
resulted in a huge volume of data, which is
increasingly being used on a cooperative
basis. These data could also be of interest
to other airlines. Understandably, they are
not keen to hand over control of their own
data, but many of them could be
persuaded if they understood the benefits.
Highly precise
maintenance
and repairs will allow the MRO companies
to reduce their own costs dramatically,
and thus also those incurred by their customers. MRO measures currently make
up some 20 percent of the operating
costs of an airplane, so significant savings
are possible.
The pilots will also benefit from predictive maintenance, because aircraft that
provide information about which components are likely to cause problems in the
near future will make their jobs easier to
plan and, most importantly, safer. The
future is all about people and machines
talking to one another.
A case in point
// Using an analysis of flight recorder
data, Lufthansa Technik was able to demonstrate that on some aircraft both ailerons constantly protruded upward from
their central position during flight. This
was observed in a few aircraft as early as
delivery; in others it worsened over time.
The aircraft can still fly straight ahead
without any noticeable effect, but in
this configuration it consumes
more fuel. On the basis of the
collected data, the ailerons
on these aircraft were repositioned – and thus their
fuel consumption was
reduced. //
20 | Engine Services
www.lufthansatechnik.com/a350
Preparing the rotor for a balancing test.
A350 capability progress
Lufthansa Technik is making great strides in expanding its capacity for the A350. The company
has now completed the test bench for the Air Cycle Machine (ACM) and preparations are also
on track for the repair of other components of the Air Generation System.
T
he Air Cycle Machine (ACM) forms
the heart of the Air Generation System, which has the task to ensure
that the correct air temperature is maintained in the cabin. The room air at the
perfect temperature required for passengers
and crew is generated from the engine
bleed air inflowing at high pressure and
high temperature using a cooling and mixing process.
The bleed air coming from the engines
at 48 psig and approximately 180 °C is
cooled down to about 135 °C in the primary
heat exchanger. In the compressor the air
pressure is then brought to about 76 psig,
with the air reaching a temperature of
about 200 °C. This compressed air is
cooled down in the main heat exchanger.
The colder air then drives the turbine and
expands down to about 16 psig. The
expansion of the air causes its temperature to drop to almost -40 °C. Directly after
the turbine warm bleed air is added to the
cold air to achieve the minimum selected
temperature for the aircraft. This premixed
air is then directed to the mixing manifold
which supplies all zones of the aircraft with
conditioned air. The A350 features up to
ten different zones, of which temperatures
can be selected by the cabin crew. From
the mixing manifold cabin ducts are leading to the individual temperature zones of
the A350. Each duct is equipped with a
so-called trim air valve, which ensures the
selected desired temperature in each zone
is maintained. The ACM of the Airbus A350
is equipped with a fan, compressor and
turbine wheel, which rotate at app. 34,000
revolutions per minute after the pack is
selected on. Two such components are
installed in each aircraft. Jan Poensgen,
project engineer for pneumatic components for the new Airbus type, explains: “As
with most modern components of this type,
the ACM in the A350 is also equipped with
air bearings. They are more reliable than
the rolling bearings formerly used.”
Engine Services | 21
Engine teardown yields quality parts
The manufacturer Honeywell tested
the new Air Cycle Machine for approval.
The component completed 250,000
cycles, i.e. from the start-up of the ACM
from a standing position up to operating
speed and subsequent run down to a
standstill position. This is a very reassuring figure since the A350 as a long-haul
aircraft flies relatively few cycles. Jan
Poensgen expects that approx. 30,000
cycles will be reached in operation. The
component is particularly stressed on
the ground because the required cooling capacity reaches its maximum level
in this case. As the air temperature is
lower at a high altitude the ACM does
not have to work as hard.
For a flexible service from one reliable source, Lufthansa Technik’s
engine teardown product is the smartest and most versatile solution in
reusing surplus parts for engine repair and overhaul work.
T
he optimum use of parts with a
remaining service life enables
Lufthansa Technik to tailor
engine repairs exactly according to
customer specifications, guaranteeing
its engine teardown customers a fast
return on investment from a single
source. With two different service packages, Teardown Classic and Teardown
Plus, the engine customer is sure to
make the most of his engine parts.
This guarantees maximum freedom as
customers get the best possible use of
the parts. Transport of the disassembled parts to Lufthansa Technik’s
Engine Parts and Accessories Repairs
(EPAR) shops is free of charge. Cleaning and inspection are further available
options. Providing an overview of
Lufthansa Technik’s material demand,
manage/m® also allows the management of repair orders. Upon request,
Teardown Classic is the basic package of the customized solution whereas
the Teardown Plus option provides a
number of additional services precisely
adapted to individual requirements. In
a tailor-made process disassembled
parts get encoded and tagged. Engine
customers can monitor teardowns
on Lufthansa Technik’s Technical
Operations WebSuite manage/m® in
real time.
repaired parts may also be dropshipped to any location in the world.
Lufthansa Technik provides the full
suite of engine teardown services in
North America. Capabilities – from
engine transportation and disassembly
to parts repair and parts drop shipment
at the customer’s doorstep – are available for the PW4000, V2500, CF6-80
and the entire CFM56 engine family.
Additionally, Lufthansa Technik has set
up a customer service team in Fort
Lauderdale, Florida. Handling the entire
teardown simplifies the process and
improves Lufthansa Technik’s ability to
make quick and best possible use of
all engine parts.
Team training in Torrance
Extensive conversion of the test bench
was needed for Lufthansa Technik to
work on the new ACM. Apart from the
ducting having to be adapted to the new
type, the electronics were also extended
by installing new measuring points. To
ensure that the engineers were properly
trained for the task, a team was sent
specially to Torrance in California to
undergo training.
For the Airbus A350 pneumatics,
Lufthansa Technik has around 20 part
numbers from Honeywell in its portfolio.
The turbo compressor for the nitrogen
generation system, which is part of the
inerting system for the fuel tank, is also
being repaired, for example, at Lufthansa Technik. The nitrogen, which is
produced using a molecular sieve, is
pushed into the tanks, preventing the
development of a flammable gas mixture. The trim air valves are also being
repaired in Hamburg. Capacity has
been built up and approval is all that is
needed now. Thanks to the on-schedule
expansion of the MRO capacity for the
pneumatic components of the Airbus
A350, Lufthansa Technik will ensure the
customary standard of quality for its
customers for the new aircraft type.
Jan Poensgen
Phone +49-40-5070-4990
[email protected]
A second life for engine parts
By making the information about
removed parts available immediately,
engine parts can be routed for repair
very quickly. The extended option Teardown Plus offers selectable services.
Here the customer receives preferred
parts supplier status from Lufthansa
Technik’s material planning department.
Michael Reinhardt
Phone +1-954-302-4422
[email protected]
22 | New aircraft services
All-round support for the
A350 nacelle system
Lufthansa Technik and UTC Aerospace Systems Aerostructures, manufacturer of the A350 nacelle
system, have entered into an agreement that gives Lufthansa Technik the status of a “licensed
service provider”. The MRO company thus gains access to all the resources required to ensure
all-round nacelle support to the A350 operators.
U
nder the agreement, UTC Aerospace
Systems’ Aerostructures business
will provide Lufthansa Technik with
proprietary information including but not
limited to repair procedures, purchase
approval for OEM tooling, access to technical publications, worldwide performance
data and technical data required to perform
full A350 MRO nacelle repair services.
Lufthansa Technik invests in a wide range
of assets to support customer needs while
minimizing aircraft ground time.
As Lufthansa Technik is the initial authorized licensee of UTC Aerospace Systems
for the A350 nacelle, Lufthansa Technik
will offer this service through its global MRO
network. Marc Duvall, President of UTC
Aerospace Systems’ Aerostructures business, explains: “The agreement will give
A350 operators more options for locations
for their nacelle MRO services from highquality, OEM or OEM-licensed repair stations. Additionally, it provides the operators
confidence that A350 nacelle system MRO
work performed by Lufthansa Technik will
be made at the same high standard of
quality and fast turnaround for which both
companies are known.”
Thanks to this agreement Lufthansa
Technik is perfectly positioned to provide
the operators of the A350 with an alternative option for Maintenance, Repair and
Overhaul of these demanding and complex
components. Procurement of replacement
parts has already commenced as operators are exposed to the risk of low spares
disassembled condition the transportation
availability in AOG cases during the early
of Trent XWB inlet cowls is limited to a
stage of the component lifecycle. Michael
small number of aircraft types.
Lotzin, Head of Product Sales Airframe
“In order not to damage the components
Related Components (ARC®) Services,
during assembly, Lufthansa Technik recexplains: “Due to the fact that the air inlet
ommends operators to keep in mind that
cowls are those components on the
the reassembly of the inlet cowl after transnacelle most exposed to foreign object
port takes up to 24
damages as well as
hours per OEM prodamages by ground
cedure and some
equipment, we are alSpares, repair, transport, wardegree of expertise,”
ready keeping the first
ranty handling, on-site repairs:
Michael Lotzin
Trent XWB inlet cowl
Our customers expect the
states. Lufthansa
for immediate AOG
complete package of support
Technik therefore
support in our main
from one of the leading MROs.
keeps one assemstore in Frankfurt. In
Michael Lotzin
bled inlet cowl for
the next months, we
immediate installawill add additional
tion in its store in Munich able to be transinlet cowls, thrust reversers and fan cowl
ported by truck. Furthermore, under its
doors to our stock to support operators in
UTAS license, Lufthansa Technik’s engisuch AOG cases.”
neering can issue temporary repair
Considerable investment is tied up in
approvals for the nacelles (fly-ons), which
this stock. That is because the costs for a
allow operators to keep the aircraft flying
complete nacelle set have increased to an
to the next spares location such as
amount in the double-digit million range
Munich, avoiding AOGs and the costly
owing to the specifications of the compotransport of the components.
nents. Trent XWB nacelles have been
Apart from owning spare parts, this
designed for minimum weight and maxiagreement will also provide Lufthansa
mum rigidity, making them high perforTechnik with access to additional spares
mance items. The materials, along with
out of the OEM pool worldwide, therefore
the size, present special challenges to the
enabling the company to support operarepair and the handling of these compotors around the globe. Lufthansa Technik
nents.
will also be able to carry out complex
Transport of these oversized comporepairs in full depth. Michael Lotzin comnents, especially the inlet cowl with more
ments: “One of our core competences has
than 141-inch in diameter, places special
always been the development of repairs.
challenges to logistics providers. Even in a
“
New aircraft services | 23
com/arc
Under the agreement, our own repairs will
be approved by UTAS, which means that
Lufthansa Technik will have ultimately OEM
approval for all out-of-manual repairs.”
Due to the complexity of the materials,
comprehensive experience and leading
expertise in processing composites – the
domain of the ARC® business unit – are the
prerequisite for secure and economical
repair solutions.
The warranty handling completes the
scope of services. Operators can turn to
Lufthansa Technik in warranty cases and
get the complete process managed. Lufthansa Technik will perform the repair or
modification and handle the warranty
claim directly with the OEM as part of the
licensing agreement, making the process
efficient and convenient for customers.
The ARC® Head of Product Sales
concludes: “Spares, repair, transport,
warranty handling, on-site repairs: Our
customers expect the complete package
of support from one of the leading MROs
and I am confident that we can meet
those expectations now also on the Airbus
A350 nacelles.” Lufthansa Technik now
provides its customers with the full range
of life cycle support services for Airbus
A350 nacelles – and is truly ready for the
A350.
Michael Lotzin
Phone +49-40-5070-64300
[email protected]
24 | Employee portrait
“A win-win situation”
As Head of Production Engineering APU Services, Matthias Berg has supported the development of
a unique cooperation between Lufthansa Technik and Honeywell Aerospace for the A350 APU
along the entire path. The engineer on one hand has an understanding of the technology while on
the other hand always keeps a watchful eye on the commercial side.
T
his cooperation is one of a kind to
date: Lufthansa Technik is a first-tier
partner for the components and APU
of Honeywell Aerospace for the Airbus A350.
The 50-year old Matthias Berg does not
want to focus overly on what he has personally contributed toward developing the
cooperation however, since he feels strongly that elaborating such a contract and preparing for its implementation requires team
effort and a cross-departmental approach.
“I am a team player. When everyone in
the team is working toward one goal, significantly more can be achieved than simply
through the sum of individual efforts,” says
Matthias Berg, who as an enthusiastic volleyball, soccer and badminton player knows
only too well what makes a team successful. This is also reflected in the standards
he sets himself in his work: “It is no good in
the long term if people only consider their
own interests in negotiations, whether internal
or external. I prefer to strive for a win-win
situation. This is the only way that a business
relationship can be sustained in the long
term.”
A first-tier partner
The cooperation between Lufthansa Technik
and Honeywell is the first of its kind and
therefore of special significance. No wonder,
with Airbus currently recording around 800
orders for the A350. 24 of the fuel-efficient
jets have been delivered to seven airlines to
date. Looking to the future, this means the
potential for more than doubling the revenue for Lufthansa Technik’s APU business
unit alone. Moreover, up to 100 people will
work on the project in Hamburg in the
coming years.
“The cooperation as a first-tier partner
for the Honeywell APU HGT1700 offers us
New aircraft services | 25
Discover the
A350 web app
ideal field of activity for the qualified engiideal conditions in the market. It can act as
neer with his additional diploma in business:
the key to further similar cooperations on
Matthias Berg gained his first professional
other aircraft types,” says Matthias Berg.
experience in aircraft maintenance manThe team in Hamburg is optimally equipped
agement at L ufthansa Technik in Frankfurt.
for the initial tasks they face as a warranty
He was then deployed in the engine divipartner and for all subsequent APU repairs.
sion with responsibility for product man“We are now also responsible for fulfillagement and customer service in sales.
ment,” reports Berg. “For us it was therefore initially about ensuring the capability
Excellent know-how
and the best conditions. This includes the
training of staff, having the tooling and
But back to the here and now and to the
materials on site as well as a test bench
cooperation with Honeywell. What makes
and calibration capabilities. We worked
Hamburg the ideal location for the implevery intensively and successfully together
mentation? “The capabilities consolidated
with Honeywell in making the necessary
here with us affect both the engine and
preparations for this.”
the associated components. And we have
Apart from technical preparations,
excellent know-how in all engineering
Matthias Berg and his team are also workmatters,” says Matthias Berg knowingly
ing on the administrative implementation
and – with the team
of the new product.
always in focus –
For example, it has
concludes: “Honeyto be integrated in
The cooperation as a first-tier
well as an OEM
SAP or preparapartner for the Honeywell
benefits from this
tions made for
APU HGT1700 offers us ideal
through the cooperaapprovals by other
conditions in the market.
tion in engineering
international aviaMatthias Berg
and the reduced
tion authorities. The
MRO costs achieved. Airlines also profit
need to deploy colleagues in different
from the efficiency gains the cooperation
areas is particularly acute in APU, a relagenerates as well as the single point of
tively small business unit from a Lufthansa
contact Lufthansa Technik offers. So we
Technik perspective. “I am also involved,
have a win-win situation that benefits
for example, in engineering topics in the
everyone.”
area of work scoping, but also participate
Repairs are also on Matthias Berg’s
in repair designs,” recounts Matthias Berg.
to-do list in his free time. Though with cars.
Yet he never loses sight of cost considerThe family man, who lives with his wife and
ations at the same time. “I really enjoy
two daughters in the north-east of Hamburg,
working in such so-called areas of conlikes to tinker with his 36-year old Suzuki
flict,” he adds.
GS1000 and his 16-year young BMW.
He came to APU Services some twelve
“I like both vintage cars and youngtimers,”
years ago when Lufthansa Technik restruche explains. “Compared with modern cars
tured its business units – and when comthat have lots of built-in electronics, it is
mercial structures were to be established
easier to perform your own repairs.”
for the first time for the APUs. It was the
Ready for the A350 // What does
Lufthansa Technik offer to guarantee
A350 operators the highest degree of
mobility for their new aircraft fleet?
The A350 web app gives insights in the
preparations for this new Airbus aircraft,
its technological challenges und the
services and products of Lufthansa
Technik to provide the very best technical support right from the start.
Have a look behind the scenes and
learn more about our partnership with
other customers. Meet our “everyday
heroes” with their personal dedication
and knowledge which enables them
to optimally support your A350 aircraft
in day-to-day operations. The comprehensive A350 services of Lufthansa
Technik are the key to the business
success for operators of this new
Airbus aircraft. //
“
Optimized also for tablets
a350.lufthansa-technik.com
26 | Engine Services
2,500 APU overhauls and counting
Lufthansa Technik turned over the 2,500th Auxiliary Power Unit (APU) overhauled in Hamburg to
customer Germanwings at the beginning of June. Thanks to a state-of-the-art overhaul chain,
motivated employees and further capacity expansion, APU Services are well equipped to
meet the increasing demand and new types.
www.lufthansatechnik.com/
apu-services
F
or decades, Lufthansa Technik has
provided technical services for a
whole range of modern Auxiliary
Power Units (APUs) to numerous international customers. APU Services are now
continuing this success story. This was
evidenced most recently at a ceremony in
Hamburg: Lufthansa Technik turned over
the 2,500th Auxiliary Power Unit overhauled
in Hamburg to the customer Germanwings
at the beginning of June.
The performance capability of the APU
shop in Hamburg is based on a number of
pillars. One important factor is the extensive
flexibility offered. This stretches from the
capacity utilization of the shop – between
two and four inspection workstations are
available depending on requirements –
through to the entire overhaul and installation. All employees can be deployed on a
multifunctional basis to ensure the success
of this approach. The mechanics have a
multiple qualification thanks to advanced
training, which allows them to work
wherever a capacity bottleneck arises.
To increase efficiency, the shop of course
also uses the most modern technology
available. An example of this is the use of
a voice-controlled inspection program that
was introduced a year ago. By virtually
halving personnel costs, the Vocollect
system has made this important step in
the overhaul chain extremely efficient.
The very high levels of repair established
over the years also contribute to the
increased efficiency.
Continuous product improvment
Extraordinary technical competence
acquired over decades is another performance pillar. It rests not only on APU
technology, but also on an engine MRO
competence of unrivaled scope, including
approval to develop proprietary repairs.
The continuously driven product improvement cycle is thus one of the most outstanding strengths of Lufthansa Technik
and a highly beneficial advantage for
every customer.
A further critical factor for success however is the team spirit embodied by the
department of Ole Gosau, Head of Lufthansa
Technik’s APU Services. Each of the
employees working here takes personal
responsibility for his or her tasks. In the next
five years the team is to be extended to
match the capability with the expected
increase in demand.
Lufthansa Technik is well equipped
thanks to approval by the German Federal
Aviation Office (LBA) and all major Aviation
Authorities worldwide for maintaining the
APUs of the two major manufacturers. It is
also demonstrated by the contract with
Honeywell to assume MRO responsibility
for the HGT 1700 APU of the Airbus A350.
Ole Gosau sums it up: “We make sure that
customers have nothing to worry about.”
APU Services has thus ensured a smooth
path to the future for itself.
Ole Gosau
Phone +49-40-5070-3868
[email protected]
Events and exhibitions | 27
For perfect surfaces
Meet us at...
27 – 29 September 2016 | Singapore
Lufthansa Technik is future-proofing the field of surface
technology with the commissioning of a new robot-controlled
blasting machine. The cutting-edge system is versatile and
operates extremely precisely.
MRO Asia-Pacific
MRO Asia-Pacific is the largest conference
and exhibition in the region dedicated
to the aircraft Maintenance, Repair and
Overhaul (MRO) market.
28 Sept. – 1 October 2016 | Monaco
L
ufthansa Technik has designed and
procured a completely new coarse
blasting system in order to ensure
the sustainability of its surface technology
in the future. The new system is fully automatic and designed to handle complex
component geometries, for example in
engine components or landing gear components. In terms of the design, attention
was focused on ensuring that engine
housings of future engine types could also
be handled. External and internal machining is possible up to a diameter or length
of 3,000 mm. A two-meter lance also allows
internal machining of longer parts, which
is necessary for example for surface preparation prior to coating inside diameters of
landing gear components.
intensity of the blasting process. The fully
automatic calibration system is a new feature industry-wide and ensures the quality
of the process in the new system and
therefore the product.
The project has now come to a con
clusion with the development of blasting
parameters. The combination of versatility
and capacity has allowed the decommissioning of the three systems previously
used. Lufthansa Technik therefore also
has state-of-the-art, highly productive
equipment at its disposal in the field of
surface technology.
Integrated calibration system
The new system handles four different
blasting media: mesh 20, 60, 90 and
120 with coarseness values of 76 to 320
µ-inch, which are switched between automatically. A special feature is the integrated calibration system, which eliminates
the former need for manual inspection
with so-called Almen strips. These are
standardized small strips of steel, which
deform into an arch under the stress of the
blasting operation, whereby the angle of
the arch is used as a measurement of the
Coarse blasting
// In order to prepare metals optimally for coating, for example prior to plasma spraying or bonding of plastic components, the contact surfaces in question are subjected
to what is known as a coarse blasting process. By blasting particles of a certain granular size and for a specific period, this process produces a precisely defined surface
roughness with optimal bonding strength, for example for bonding acoustic elements
from fiber-reinforced composites in an engine intake. The microstructure of the material is readied optimally for the connection following the treatment, which is why the
subsequent coating process also has to take place within a matter of hours. //
Monaco Yacht Show
The Monaco Yacht Show (MYS) is the
place to admire, visit and purchase
around 120 extraordinary one-off super
yachts built by the world’s most respectful
shipyards. 40 new launches are unveiled
in world premiere at every edition. Luft
hansa Technik will be present with its own
booth, demonstrating its competence in
VIP aircraft completion and VIP cabin
upgrades.
18 – 20 October 2016 | Amsterdam
MRO Europe
At MRO Europe the latest standards for
productivity and aerospace technology
are presented. In addition to networking,
MRO Europe presents opportunities with
other service providers and aerospace
companies. Lufthansa Technik will participate with its own booth and two speakers
at the conference running in parallel.
19 – 21 October 2016 | Hunter Valley
RAAA Convention
The Regional Aviation Association of Australia (RAAA) Convention is highly regarded as a premier annual aviation event.
CASA, the government and other regulatory bodies are well represented and contribute significantly to the program, which
is open to members and non-members.
Lufthansa Technik AERO Alzey will be
present at this event.
Follow this link to find
out more about Lufthansa
Technik’s participation and
presentations at upcoming
fairs and conferences.
lufthansa-technik.com/events
28 | Products and services
Airbus
World of services
Our range of products and services can be
tailored for commercial and private fleets of
every mix, kind and age.
A300/A310
Line Maintenance
Base Maintenance
Component Services
Engine Services:
JT9D, PW4000-94,
GE CF6-80C2
Total Support Services
Total 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™)
• Aircraft Leasing & Trading Support (ALTS®)
A318
A300
A319
A318
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 & Special Mission Aircraft Services
A320/neo
A319
A321
A320neo
H otl i ne
A321
49
- 4 0 - 5 0 70
Hotline
24/7
k
AOG des
308
Please follow this link for the complete MRO service portfolio and more
details about Lufthansa Technik’s
solutions for fleets of any size.
www.lufthansa-technik.com/services
A330
-4
eServices
Lufthansa Technik’s Technical Operations
Websuite manage/m® allows operators
to manage their technical operations via a
web-based system.
+
Special Services
Lufthansa Technik offers a product portfolio
reaching beyond traditional MRO services
from the manual.
• Composite Repairs (ARC®)
• Engine Parts & Accessories Repair (EPAR)
• Maintenance Management Services (MMS)
• Logistics and training
• AOG services
• Surface treatment
Original Equipment Innovation (OEI)
Lufthansa Technik has successfully
established a line of cabin products.
• Cabin management & IFE systems
• Aircraft and cabin equipment
• Connectivity
• Patient transport solutions
Airbus
A300/A310
A340
A330
Airbus A318
Line Maintenance
Base Maintenance
Component Services
Engine Services:
CFM56
Completion
Airbus
A319
Line Maintenance
Base Maintenance
Component Services
Engine Services:
CFM56-5, V2500-A5
Completion
Airbus
A320/neo
Line Maintenance
Base Maintenance
Component Services
Engine Services:
CFM56-5, V2500-A5
Completion
Airbus
A321
Line Maintenance
Base Maintenance
Component Services
Engine Services:
CFM56-5, V2500-A5
Completion
Airbus A330
Line Maintenance
Base Maintenance
Component Services
Engine Services: CF6-80,
PW4000-100, Trent 700
Completion
Airbus A340
Line Maintenance
Base Maintenance
Component Services
Engine Services:
CFM56-5, Trent 500
Completion
A350
A340-300
Airbus A350
Line Maintenance,
Component Services,
Engine Services:
Trent XWB
A380
Airbus A380
Line Maintenance
Base Maintenance
Component Services
Engine Services: Trent 900
Completion
Products and services | 29
Boeing
737 CL/NG
Regionals
Boeing 737 CL/NG
Line Maintenance
Base Maintenance
Component Services
Engine Services:
CFM56-3, CFM56-7B
Completion
737 MAX
737NG/MAX
Boeing 737 MAX
Q-Series
Bombardier Q400
Line Maintenance
Base Maintenance
Component Services
Engine Services:
PW100, PW150
Q-Series
CRJ
Bombardier CRJ
Line Maintenance
Base Maintenance
Component Services
Engine Services: GE CF34
Component Services
Further services
in preparation
CRJ 700
747
737MAX
757
747-8
Boeing 747
Line Maintenance
Base Maintenance
Component Services
Engine Services: JT9D,
PW4000, CF6-80C2
Completion
ERJ/E-Jets
ERJ 190
Embraer
135/145, 170/175, 190/195
Line Maintenance
Base Maintenance
Component Services
Engine Services: GE CF34
Boeing
757
Line Maintenance
Base Maintenance
Component Services
Engine Services:
RB211-535
Completion
757
767
Boeing 767
Line Maintenance
Base Maintenance
Component Services
Engine Services:
PW4000-94, CF6-80C2
Completion
767
777
Boeing 777-9X
vorläufige Zeichnung
777
777X
Boeing 777
Business Jets
Airbus Corporate Jets
Line Maintenance
Base Maintenance
Component Services
Completion
ACJ
Line Maintenance
Base Maintenance
Component Services
Engine Services:
CFM56, V2500-A5
Completion
Boeing 777X
Boeing Business Jet
in preparation
Airbus Corporate Jetliner Line Maintenance
BBJ
Base Maintenance
Component Services
Engine Services:
CFM56-7B
Completion
787
Boeing 787
Line Maintenance
Component Services
Engine Services*
Completion
Bombardier
Challenger, Learjet,
Global Express.
Line Maintenance
Base Maintenance
Component Services
Engine Services: CF34
*schedule to be defined
787
MD-11
MD-11
Line Maintenance
Base Maintenance
Component Services
Engine Services:
CF6-80C2, PW4000-94
Bombardier
Boeing Business Jet (BBJ)
Challenger Family
Embraer
Embrear Executive Jets
Embraer
Legacy, Lineage.
Line Maintenance
Base Maintenance
Component Services
Engine Services: CF34
30 | Contacts
Senior Vice President
Corporate Sales
EUMEA
Corporate Sales
Americas
Robert Gaag
p +49-40-5070-68406
[email protected]
Frank Berweger
p +1-305-379-1222
[email protected]
Let’s talk about solutions
Vice President
Corporate Sales
Eastern Europe
and CIS
Dmitri Zaitsev
p+49-40-5070-5404
[email protected]
Vice President
Corporate Sales
USA and Canada
Vice President
Corporate Sales
Europe
Sahib Ajjam
p+1-305-677-5199
[email protected]
Georgios Ouzounidis
p+49-40-5070-5295
[email protected]
Vice President
Corporate Sales
Middle East and Africa
Vice President
Corporate Sales
Latin America
and Caribbean
www.lufthansatechnik.com/sales
Richard Haas
p+49-40-5070-3053
[email protected]
Jörg Femerling
p +1-305-379-2604
[email protected]
Americas
Europe, Middle East and Africa
Canada
Dan Hepworth
p +1-514-245-0143
daniel.hepworth@
lht.dlh.de
BeNeLux
Rudi Preud’homme
p +32-2-752-8690
rudi.preudhomme@
lht.dlh.de
Dubai
Chile
Italy
Emanuela Marabese
p +39-02-58571483
emanuela.marabese@
lht.dlh.de
Turkey
Carlos Sotomayor
p +56-2-2573-7770
carlos.sotomayor@
lht.dlh.de
Ziad Al Hazmi
p +971-4-4057-557
ziad.al-hazmi@lht.
dlh.de
Fulya Türköz
p +90-212-465 55 57
fulya.tuerkoez@
lht.dlh.de
Contacts | 31
Corporate Sales
Asia Pacific
Gerald Steinhoff
p +65-6733-5539
[email protected]
Vice President
Corporate Sales
VIP & Special Mission
Vice President
Corporate Sales
Lessors & Banks
Line Maintenance
Worldwide
Wieland Timm
p +49-40-5070-2548
[email protected]
Andreas Kehl
p +49-40-5070-4780
[email protected]
Michael Struck
p +49-69-696-69660
[email protected]
Affiliates & Corporations
Lufthansa Technik
AERO Alzey
Phone+49-6731-497-0
Fax +49-6731-497-197
[email protected]
www.lhaero.com
Lufthansa Technik
Brussels
Phone +32-2-752-8660
Fax +32-2-752-8673
[email protected]
www.lufthansa-technik.com/
brussels
Vice President
Corporate Sales
North East Asia
Benjamin Scheidel
p+852-2846-6370
[email protected]
Lufthansa Technik
Budapest
Phone +36-1-296-3000
Fax +36-1-296-3001
[email protected]
www.lht-budapest.com
Lufthansa Technik
Component Services
Phone +1-954-440-7014
Fax +1-954-302-3925
[email protected]
www.lht-componentservices.com
Lufthansa Technik
Intercoat
Phone +49-4191-809-100
Fax +49-4191-2826
[email protected]
www.lht-intercoat.de
Vice President
Corporate Sales
South East Asia
and Australia
Zang Thio
p +65-6733-9081
[email protected]
Lufthansa Technik
Landing Gear Services UK
Phone+44-20-8589-1941
Fax +44-20-8589-1901
[email protected]
www.lht-landinggear-uk.com
Lufthansa Technik
Logistik Services
Phone+49-40-5070-5331
Fax +49-40-5070-8667
[email protected]
www.ltls.aero
Asia and Australia
Australia &
Pacific
China
Joseph Giarrusso
p +61-3-9551-9064
joseph.giarrusso@
lht.dlh.de
Steven Wang
p +86-10-6465-1593
steven.wang@
lht.dlh.de
India
Japan
Reshma Singh
p +91-11-2568-7713
reshma.singh@
lht-services-india.com
Hidenori Sato
p +81-45-309-2777
hidenori.sato@
lht.dlh.de
Lufthansa Technik
Maintenance International
Phone+49-69-696-141910
Fax +49-69-696-90942
[email protected]
com/ltmi
Lufthansa Technik
Malta
Phone+356-2560-4000
Fax +356-2560-4190
[email protected]
www.lht-malta.com
Lufthansa Technik
Middle East
Phone+971-4-299-4443
Fax +971-4-25176-55
[email protected]
lht-middle-east
Lufthansa Technik Milan
Phone+39-02-585714-24
Fax +39-02-748-64924
[email protected]
www.lht-milan.com
Lufthansa Technik
Philippines
Phone +63-2-855-9311
Fax +63-2-855-9309
[email protected]
www.lht-philippines.com
Lufthansa Technik
Puerto Rico
Phone +1-787-230-7700
[email protected]
www.lht-puertorico.com
Lufthansa Technik
Services India
Phone+91-22-935-37409
Fax +91-99-5800-5695
[email protected]
india
Lufthansa Technik Shannon
Phone +353-61-370-000
Fax +353-61-361-100
[email protected]
lht-shannon
Lufthansa Technik Shenzhen
Phone+86-755-2777-5925
Fax +86-755-2750-0269
[email protected]
www.lht-shenzhen.com
Lufthansa Technik Sofia
Phone+359-2-4601-777
Fax +359-2-4601-251
[email protected]
www.lht-sofia.com
Lufthansa Technik
Turbine Shannon
Phone+353-61-365-512
Fax +353-61-360-513
[email protected] | www.ltts.ie
Lufthansa Technik
Vostok Services
Phone+7-495-981-5850
Fax +7-495-981-5852
[email protected]
vostok
Lufthansa
Technical Training
Phone+49-69-696-2751
Fax +49-69-696-6384
[email protected] | www.ltt.aero
Lufthansa Bombardier
Aviation Services
Phone+49-30-8875-4600
Fax +49-30-8875-4511
[email protected] | www.lbas.de
Lufthansa LEOS
Phone+49-69-696-8222
Fax +49-69-696-93888
[email protected]
www.lufthansa-leos.com
Airfoil Services
Phone +603-6145-3612
Fax +603-6141-6810
[email protected]
www.airfoilservices.com
Ameco Beijing
Phone +86-10-6456-1122
ext 4100/4101
Fax +86-10-6456-1823
[email protected]
www.ameco.com.cn
BizJet International
Phone +1-918-832-7733
Fax +1-918-832-8627
[email protected] | www.bizjet.com
Hawker Pacific Aerospace
Phone+1-818-765-6201
Fax +1-818-765-5759
[email protected]
www.hawker.com
Heico Aerospace
Phone +1-954-961-9800
Fax +1-954-987-7585
[email protected] | www.heico.com
IDAIR
Phone+49-40-5070-69416
Fax +49-40-5070-64144
[email protected] | www.idair.aero
INAIRVATION
Phone +43-2644-21111
[email protected]
www.inairvation.aero
lumics
Phone+49-40-5070-61361
[email protected]
www.lumics-consulting.de
N3 Engine Overhaul Services
Phone+49-3628-5811-0
Fax +49-3628-5811-8240
[email protected]
www.n3eos.com
Spairliners
Phone +49-40-5070-66499
Fax +49-40-5070-66742
[email protected]
www.spairliners.com
You’ve got
A350
reasons to trust us.
Airlines know what airlines need. That’s why we’re
the best choice for the support of your A350 from
day one. We’re ready for all the maintenance, repair
and overhaul services it will need – even before its
entry into service. We have the technology and the
equipment, but what’s more, we know how to keep
airlines’ most valuable assets where they belong –
in the air. And thanks to our decades of experience,
we can integrate new aircraft types quickly and
cost-effectively into existing fleets. That makes us
the ideal partner for the A350 anywhere in the world.
Lufthansa Technik AG, [email protected]
Call us: +49-40-5070-5553
www.lufthansa-technik.com/a350

Lufthansa Technik | Technik Connection

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