- Lufthansa Technik AG

Transcription

The Lufthansa Technik Group Magazine
5.2015 September/October
From Guideline® to GuideU
Leading the way
for 20 years
Lufthansa Technik in Europe
“Best value
for money”
Maintenance international
Fleet Exit Services
Thumbs up
in Frankfurt
Carefree final
years
2 | Content
Lufthansa Technik Connection 5.2015
“Best value for money”
Georgios Ouzounidis, Director
Sales Europe, about Lufthansa Technik’s
strength in its home market.
6
8
“Thumbs up” for United Airlines
A photo story about Lufthansa Technik Maintenance
International’s daily support for the US carrier in Frankfurt.
The latest-generation emergency floor path marking
system offers unrivaled features.
14
Corporate Sales
• Interview with Georgios Ouzounidis: 6
Aircraft Services
• Maintenance in Frankfurt:
8
“Thumbs up” for United Airlines
• Lufthansa Technik Milan:
13
easyJet increases work volume
• Aircraft Base Maintenance:
16
Start of operations in Puerto Rico
Innovation & Technology
• Fleet Exit Services project:
10
Carefree final years
Original Equipment Innovation • Non-electric floor path marking:
14
• Patient Transport Compartment:
26
Intensive care unit on all
long-haul routes
Component Services
• Airframe Related Components:
18
Extending operational limits of CFRP
• Begin of construction:
19
New wheels and brakes shop
• Lufthansa Technik Intercoat:
22
Epoxy repair of metal parts
Employee Portrait
• Sabrina Hornig: 20
“Prepared for the impossible”
Engine Services
• Airline Support Teams – AST®:
24
Threefold power for on-site support
Categories
• News
3– 4
• Personalities
5
• Events 27
• Products & Services
28
• Contacts
30
“Prepared for the
impossible”
Employee portrait of Sabrina Hornig
who has completed the first part
of her training as Fleet Manager.
20
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
Tilman Tesseraux · Marketing · HAM TS1/M
Weg beim Jäger 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, Hamburg
Design: Art Works! Werbeagentur, Hamburg
Photos: Lufthansa Technik AG, Lufthansa AG
Printing: Beisner Druck GmbH & Co. KG
News | 3
For more information:
www.lufthansa-technik.com/tcs
TCS® for Air Europa’s 787 fleet
The Spanish private airline Air Europa has put the integrated component support
for its future 787 fleet into the experienced hands of Lufthansa Technik.
The contract will start with the arrival of the first Dreamliner in March 2016.
T
he long-term Total Component Support (TCS®) agreement with Air
Europa covers airframe and engine
related component overhaul, engineering
services as well as pooling and Home
Base Lease. The component supply will be
realized via Lufthansa Technik’s German
facilities in Frankfurt and Hamburg.
“For Air Europa, assurance in quality
and flight safety is a key topic,” said Alberto
Linés, Maintenance & Engineering Director
from Air Europa. “In the past we made
good experience with Lufthansa Technik’s
support in different technical services.
This is the reason why we have decided to
expand our partnership with Lufthansa
Technik to component services for our new
Boeing 787 fleet, the future core of our
long-haul operation.”
“We are extremely proud that Air Europa
has put its trust in our capabilities to deliver
the optimal component services for the new
Boeing 787 fleet, making the airline our first
787 customer in Europa,” said Georgios
Ouzounidis, Director Sales Europe, at
Air Europa
Founded in 1986, Air Europa is the airline of Globalia Corporacion Empresarial,
one of the largest touristic groups in
Spain with its headquarter in Palma de
Mallorca. Air Europa is full member of
the Sky Team alliance and operates
over 170 daily flights on domestic,
European, North African and Transatlantic routes with Madrid as its major hub.
Its fleet comprises of 14 Airbus A330,
20 Boeing 737NG, 11 Embraer 195
aircraft and will add 22 new Boeing 787
from 2016. //
L ufthansa Technik. “This contract signature
is the latest milestone in our long-lasting
partnership which started in 2002. We will
do our best to help ensure that Air Europa
continues to meet its customers’ expectations of providing a highly reliable product.”
Since 2002 Air Europa has contracted
Lufthansa Technik with different maintenance, repair and overhaul services. Currently, Lufthansa Technik is providing landing gear services for the airline’s Boeing
737NG and Airbus A330 fleets and is also
executing overhaul services for a certain
number of CFM56-7 engines. Lufthansa
Technik Aero Alzey is overhauling the
CF34-10 engines of Air Europa’s Embraer
195 Fleet.
Markus Salzig
Phone +49-40-5070-4096
[email protected]
4 | News
Hamburg
Berlin
Manila
Hangar expansion
on track
Lufthansa Technik Philippines
// Six months after the Manilabased aircraft maintenance,
repair, and overhaul (MRO)
provider broke ground in January to extend its main hangar,
Lufthansa Technik Philippines’
hangar extension is on track.
“With the rising opportunities
presented by regional growth,
we have been building up our
capabilities. This hangar expansion project is the latest in our
continued efforts to meet different aircraft requirements and
stay competitive in the market,”
says Dr. Burkhard Andrich,
President and CEO of Lufthansa
Technik Philippines (LTP).
The construction expands two
existing bays equipped with
versatile docking systems that
can accommodate current
widebodies and newer models
of the Airbus A350, Boeing
777-9X, and 787. This will also
be Lufthansa Technik Philippines’ second line for A380
base maintenance and its entry
into Boeing 777 base maintenance. The development is
expected to expand the
company’s yearly capacity by
200,000 manhours. //
Extension of contract
with FedEx
Lufthansa Technik Logistik
Services // Federal Express
(FedEx) recently extended its
existing transport contract with
Lufthansa Technik Logistik Services (LTLS). FedEx is a logistics
service provider that offers
worldwide courier, express and
parcel services (CEP) among
others.
Lufthansa Technik Logistik Services’ central transport procurement division in Hamburg
negotiated the Lufthansa Technik
Logistik Services import and
export rates as well as the freight
tariffs for Lufthansa Technik
Component Services (LTCS)/
America (LTLA). The logistics
division of Lufthansa Technik
Component Services is responsible for integrated transport
and warehouse solutions and is
an integral part of the global
Services logistics network.
Transport costs were reduced
significantly as a result of the
central freight negotiations,
resulting in an enhanced competitive edge for Lufthansa
Technik.
Ingmar Bergman, Vice President
Sales at FedEx, said: “We operate an airline ourselves and are
part of this sector. We know
only too well what is important
for aviation companies in terms
of their transport – whether
especially fast transit times for
urgently needed spare parts,
customs clearance or documentation. We are all the more
pleased therefore to continue
the shared success story with
Services into the future.” //
Beijing
V2500 capability
approved
Ameco Beijing // On June 30,
2015, Ameco’s capability application of IAE V2500-A5 series
engines has been approved by
the Chinese CAAC as well as
by the US aviation authority FAA
and the European EASA. Thus,
Ameco has been authorized to
provide overhaul and modification on V2500-A5 series.
The service on V2500-A5
engines as a new product will
help promote Ameco Beijing’s
market competitiveness and
support it to serve more customers at home and abroad.
The first engine for overhaul
was planned to the workshop in
July. In addition to V2500-A5
series, the Beijing-based MRO
provider overhauls PW4000
series and RB211-535E4
series, also provides QEC kit
and module change on CFM56
series. //
Expanded cooperation
with OHS
Lufthansa Bombardier Aviation
Services // OHS Aviation Services, the specialist for interior
design of business jets, and
Services (LBAS), a Lufthansa
Technik joint venture and leading
maintenance facility exclusively
for Bombardier business jets,
now offer more services from a
single source.
“We now want to expand our
successful cooperation in the
form of joint customer acquisition
abroad and rely on combined
refurbishment and maintenance
product packages,” says
Christoph Meyerrose, CEO of
Services. For the customer,
refurbishment services are
attractively priced and optimally
integrated into a forthcoming
check. Even short-term requests
are served. OHS has also
expanded its engineering sector: besides “Minor Changes”,
the EASA Part 21J-certified
Design Organization can now
permit “Major Changes” and
Supplemental Type Certificates
for all aircraft categories.
At Berlin Schönefeld airport,
LBAS and OHS offer a comprehensive maintenance and refurbishment program, including
engineering services. The close
proximity of both companies
allows a straight forward common customer care which has
proven to be very efficient over
the years. //
Personalities | 5
Robe rt Gaag has
been promoted to the
position of Vice President Corporate Sales
EUMEA. As of October
2015, he will take over
this responsibility from
Wolfgang Weynell, who held this position
together with the office of SVP Corporate
Sales & Marketing. With a Master’s Degree
in Aeronautical Engineering from the
Technical University of Munich, Robert Gaag
started his career as Project Engineer for
MTU Munich in 1986. He joined Lufthansa
in 1989 as Project Manager in the aircraft/
engine evaluation team in Hamburg. After
an assignment as Resident Representative
for Lufthansa at the Boeing Company in
Seattle, he returned to the Technical Directorate of Lufthansa Passenger Airline Services in Hamburg in 1995 as Boeing 747
Fleet Manager.
Robert Gaag joined Lufthansa Technik in
2000 as Manager Key Accounts Lufthansa
Group before he was assigned the position
of Sales Director Central Europe in June
2002. Before his latest p
romotion he served
as Vice President Sales North America.
Sahib A j jam
has been appointed
Regional Director Sales
North America, succeeding Robert Gaag.
Effective October 1,
Sahib Ajjam will be
leading Lufthansa Technik’s sales activities in the USA and Canada together with
his team in Miami and the affiliated sales
organization in North America.
Sahib Ajjam possesses a wealth of MRO
experience. After earning a degree in
mechanical engineering at the University
of Braunschweig, Germany, he started
his career as a Key Account Manager for
Schott Glass in 1994. He joined Lufthansa Technik in 1996, working as a project
engineer in the engine MRO division.
Further responsible positions with Lufthansa Technik included Project Director
Airbus A318 Elite, Director of Narrowbody
VIP-Programs and, since 2008, Director
of Aircraft Maintenance Munich.
Thomas Kuhn has
been named new President and CEO of BizJet
International. He succeeds Manfred Gärtner,
who has been leading
BizJet International since
2013. Thomas Kuhn studied aeronautics
and completed his education with a diploma. In 1989 he joined Lufthansa Technik,
holding various management functions
during the following years. In 2008, Kuhn
became Sub-Division Manager Overhaul at
Ameco Beijing, the Lufthansa joint venture
with Air China. Prior to his latest promotion,
Thomas Kuhn served as Director Engineering Services in Lufthansa Technik’s VIP &
Executive Jet Maintenance Business Unit in
Hamburg.
Holger Beck has
been appointed Director
Business Development,
Sales and Customer
Services of Lufthansa
Technik Maintenance
International (LTMI).
Holger Beck is an electronics engineer, holds
a Master’s degree in Technical Management and a Senior degree in Airline Management. Since joining Lufthansa Technik
in 1989 he has held numerous responsible
positions, among them Managing Director
at Lufthansa LAN Technical Training in
Chile and General Manager at Lufthansa
Technical Training Philippines. Prior to his
latest promotion he was Director Finance
and Key Account Management at Lufthansa
Technik Maintenance International.
Andr eas van de
Kuil has taken over the
position of Chief Executive
Officer (CEO) at Lufthansa
Technik Vostok Services
in Moscow effective September 1, 2015. Andreas
van de Kuil studied at the
Northeastern University, Boston and the
European School of Business (ESB
Reutlingen), where he acquired a Master in
International Business Administration. He
joined the Lufthansa Technik sales team in
2009 as Project Manager Sales Support.
Before being promoted to his current position, he served as General Sales Manager
Russia & CIS located in Moscow.
S andr a E ckstein
has taken over the position of Managing Director of Lufthansa Technik
Landing Gear Services
in London, UK.
Sandra Eckstein can
look back on more than a decade of
experience in aviation, launching her carreer at Lufthansa CityLine. With numerous
trainings in project management, leadership competence and others she soon
aquired responsible management positions.
She joined Lufthansa Technik in 2007,
working in Strategy and Product Management, as team leader Key Account
Management and as manager c
ontract
controlling. In 2013 Sandra Eckstein was
given the responsibility of CFO of Lufthansa
Technik Landing Gear Services UK Ltd, the
position she held before being promoted
to her current field of work.
C hr istian
L anger has been
appointed as Managing
Director of Lufthansa
Technik Logistik Services
(LTLS) with effect from
September 1, 2015.
Christian Langer has earned a PhD from
the WHU – Otto Beisheim School of
Management and a Master’s Degree in
Computer Science from the University of
Koblenz. He joined Lufthansa Technik in
2004, being responsible for the introduction of lean production principles in the
Aircraft Maintenance Division in Frankfurt.
In October 2007 he was appointed as
Head of Lean Production Management for
the Lufthansa Technik Group. In 2012 he
additionally took over responsibility for a
restructuring project of the administrative
body of Lufthansa Technik.
Since July 2013, Christian Langer has
been Managing Director of Lumics, the
joint venture between Lufthansa Technik
and McKinsey & Company.
6 | Corporate Sales Europe
tober 201
Oc
5
13-1
5
In the run-up to this year’s MRO Europe in London (October 13 – 15) Connection talked to
Georgios Ouzounidis, Director Sales Europe at Lufthansa Technik, about the supporting pillars
that will enable the MRO provider to remain market leader and a partner for airlines in every
market segment in the future.
MRO e
p
Euro 426
Booth
n
Londo
What’s the current situation of the
MRO industry in Europe?
Georgios Ouzounidis: We have a market
of 6,000 aircraft in Europe, which is
divided into three major segments: First,
there’s the large legacy airlines, secondly
the major low-cost airlines and finally the
third group consisting of small and medium-sized airlines. Overall, the market is
growing by three to four percent a year,
but the development in different segments
varies significantly. The most prominent
growth is generated by low-cost airlines –
growth rates in the other two segments
are relatively low.
If you want to grow in this low-cost segment, you automatically expose yourself
to cost pressure, which is particularly
pronounced here. There are no niches
where operators can flourish undisturbed.
As a result, there is great pressure on
suppliers, including MRO companies, to
reduce costs and provide better services.
In addition, OEMs are pushing into the
MRO market, intensifying the competition
even further.
How does Lufthansa Technik
operate in this environment?
Lufthansa Technik can only prevail through
a combination of factors: Price, service,
product and location, which all have to
be just right. Our advantage is that we’re
well positioned: Europe is our home market and we have the biggest market share.
Lufthansa Technik takes care of 960 aircraft in Europe alone, plus the aircraft of
Lufthansa German Airlines. We have an
excellent network of facilities in our home
region, for instance in Budapest, Sofia,
Malta and London, to name just a few.
This size as well as our global network
and good relations to many customers
Corporate Sales Europe | 7
gives us the opportunity to defend or even
increase our market share. To ensure continuous growth, we need first-class service
and high customer satisfaction. At the same
time, we are establishing partnerships with
our customers, since that creates a true
win-win situation. What characterizes us is
that Lufthansa Technik takes a long-term
view of the MRO business to minimize the
total cost of ownership for its customers
and create value in the long run.
subsidiary of Lufthansa, we at Lufthansa
Technik know how airlines think and what
the challenges are for an airline’s daily
operation. We know how important reliability is. That’s what sets us apart from
other MROs without an airline background, MRO providers simply can’t have
the same understanding of the customer’s
situation.
Our primary consideration is always to
understand the customer’s requirements.
Listening and understanding are important
so that we can then create a tailor-made
solution. As a full-service provider, we are
able to optimally adapt our products to
these customer requirements. One example is our IT integration: We have readymade interfaces available that we can
offer and activate quickly so that the customer experiences fully integrated service.
What are the highlights of the
current fiscal year in this context?
At the beginning of 2015, Lufthansa Technik
won a major support contract for the
Thomas Cook fleet and phased in a variety
of aircraft types at different locations in a
very short time. We were able to implement
this seamlessly, providing excellent customer satisfaction – this proved a great
What role does the company’s
success and demonstrated that what
innovative power play here?
Lufthansa Technik promises will be delivered. The A350 contract with Finnair shows We are the most innovative company in
the MRO industry. Through our innovathat we’re also excellently positioned to
tions, we convince many potential customeffectively and efficiently support this new
aircraft type. That we were able to sign the ers that we’re the best partner to work with
– a partner who helps reduce costs, for
first A350 supply contract worldwide
example through repair procedures that
speaks for itself. We were awarded the
have been develcontract because
oped in-house.
we know what it
Every year, we
means to phase in
We prove on a daily basis
invest millions of
a new aircraft type
that we serve the low-cost
euros in innovations
– after all, we’ve
segment very well.
and generate prodbeen doing this
Georgios Ouzounidis
ucts that meet the
successfully again
requirements of
and again with
customers. And our customers know that
other new aircraft over the past years. The
first TCS® (Total Component Support) con- they’re working together with the best and
most innovative MRO provider. That is a
tract for the 22 aircraft of Air Europa’s
strong argument because customers ben787 fleet (see article on page 3) also highefit from having a share in that. And in
lights our convincing performance. Our
terms of the specified targets, our airline
success can be attributed to the fact that
experience comes into play once again.
we understand and solve the problems of
We know what airlines are concerned with:
our customers. This kind of thinking is not
problems such as fuel consumption, relimerely a claim; it’s firmly fixed in the
ability and other vital issues. That’s why we
heads of our employees – they’re able to
develop products to support customers
think and understand the problems from
with these points in particular.
the perspective of an airline.
“
What characterizes Lufthansa
Technik in particular?
One outstanding factor is our airline experience. There are many customers in
Europe who want to work together with a
partner who thinks like they do. And as a
Which role does the global
Lufthansa Technik Group play for
European customers?
Since our customers fly throughout the
world, they benefit from our network everywhere. Our strength here is once again
Photo: Airbus S.A.S. 2014
that we’re able to help them quickly all
over the world. Whether it’s a component
pool in Miami, a component workshop in
Shenzhen or the base maintenance
location in Manila – our customers benefit
directly from our great number of sites.
Many customers from Europe, for example,
fly their aircraft all the way to Manila for
base maintenance layovers.
What development are you aiming
for over the coming years?
Our success is based on greatest possible
customer satisfaction and this leads to our
customers staying loyal to us year after
year. That’s the foundation of our customer
retention philosophy. But of course we
also want to generate more business in
the growth segment of low-cost airlines.
After all, we prove on a daily basis that
we’re capable of serving this market segment very well. As a full-service provider
for Wizzair, for instance, we’re supplying
the biggest ultra low-cost carrier in Eastern
Europe. For me, that's a perfect example
to show we’re also able to provide excellent services at reasonable prices in this
segment.
Low-cost airlines are not always looking
for the lowest unit price for single maintenance activities, but often they seek the
lowest total cost of ownership – and we
can deliver that.
Which pillars will support
Lufthansa Technik in future?
What makes us strong is a combination
of the following elements: customer satisfaction, efficient products, best value for
money and beneficial innovations. These
four pillars are a basis upon which we can
build the future.
8 | Aircraft Services
“Thumbs up”
for United Airlines
When the line maintenance technician in Frankfurt signals “thumbs
up” for UA 945 to Chicago at 8 AM he knows the day has been
set for a good start. It is the first of eight daily flights that United
Airlines operates out of Frankfurt, with Lufthansa Technik
Maintenance International (LTMI) performing the transit checks.
U
nited’s major destinations in Europe
are London, Paris and Frankfurt.
Since June, transit checks in Frankfurt are performed by Lufthansa Technik’s
Frankfurt-headquartered line maintenance
organization Lufthansa Technik Maintenance International. Currently Boeing 747,
767 and 777 aircraft are serviced and,
starting in September, the new 787
Dreamliner will join the fleet. “That is quite
a challenge”, says Matthias Thon, who is
coordinating the team of mechanics that
take care of United Airlines. “Departure
times are stretched over the day, so we
had to adjust our shift pattern accordingly.”
Matthias Thon is upbeat when he describes
how the team put their act together.
“Six mechanics are dedicated to United’s
operation in Frankfurt every day. Planning
is a challenge, not only because we saw
a 15 percent increase in the number of
United Airlines
ICAO-Code: Founded: Headquartes: Fleet: Employees:
Passengers: Alliance: UAL
1926
Chicago, IL, USA
712
84.000
138 million
Star Alliance
departures that we handle.” Thon’s
department is supporting about 50 different airlines in Frankfurt.
Lufthansa’s own operation is handled
by a separate unit. “We found the dedication to customers more effective, so we do
not mingle with the more than 400 daily
departures of Lufthansa in Frankfurt.” The
dedication pays off when the requirements
are clearly different, best illustrated by the
types of aircraft that are handled. Matthias
Thon explains: “Equipment is sometimes
substituted, say a 767 is scheduled to
operate a flight that is normally performed
by a 777. In such a case I’m glad that I
can count on the flexibility of our staff.”
A lot of flexibility was also needed to
start the transit checks in the first place.
“After being awarded the contract we had
about four weeks to prepare. Thanks to a
lot of support from United themselves we
were able to set up a training scheme in no
time. Some of our guys had to postpone
plans for summer holidays, but that’s ok.”
A lot of flexibility
From a mechanics point of view today’s
767 may not be quite the same as yesterday’s 767 on the same flight, because the
fleet of United reflects the 2010 merger
with Continental airlines. The aircraft are
released to service electronically in United’s
IT system and in case of trouble there is
always the Technical Operations Maintenance Control Center of United Airlines
that can be contacted 24/7.
At 5 PM the last flight of the daily shift is
released to San Francisco. While the passengers relax in their seats, Matthias Thon
gets the message that the transit check
went all right, the aircraft has been
released and his mechanics are packing
up for the day. He has meanwhile done
the preparations for the coming days.
Aircraft Services | 9
Responsible for the transit checks in Frankfurt:
Matthias Thon is coordinating the team of
mechanics and seen here checking various items.
Line Maintenance in Frankfurt
// Lufthansa Technik Maintenance International (LTMI) offers maintenance services
and technical support to Lufthansa Technik’s
international maintenance customers.
Lufthansa Technik’s maintenance subsidiary
has all the required aviation authority approvals and has developed within a short time
into an important hub of expertise for aircraft
maintenance within the globally operating
Lufthansa Technik Group. In addition to
carrying out aircraft maintenance for all of
the current Airbus and Boeing aircraft
types, the company’s portfolio of services
also includes heavy checks (IL- and D-checks)
of the Boeing 757 and 767 series aircraft. A
dedicated Customer Support Center (CSC)
is functioning as L ufthansa Technik’s central
point of contact for all technical enquiries of
its maintenance customers. //
www.lufthansa-technik.com/
linemaintenance
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Carefree final years
no
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In
Innovation & Technology | 11
a Te c
h
With larger fleets being replaced by newer aircraft generations, Lufthansa Technik’s ongoing
“Fleet Exit Services” project is establishing the base for a significantly improved service
portfolio dedicated to supporting customers even better in phasing out their flying assets.
S
everal hundred passenger aircraft
are taken out of service every year
around the world, with an increasing tendency. Some 450 aircraft will be
decommissioned each year in the next five
years alone, and more than 350 others will
be returned to lessors. These are primarily
aircraft in the Airbus A320 family, A330/
A340 as well as Boeing 737 Classic/NG,
747, 767 and Bombardier CRJs – aircraft
types that Lufthansa Technik has in its
portfolio. Airlines frequently do not have
the required expertise when it comes to
these phase-outs, especially in relation to
optimizing residual lifetimes and parts
management.
Because of their complexity and rare
occurrence, phase-out programs constitute an exceptional additional burden on
top of daily business for many customers.
Often, the parallel introduction of new
aircraft further adds to the intricacies operators are facing during this phase. The
resulting operative and financial risk is
difficult to quantify, especially considering
the required handover conditions for the
phased-out aircraft. Lufthansa Technik is
therefore developing an integrated service
portfolio together with selected clients
that will ease the burden on airlines in the
future.
Optimized supply
Based on the results of the ongoing project
“Fleet Exit Services”, Lufthansa Technik
is developing a plan to offer a significantly
improved service portfolio in 2016, dedicated to customers who want to phase out
their aircraft fleets. Operators would then
have the option of transferring the tasks
associated with a fleet exit fully or partially
to Lufthansa Technik, which would support
customers with their phase-out planning.
Customers will benefit from Lufthansa
Technik’s know-how in the thorough preparation of phase-out programs as well as
through a financially and technologically
optimized maintenance and material
supply tailored to the individual customer’s exit scenario, without reductions in
reliability or safety.
Customers also enjoy the scale effects
of a large MRO provider with a broad
customer base. These economies of scale
are not achievable when supplying a small
fleet in-house. The existing in-house capabilities of customers can also be incorporated in the supply concept.
The goal of the Fleet Exit Services project is to optimize maintenance services in
the final years of the fleet’s operation and
at the same time enable seamless aircraft
availability. The affected aircraft therefore
receive – in close coordination with the
customers – integrated, individual and
cost-effective technical support. A simple
transition to an attractive overall product
will be ensured by bringing together a
number of tried and true individual measures and products that are currently
offered by Lufthansa Technik, and making
effective use of the global Lufthansa Technik
Group network and strategic partners. This
applies, for example, to the intensified use
of surplus material in the area of components and landing gear parts, and to the
targeted optimization of repair scopes and
the residual lifetimes of engines in relation
to the individual exit scenario. The latter is
already available today through Lufthansa
Technik’s comprehensive smart.life product.
Risk reduction
Owing to some degree to its very close
and successful long-standing cooperations
with authorities and original equipment
manufacturers (OEMs), Lufthansa Technik
would also be able to handle regulated
lifetime extensions. The employment of
Lufthansa Technik’s flexible Airline Support
�
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12 | Innovation & Technology
Teams performing smaller on-site works
further help to avoid bigger shop events
shortly before phase-out. This gives airlines
greater flexibility cost- and time-wise with
their phase-out planning, while fulfilling
their requirements for meeting the specific
handover conditions.
The range of services envisioned by an
improved services package also include
support for the demanding field of aircraft
documentation. Thanks to a long-term and
close consultation with the customers and
recipients of the phase-out fleets (usually
lessors or traders), the financial risks of
phase-out programs are reduced significantly and planning certainty is increased.
Even long after the phase-out, Lufthansa
Technik can answer questions on aircraft
documentation.
Individual financial solutions
Customers’ financial maneuverability
and ultimately their competitiveness are
strengthened through asset acquisitions,
purchase-and-lease-back options and
individually coordinated billing and financing solutions (e. g. in regards to maintenance reserves). Moreover, the recycling
potential of non-reusable material of
decommissioned aircraft is currently being
assessed with the aim of feeding highquality materials back into the industry’s
recycling material chain in cooperation
with specialized partners. Not only will this
allow additional cost savings potential to
be exploited, but resources can be saved
and the burden on the environment
reduced.
Support with the introduction of new
fleets and with potential organizational
adaptations (e. g. training, provision of
tooling, etc.) round off the service portfolio.
The “Fleet Exit Services” project will
therefore not only lead to a modular,
flexible and customizable product that
provides airlines with cost-effective maintenance services and improved material
management, but will also support airlines
in concentrating on their core business
and the introduction of new aircraft
types.
Ulrich Hoffmann
Phone +49-40-5070-67709
[email protected]
Major retrofit for A380
Lufthansa Technik Philippines (LTP) successfully carried out a passenger door retrofit and flap
track #6 modification on an Airbus A380. The modification is the first such event performed within
the Lufthansa Technik Group, underlining LTP’s status as the Group’s center of excellence for
Airbus A380 overhaul services in Asia.
M
odification programs for the LH/
RH flap track #6 assembly and all
16 doors of the A380 are the latest
from the service bulletins implemented by
Airbus to address and improve the aircraft’s performance as it enters maturity.
Despite the extensive program, the A380 is
safe to fly and operators can opt to carry
out the passenger door retrofit program at
planned intervals alongside scheduled
C-checks. For this particular event, the aircraft underwent a C4-check at the Manilabased facility, combined with retrofit tasks
for wing-rib, flap tracks, and passenger
doors. Major modifications entail MRO
providers to work closely with OEMs. To
prepare for this competency, structural and
aircraft mechanics of Lufthansa Technik
Philippines were trained by Airbus experts
on site. The onsite Airbus retrofit team also
assisted Lufthansa Technik Philippines in
setting up dedicated equipment and the
right environment to support the aircraft’s
large components.
During the retrofit programs, the doors
and flap tracks are carefully detached from
the aircraft for structural modifications and
reinforcements. With the necessary modifications complete, the doors and flap
tracks are prepped, re-installed and skillfully
rigged back to the aircraft. Lufthansa
Technik Philippines will perform more passenger door and flap track retrofit works for
the A380 in the coming months.
“We are committed to helping A380
operators optimize their aircraft’s ground
time by offering our customers a comprehensive service suite for their requirements,” says Marek Wernicke, Senior
Vice President for Base Maintenance at
Lufthansa Technik Philippines.
easyJet increases work volume
easyJet, the leading low-cost airline in Europe, has enlarged its contract with Lufthansa
Technik Milan, raising the volume of work by some 50 percent. The Lufthansa Technik
subsidiary is thus growing with the increasing demand of the customer.
E
asyJet, the European low-cost airline based in London Luton Airport,
has been a customer of Lufthansa
Technik Milan at the Malpensa airport
(MXP) since late 2010, when a light base
maintenance line was established at the
North Italian hub, easyJet’s largest on the
European mainland. The contracted
scope of work has grown continuously
ever since, ranging from equalized maintenance checks to comprehensive defect
rectifications to structural repairs and
modifications for the airline’s A319/320
aircraft fleet. The current volume increase
involves the installation of a second light
base maintenance line for several days
per week.
The planned rise in work volume is
caused by the remarkable expansion of
easyJet’s fleet. “We were looking for additional maintenance capacity within our
existing network, and based on our experience with Lufthansa Technik in Milan,
increasing capacity here was a logical
decision,” states Brendan McConnellogue,
Head of Line and Base Maintenance at
easyJet. “The Lufthansa Technik team in
Milan has adapted very well to our requirements of on-time performance, flexible
problem-solving and transparent communications. We are happy to extend our
partnership in MXP.” Jürgen Hupe, Managing Director of Lufthansa Technik Milan,
highly appreciates the additional work:
“We are proud to have been entrusted with
this program expansion, while we are also
aware that we have to confirm the trust
every day. It is a privilege for us to work
with a benchmark partner like easyJet.”
easyJet has contracted Lufthansa Technik
line and light base maintenance services
also in Berlin-Schönefeld as well as line
maintenance services in Hamburg. In
addition, Lufthansa Technik performs
engine washes (Cyclean®) for the entire
easyJet aircraft fleet at various stations
across Europe on an annual basis.
Cesare Ghermandi
Phone +39-02-585714-24
[email protected]
14 | Technology & Innovation
vation b
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In
a Te c
h
The modern emergency floor path marking system GuideU 1000 offers unrivaled
features with respect to installation effort, reliability, and flexibility. It represents the
enhanced development of the first system based on the principle of photoluminescence,
which Lufthansa Technik introduced some 20 years ago. A true success story.
T
he impetus for development came
directly from Lufthansa German
Airlines. Continuous defects were
occurring in the electrical systems at
Lufthansa powering the emergency exit
routes, with more than 200 delays by more
than 10 minutes being recorded annually.
Because the emergency floor path marking
system is part of the Minimum Equipment
List (MEL), a repair was then necessary
each time prior to start-up. In their efforts to
ensure maximum reliability, the developers
came upon the principle of photoluminescence. A suitable plastic is “charged” so to
speak by illuminating it in a relatively short
time and then releases the stored energy
again slowly. Lamps, wires, and a current
source as well as all associated potential
errors are quite simply eliminated.
To allow use as a replacement for the
electrical systems used to date, its width
was used as a guide for the strip width of
the new system. However, while the electrical systems were only installed on one
side of the exit path, the new system was
installed on both sides, therefore offering
a clearly visible view of the aisle. The system, which was developed in cooperation
with an external manufacturer, was initially
installed in the Lufthansa fleet. The experience of the airline with the new system
was so good that a contract was concluded with Airbus in 1999, which saw the
Original Equipment Innovation | 15
20 years of progress: Hans-Christian Lierow (left)
headed the GuideU product since 1999. As of
April 2015 Torben Biehl has taken on this task.
equipping of all new aircraft for Lufthansa
with the system, referred to by the name
Guideline® Classic.
The first external customer for the innovative product was Southwest Airlines in
2000. The airline had its large Boeing 737
fleet equipped with Guideline®. In this case
also, the customer was unhappy with the
unreliability of the electrical system installed
ex works and therefore decided to replace
it at the first maintenance layover with the
Lufthansa Technik product.
Colored, curved, light-weight
A dedicated product team was formed in
2004 in Lufthansa Technik, whose primary
tasks included developing an improved
system. Aircraft manufacturer Airbus was
looking for a lower-weight system, which
could also offer a variety of colors. The
result was presented at the Aircraft Interiors
Expo in 2005. Guideline® Colorfit fulfilled
the requirements precisely and was available initially in eight colors.
This system was not only installed in the
Airbus A380, but also as standard then in
an entire series of popular aircraft types. A
contract was subsequently signed with
Bombardier in 2007 for equipping the CRJ
regional jets. Lufthansa’s 747-8 was also
ordered with this system. The next stage
in development followed on from a call for
tender from Airbus. Lufthansa Technik
developed the current system under the
name GuideU 1000. It offers more colors
and with only one part number won the
tender for the standard equipping of the
A350. Boeing also took on the ultra-modern system later as an option for the 787.
The last development stage followed
one year later. GuideU ColorCurve is the
first emergency exit route marking system
that can be installed in almost any radii. It
therefore not only offers the design team a
greater degree of freedom, it is also lighter
than all previous systems. The weight
savings in the case of a twin-aisle aircraft
amount to almost 8 kg. With a thickness of
2.5 mm, it is also compatible with the very
www.guideu.com
thin carpets that are being used increasingly.
Extremely light underlays are available for
thicker floor coverings. And another advantage: The material can be installed in the
aircraft using a simple tool.
Thanks to its excellent properties, GuideU
1000 represents the pinnacle of a development that began 20 years ago with a simple,
illuminated plastic green strip.
Torben Biehl
Phone +49-40-5070-66623
[email protected]
Customer advantages
• No life limit
• No maintenance
• No power required
• FAA/EASA approved
• Light weight
• Curved shapes
• Cuttable on board
• 19 different colors
• One-piece system
Start of operations in Puerto Rico
On July 21, Lufthansa Technik’s new overhaul facility in Aguadilla, Puerto Rico has started
operations with its first overhaul line. On time and just eleven months after ground-breaking in
August 2014 the first Airbus A320 from US-carrier Spirit Airlines arrived for a C-check.
A
pproved according to FAA Part 145
and EASA Part 145, Lufthansa
Technik Puerto Rico (LTPR), the new
member of the Lufthansa Technik’s base
maintenance network, has commenced
operations. Initial customers are Airbus A320
family aircraft operators, Spirit Airlines and
JetBlue Airways, from the Americas. A second overhaul line is planned to be operational in November, followed by three more
lines until early 2017 to include Boeing 737
by then.
“Lufthansa Technik Puerto Rico has been
founded to strengthen significantly our service portfolio in the Americas, one of the
most important MRO markets worldwide.
I would like to thank Governor Alejandro
García-Padilla and his team for their comprehensive support and the excellent partnership which we could establish over the
past two years,” said Dr. Johannes Bussmann, Chairman of the Executive Board of
Lufthansa Technik. “And of course, I also
would like to thank our launching customers, Spirit Airlines and JetBlue Airways, for
the trust they have set in us in the forefront
of this day. With the arrival of the first A320
Lufthansa Technik Puerto Rico becomes
operational. Management and staff can
be really proud of what they have achieved
so far.”
“Today we begin to see the results of
one of the most important projects of the
economic agenda of this administration.
Even in the midst of the fiscal situation our
country is facing, we continue working to
carry out those strategies which result in
economic benefits for our island. Today,
this MRO is finally a reality. The agreement
between the government of the Commonwealth of Puerto Rico and Lufthansa
Technik begins to translate into work and
the facility begins to offer its services.
Nonetheless, this is only the beginning.
We will continue to see these facilities
become the economic motor of this region
both because of the jobs they create and
their national and international alliances.
Results such as these are the ones that
guarantee that Puerto Rico has the capacity to overcome our present and inherited
economic situation and achieve sustainable growth, as we unite outside of political party lines and commit to radically
transform the way in which our government and our economy operates,” said
Governor Alejandro García-Padilla.
State-of-the-art technologies
“We are thrilled to be Lufthansa Technik’s
first customer in Puerto Rico,” said Spirit
CEO Ben Baldanza. “We’ve had a long
history with them as they have provided
excellent support on our Airbus fleet
through inventory, parts repairs and Reliability Engineering support. We’re excited
about the next chapter as they provide
heavy maintenance airframe support in
Puerto Rico.”
“This is a fantastic moment for us,” said
Elmar Lutter, CEO of Lufthansa Technik
Puerto Rico. “I would like to thank my
team which has carefully planned and
worked hard for this moment since the
beginning of this project two years ago.
Now we can focus on the next milestones
which are the ramp-up of the operations,
the further development of our capabilities
and the constant training of our highly
motivated employees. I’m sure that
Lufthansa Technik Puerto Rico will become
an internationally acknowledged center of
excellence for base maintenance services
soon.”
Currently, about 140 highly qualified
employees have been trained and are
working for Lufthansa Technik Puerto Rico.
It is planned to grow up to a workforce of
400 in the next two years. The facility
extends over a total area of 215,000
square feet. In its final configuration it will
offer five lines for base and heavy maintenance checks (C-, IL- and D-checks), along
with other maintenance work on narrow
body aircraft. By using state-of-the-art
technologies it is even possible to paint
aircraft in the hangar while overhaul work
is being conducted in parallel.
Thanks to the geographic location of
Lufthansa Technik Puerto Rico in Aguadilla,
on the west edge of Puerto Rico, the maintennace facility is within flying distance of all
Airbus A320 family aircraft in the Americas.
Lufthansa Technik Puerto Rico
Phone +1-787-230-7700
[email protected]
Precisely according to schedule: Employees of Lufthansa
Technik Puerto Rico have gathered to salute the first customer
aircraft, a Spirit Airlines Airbus A320.
18 | Component Services
Extending operational limits of CFRP parts
Engineers in the Airframe Related Components (ARC®) unit of Lufthansa Technik have succeeded in
extending the lifetime of the CFRP cascades of the CF6-80C2 thrust reverser. This highly innovative
approach even eliminates the need for repairing such cascades within newly established limits.
Reverse engineering of the
cascade involved cutting it up
at critical sections.
T
he cascades of a thrust reverser redirect the airflow forward and hence
ensure the desired deceleration of
the aircraft after landing. The CF6-80C2
thrust reverser uses carbon fiber reinforced
composite (CFRP) cascades in order to
reduce weight. During overhaul a certain
percentage of these components exhibit
defects. During the inspection phase
cracks could be found at certain edges with
a high probability. If the crack length
exceeds predefined limits, the manufacturer
prescribes the scrapping of such part.
While exploring potential savings – one
cascade segment costs approximately
5,000 US dollars and max eight each are
installed in one CF6-80C2 reverser half –
the ARC® experts at Lufthansa Technik
started to carefully examine the component. In order to gain a better understand-
ing of the cascade’s stress characteristics
and the resulting strain, an engineer specialized in such tasks established a finite
element model (FEM) of the component
and performed a simulation. The first issue
which needed to be solved was that the
properties of CFRP structures are dependent on the direction of the embedded
fibers. As this inner structure cannot be
Finite element analysis was used to simulate
operational loads of the cascade.
identified from the outside, a defective cascade was cut at the critical areas in order
to determine the fiber orientation as well as
the number and thickness of the individual
layers. Reverse engineering then enabled
the compilation of a precise, accurate and
comprehensive computer model.
Damage simulation
Operating loads were applied to this model
during the next step. For this calculation
the ARC® experts benefited from the fact
that they were able to draw on values
measured while testing the engines after
overhaul on the Lufthansa Technik test
bench. The load range for the cascade
was simulated with the measured data.
The results showed that an asymmetrical
load is created in the cascade when the
Component Services | 19
New wheels and brakes shop
Lufthansa Technik has begun the construction of a new wheel
and brake workshop at Frankfurt’s East Harbor. The ultra-modern
facility will create sufficient capacity for the foreseeable future.
thrust reverser is operated, which
causes the cracks to appear. The ARC®
specialists went ahead with another
decisive step. They asked the question:
What impact might such cracks induce
to the future operating behavior of the
component? To find that out, a simulation
of the operation of a cascade that was
already damaged was introduced. The
result was to some extent perplexing:
the damage that occurred namely has
no influence on to the reliability of the
component. Based on this result, the
engineers acknowledge the possibility
to extend the lifetime limit of a defective
cascade following individual inspections
– with immediate knock-on cost savings
for the operator. The corresponding
approval was issued and approved at
the end of August 2015. Furthermore,
additional applications to other reverser
types with similar structures are being
planned.
The analysis of a vast number of units
at Lufthansa Technik was needed to
achieve such result. In addition to the
encompassing know-how of the innovation engineers at the ARC® business unit
in the areas of composite materials and
the ability to perform and correctly interpret
FEM models, the engine shop also made
an important contribution while providing
real time data from the engine from the
test bench. The result underscores the
extensive problem solving expertise of
Lufthansa Technik, which led once more
to a highly cost efficient solution.
Sebastian Krause
Phone +49-40-5070-63454
[email protected]
Turning the first sod: Bernhard Massberg, from the Hessian Ministry of
Economics, Energy, Transport and
Regional Development, Karl Ulrich
Garnadt, Member of the Board of
Lufthansa Group and CEO of Lufthansa
German Airlines, Dr. Johannes Bussmann, Chairman of the Executive
Board of Lufthansa Technik, project
manager Frank Zimmermann, Markus
Frank, Frankfurt’s Economic Affairs
Officer, Dr. Thomas Stueger, Lufthansa
Technik Executive Board and Tino
Fritsche, Chief Executive of C&E
Consulting and Engineering (from left).
A
n investment of just under 60 million euros for the new shop will
yield a production facility which
meets all requirements concerning lean
production, ergonomic working environment and sustainability. The ultra-modern
workshop will comprise a gross floor area
of 14,500 sqm built on a 35,000 sqm plot.
The building technology will enable the
requirements of the Energy Saving Ordinance to be exceeded by 30 percent. For
this purpose a separate combined heat
and power plant will be constructed. Even
the waste heat from the machines will be
used for air conditioning the building.
Thanks to optimized processes, tailored
logistics and state-of-the-art plant equipment, the new site enables the cost-effective provision of wheels and brakes to
Lufthansa and numerous other European
customers. And while business with lowcost carriers is already strong, the new
shop opens up opportunities for even
further growth in this area.
The new facility will be put into service
at the beginning of 2017. It will enable
Lufthansa Technik to continue to grow in
the segment of wheel and brake overhaul.
The leading MRO provider is thus not only
securing the 130 qualified jobs that
already exist in Frankfurt, but is also creating opportunities for further growth. The
most recent figures showed growth rates
at more than three percent per annum
based on the volume of serviced wheels
and brakes.
Dr. Johannes Bussmann, Chairman
of the Executive Board of Lufthansa
Technik, said: “Today we operate one
of the largest maintenance shops for
aircraft wheels and brakes in the world.
We expect even more efficient processes
under excellent working conditions with
the new facility.”
Considerable effort is invested in the
maintenance of aircraft wheels and
brakes owing to their importance for the
safety of aircraft operations. Lufthansa
Technik takes care of all the necessary
work – from wheel or brake changes to
small repairs or complete overhauls of a
wheel or brake.
Dirk Heil
Phone +49-69-696-64936
[email protected]
20 | New Aircraft
“Prepared for the impossible”
Sabrina Hornig loves the variety – and the challenges. The perfect conditions for her
current responsibilities with Lufthansa Technik in Sofia. This is where the engineer has been
completing the first part of her training as TOM Fleet Manager since October.
S
abrina Hornig originally wanted a
career in the cockpit. “But then I
was drawn to a more down-to-earth
role,” she explains smilingly. She quickly
decided to go the route of a dual study
program in cooperation with Lufthansa
Technik. Having graduated in 2012, the
mechanical engineer started working in
the company in the area of component
services. Since October 2014 she has been
working with Lufthansa Technik based in
Sofia, where she is completing the first
stage of her training as a TOM Fleet Manager (see info box right). The Fleet Manager
trainees work through a number of deployment phases in several product divisions.
Line maintenance is a central aspect here
as this is where they get to know their
future area of activity intensively together
with all the related processes.
Sabrina Hornig was deployed on a d
aily
basis for Bulgaria Air during the initial
months of the demanding program – a
program that requires extensive technical
Employee Portrait | 21
Sabrina Hornig checking an aircraft.
Technical Operations
Management – TOM
knowledge and is expanding continuously.
Taking on responsibility
Like a trained TOM Fleet Manager she was
closely integrated in the customer’s workSabrina Hornig now has to prepare for the
flows, from technical consulting to the
new responsibility in a number of ways:
clarification of technical processes, the
establish good connections between both
improvement of material availability, hand
companies that will improve the exchange
ling of AOG events and follow-up, for
of information. And naturally ensure inteexample in the logistics of time-critical
gration of all associated services for the
components. The program consists of
winter layover times, from material mannumerous further training courses, such as
agement to engineering services through
in certified project management, negotiato takeover of related contracts between
tion management as well as corporate
the airline and Lufthansa Technik. “The
strategic planning
project should be
simulation and also
concluded within
includes a sevenfour months,” she
Except for certain invariables,
week EASA part-66
reports. “This is a
one never really knows what
aircraft type training
rather tight schedthe day will bring.
course. As a techniule.” As she talks
Sabrina Hornig
cal consultant for her
about it, her
customers’ entire
respect for the task
fleet, she will therefore have accumulated
is clear as well as her real sense of pleavery comprehensive knowledge of the major sure about the challenge.
civil aircraft types on the market by the end
Sabrina Hornig has already learned a
of her training.
little Bulgarian including the Cyrillic alphaFor Sabrina Hornig, Sofia is an ideal
bet during the first few months of her stay.
training location for getting to know fleet
“Sometimes the language changes
management on a smaller scale where much
from English to the local language during
is accomplished locally. She loves the
meetings. But once I show that I can
unpredictable moments of the working day. understand some of the content, everyone
“Except for certain invariables, such as the
quickly starts speaking English again,”
morning information briefing on special events she grins.
in the respective fleet and regular meetings
with the customer, one never really knows
Prepared for the unexpected
what the day will bring,” she reports.
The new task that Sabrina Hornig has
What impressed her most during the past
been working on recently is ideal for her:
months? “Out of the box thinking is an
she has solely taken on the role of Impleeveryday occurrence in Sofia, probably
mentation Project Manager for integrating
also because Lufthansa Technik’s Product
the new Base Maintenance contract for the
Divisions are not simply sitting in the office
entire Germanwings fleet. Sofia will therenext door,” says Sabrina Hornig as she
fore be the Base Maintenance hub for all
comes back again to why she likes her job
61 aircraft in the current Germanwings fleet so much. “I have learned to be prepared
for the next ten years. Many tasks for which for the impossible. After all, no matter how
the airline itself was responsible formerly
many steps are planned in advance – the
will be transferred to Lufthansa Technik
unexpected can still happen.”
Sofia as of the 2015/2016 season. This
is an impressive feat, not least because
Thoroughly enjoying her work: Sabrina
Hornig is looking forward to challenges.
Sabrina Hornig is just 28 years of age.
“
// In conjunction with a Total Technical
Support (TTS®) contract, TOM enables
operators to enjoy far-reaching efficiency advantages resulting from synergies
in service integration and reduced
complexity in their organizations.
Operators can focus their resources
on business development while maintaining full control over technical issues.
Fleet manager on site
Lufthansa Technik is working closely
with the operator to optimize the integration of maintenance and engineering services into the airline’s flight
operations and ensure the smooth
functioning of all other MRO services.
The permanent presence of the fleet
manager at the customer’s home
base ensures a close working relationship and the optimal adaptation of
Lufthansa Technik’s services to the airline’s requirements. The fleet manager
solves all technical problems, having
direct access to the entire range
of solutions offered by the global
Lufthansa Technik network. Thanks to
service guarantees and transparent
performance measurements, the
operator retains control and the ability
to monitor operations at all times.
Full control with manage/m®
IT integration via Lufthansa Technik’s
websuite manage/m® is a key element
of TOM. 24/7 access to relevant data
via a simple Internet connection and
unlimited data ownership ensure that
aircraft operators retain full control of
maintenance activities. m
anage/m®
is secured with the latest encryption
technology and maintained by
Lufthansa Technik. //
22 | Component Services
Epoxy repair of metal parts
When aircraft components such as pumps are worn or corroded,
the “Advanced Epoxy Coating Process” by Lufthansa Technik
Intercoat often provides a suitable repair solution. Using the
proprietary INTERFILL® material, components can be salvaged
when other repair methods fail and parts normally need to be
scrapped.
D
amage to components caused by
wear and tear, corrosion or cavitation does not automatically mean
these parts have to be scrapped. Thanks
to their “Advanced Epoxy Coating Process”,
the specialists from Lufthansa Technik
Intercoat in Kaltenkirchen, Germany, can
repair such components. INTERFILL® is
applied as a paste and then hardened by
curing to develop its special characteristics. The surfaces are then machined in a
second step to create the final contour.
INTERFILL® consists of epoxy resin,
which is mixed with filler materials. A wide
range of variants have been established
over the years, which can be differentiated
in terms of their abrasion resistance,
media resistance and acceptable operating temperature. The result is that the
characteristics of coated components are
often better today than those of the original
ones. And as the base material properties
remain unaffected, the repair can be
repeated several times.
Customer benefits
• Highly cost-efficient
• Component scrapping avoided
• Excellent surface finish
• Performance enhancement
• Repair of highly complex components
• Component life extension
• Almost unlimited repair repeatability
Choosing the matching fillers, taking
account of the base material of the
repaired part and the given conditions, is
one of the most difficult steps within the
work process. The main criterion of the
“Advanced Epoxy Coating Process” is a
good wear characteristic, smooth surface
quality and good protection against
foreign object damage. “If we get, for
example, a hydraulic pump in for repair
we evaluate which INTERFILL® type is
most suitable depending on the damage
and component. And if there is no
solution as yet for the case to hand, we
mix the base material to order with the
respective particle and fiber fillers,” says
Martin Cholewa, Head of Engineering
and Deputy CEO of Lufthansa Technik
Intercoat.
Lufthansa Technik Intercoat has
meanwhile extended its product portfolio
beyond repair technology. Thanks to the
extensive machinery – a new 5-axis
milling center was only commissioned in
2013 – the company can now also produce components in small batch series.
For example, a door handle is currently
being produced in cooperation with
Lufthansa Technik. As far as Sales
Manager Stefan Beinroth is concerned,
this is just the beginning: “We are
currently setting out to tackle the highgrowth Chinese market more intensively
with an extended sales strategy.”
Lufthansa Technik Intercoat is certified by
the authorities in Europe, the U.S., Canada
and China and also directly by engine
manufacturer Rolls-Royce. In addition to
customers in the aviation industry, repairs
are also taken in in Kaltenkirchen from
customers in shipping, gas turbine produc-
Component Services | 23
Three questions to
Andreas Sauer, CEO
of Lufthansa Technik
Intercoat.
You are the new CEO of Lufthansa
Technik Intercoat (LTI) since February 1,
2015. What are your goals for the future?
Andreas Sauer: We want to involve our customers more intensively in our developments
so that we can tailor our products and services more individually to their needs and
wishes. Our highly qualified employees have
excellent know-how that we want to bundle
in a new center of excellence. Moreover, we
want to expand our portfolio and also extend
the production for parts in small series, for
example, in addition to component repair.
Which target group is Lufthansa
Technik Intercoat addressing?
Our customers from the aviation sector and
industry are located all around the globe.
As highly professional providers, we are of
course available to the entire Lufthansa
Group. At the moment, for example, we are
supporting the GuideU team at Lufthansa
Technik in Hamburg in the manufacture of
components. We also have close contact
with the workshops in Hamburg as well as
the Lufthansa Technik subsidiaries in Tulsa
and Shenzhen.
What innovations are you planning?
In the future we want to develop and manufacture the epoxy resin ourselves, that’s
the base material for INTERFILL®. This will
create an additional unique selling proposition for us. This is because our competitors
only offer ready mixed standard pastes.
We are also considering introducing innovative procedures for restoring surfaces. We
are searching for new procedures at present
that will help us to develop additional application areas. //
For preparation and final machining substantial
equipment is required, whereas the application
of the Interfill® material is a manual process.
tion and general engineering – all of whom
receive a repair solution that is technically
and economically state-of-the-art.
Andreas Sauer
Phone +49-4191-809-152
[email protected]
www.lht-intercoat.com
24 | Engine Services
Threefold power for on-site support
s
ne
n si
gi
:+
H o t li n e
Fault rectification on site is the trademark of the AST® teams.
AS
24/7
Hotline
1
111
Ex
te
-6
The Airline Support Teams (AST® Engines) are the efficient answer to engine problems thanks
to their on-wing and on-site support. New bases in Canada and China mean that Lufthansa Technik
is now even closer to its customers, tripling its capacity and reducing deployment
- 4 0 - 5 070
49
times to ensure an even more efficient service.
T®
n
o n 2: E
Engine Services | 25
Montreal
Frankfurt
Shenzhen
Three independently operating bases are
effectively tripling the capability of Lufthansa
Technik’s AST® Support. Each location features
a separate AOG desk with 24/7 availability.
W
hen Lufthansa Technik set up the
Airline Support Teams (AST®)
more than twenty years ago, they
came about from the necessity to resolve
an AOG incident caused by engine failure
locally at the aircraft location. This rapid
intervention soon became known by the
name “Flying Doctors”. However, the development showed that the AST® principle
offers even greater potential. By strategically
developing its own procedures that allow
engines to be maintained directly on wing or
on site, Lufthansa Technik also succeeded
in allowing modification packages to be
implemented by the AST® teams, such as
for example processing of service bulletins
(SB) and AD notes.
As Director of Engine Services at Mainbase Frankfurt, Bernhard Husenbeth is
responsible for development of the product.
He explains the basic concept: “The idea is
not to dismantle the entire engine, rather to
always only work at the location of a finding.”
A shop visit causes considerable additional
expenditure, regardless of any other problems actually found. Apart from transport
costs, there is the cost of the full disassembly,
diagnosis, documentation and the – likely –
additional repairs needed to many components. By avoiding the shop visit, an AST®
deployment is therefore an extremely efficient maintenance element for the customer.
AST® deployment typically takes between
one and six days. With the demand for
AST® services increasing and the realization
that serving an increasing number of customers from all over the world from Frankfurt
does not make sense, a re-alignment of the
service was planned.
Efficient on-site solution
The new AST® service brings Lufthansa
Technik closer to the customer, therefore
directly into the regions. For the Americas
the relevant facility is being extended in the
Canadian city of Montreal and at Lufthansa
Technik in Shenzhen in China for the AsiaPacific region. Currently the capacity
expansion is in full swing, the tooling has
been acquired for Montreal, while the tooling for Shenzhen is being procured.
Apart from the technical requirements,
a separate AOG desk with 24/7 availability
is being set up both in Canada and in
Shenzhen. Expert technicians and engineers
will be on site permanently at the same
time in order to define the workscopes,
which essentially means three independently operating AST® bases for the future.
Thus Lufthansa Technik is set
to triple its capacity with the AST®
expansion, with the faster response time
to customer requests being the most
important reason for the development.
The installation of three independent
AST® bases firstly means faster on-site
availability with the customer but also
lower costs because of the con-siderable
reduction in transport costs for the tooling
– often a significant factor when tonweight containers with tools have to be
flown from Frankfurt to the respective
deployment location.
The expansion of the AST® network
indicates that as founder of the AST® principle, Lufthansa Technik is not resting on
its laurels, rather is investing increasingly
in future development and changing customer demands in a dynamic market. The
discussions the MRO provider is holding
with various OEMs on the inclusion of new
engines in the portfolio will also serve to
underpin this future proofing. This ensures
that the term AST® will remain synonymous in the future with optimal efficiency
through on-wing or on-site maintenance
at the customer’s location.
Olaf Hamm
Phone +49-40-5070-1763
[email protected]
Closer to the customer
AST® deployments focus at present on performing planned modifications. The affected
aircraft frequently are in a layover during
which time the AST® teams then look for a
suitable slot to perform the modification.
Depending on the problem, the engine type
and its suitability for rapid intervention, an
www.lufthansa-technik.com/ast
26 | Original Equipment Innovation
Intensive care unit on
all long-haul routes
New Supplemental Type Certificates (STC) have been
granted for the installation of the Patient Transport
Compartment PTC in Boeing 747-8 and Airbus A380
aircraft. Developed by Lufthansa Technik, the flying
intensive care unit can therefore now be used for
transporting patients on all Lufthansa long-haul flights.
L
ufthansa can now offer its Patient
Transport Compartment (PTC) in its
entire network of long-haul flights
from its hubs in the German cities of
Frankfurt and Munich. Since 1999, the
company has already been using the PTC
on its Boeing 747-400 and Airbus A330/
A340 aircraft. A total of up to 100 intensive
care patients are transported in the PTC
by Lufthansa every year.
Developed by Lufthansa Technik in
cooperation with Lufthansa’s Medical Service, the new Patient Transport Compartment features a multitude of advantages
compared to a conventional air ambulance, for example a time saving of up to
50 percent due to the fact that it is
installed in an airliner, which can fly nonstop from South-America or Southeast
Asia to Europe. The spacious interior of
the compartment offers enough space
for a patient bed, two seats for the doctor
treating the patient and a Lufthansa
Perfect integration of the Patient Transport Compartment in the cabin. The new version is a lot roomier
than its predecessor.
Medical Crew Member as well as intensive
care equipment together with the required
consumables and medication.
The Patient Transport Unit Next Generation (PTU NG) forms the core of the compartment. The comfortable and flexibly
adjustable bed is suitable for extreme
long-haul flights. The 13,000-liter oxygen
supply and electrical power supply of
1.6 kW enable the use for repatriation
missions with flight times in excess of
15 hours. The PTU NG has a low system
weight for rapid conversion. The robust and
modular design allows adaptation to the
specific needs of each individual customer
including VIP, military and special mission
operations. In addition to a wide variety of
options for accommodating medical consumables, medical equipment can be
attached to the PTU NG itself or to a separate rack – depending on the requirement
defined by the medical teams of customers
flying the PTU NG without the compartment.
Improved medical supply
Extensive effort was required to obtain
approval for the new, improved PTU NG
owing to the rigorous tightening of airworthiness requirements in recent years.
However, this was finally achieved thanks
to the extensive and unique experience of
Events & Exhibitions | 27
Meet us at...
6 – 8 October 2015 | Munich
inter airport Europe
Focusing on airport equipment, inter
airport Europe is a worldwide recognized airport industry international
meeting hub of vendors, decision
makers, system integrators and buyers.
13 – 15 October 2015 | London
MRO Europe
For maintenance, repair and overhaul,
as well as manufacturing, at MRO
Europe the latest standards for productivity and aerospace technology
are presented.
21 – 23 October 2015 | Hunter Valley
RAAA Convention
Lufthansa Technik’s design and certification
engineering. The oxygen system integrated
in the PTU NG was also approved in
accordance with new stricter EASA
requirements.
As a product of the new Lufthansa
Technik “Original Equipment Innovation”
product division, the PTU NG is more than
just a customized instrument for long-haul
medical transport. It is also proof of the
innovative strength of a company that
continues to work on further projects to
improve medical supply. In the area of
Patient Transport & Medical Solutions
Lufthansa Technik is developing further
innovative products and services and
offers medical turnkey solutions for VIP
and business jets as well as Medevac
Special Mission operators. The expertise
of the Lufthansa Technik medical care
specialists is also available in the form of
consultancy services concerning the
integration of medical equipment in the
PTU NG or the development of medical
products. For example development is
currently under way on a dedicated child
restraint system as well as a special
children’s oxygen mask.
The Regional Aviation Association of
Australia (RAAA) Convention is highly
regarded as a premier annual aviation
event of the region.
3 – 5 November 2015 | Singapore
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.
Eckhard Freimuth
Phone +49-40-5070-3147
[email protected]
Preview
Highlights of the next issue:
• Aircraft Base Maintenance
• Side-by-side engine teardown
• Lufthansa Technik Shannon
patient-transport-unit
www.lufthansa-technik.com/events
28 | Products & Services
Airbus
World of 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.
A300/A310
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
Line Maintenance
Base Maintenance
Component Services
Engine Services:
JT9D, PW4000-94,
GE CF6-80C2
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 & Executive Jet Solutions
A320
A319
A321
A320neo
H otl i ne
www.lufthansa-technik.com/services
A321
H
308
eServices
Lufthansa Technik’s Technical Operations
Websuite manage/m® allows operators
to manage their technical operations via a
web-based system.
A330
-4
+
Special Services
The world’s 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)
• Logistics & Training
- 4 0 - 5 0 70
49
• AOG Services
• Surface treatment
otline
Original Equipment Innovation – OEI
Lufthansa Technik has successfully
established a line of cabin products.
• Cabin Management & IFE Systems
• Aircraft & Cabin Equipment
• Connectivity
• Patient Transport Solutions
Airbus
A300/A310
24/7
k
AOG des
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
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 & Services | 29
Boeing
737
Regionals
Boeing 737
Line Maintenance
Base Maintenance
Component Services
Engine Services:
CFM56-3
Completion
737 NG
737
Boeing 737NG
Line Maintenance
Base Maintenance
Component Services
Engine Services:
CFM56-7B
Completion
747
737NG/MAX
Boeing 747
Q-Series
Line Maintenance
Base Maintenance
Component Services
Engine Services:
PW100, PW150
Q-Series
CRJ
Boeing
757
Line Maintenance
Base Maintenance
Component Services
Engine Services:
RB211-535
Completion
757
767
CRJ 700
CSeries
Boeing 777-9X
vorläufige Zeichnung
777
777X
Bombardier CSeries
in preparation
E-Jets
ERJ 190
Embraer
E-Jets 170/175, 190/195,
Line Maintenance
Base Maintenance
Component Services
Engine Services: GE CF34
Boeing 767
Line Maintenance
Base Maintenance
Component Services
Engine Services:
PW4000-94, CF6-80C2
Completion
767
777
Bombardier CRJ
Line Maintenance
Base Maintenance
Component Services
Engine Services: GE CF34
Line Maintenance
Base Maintenance
Component Services
Engine Services: JT9D,
PW4000, CF6-80C2
Completion
757
747-8
Bombardier Q400
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 & Marketing,
Vice President
Corporate Sales EUMEA
Vice President
Corporate Sales
Americas
Wolfgang Weynell
p +49-40-5070-2547
[email protected]
Frank Berweger
p +1-3053791222
[email protected]
Let’s talk about solutions
Director Sales
Eastern Europe
and CIS
Dmitri Zaitsev
Director Sales
USA and Canada
Director Sales
Europe
Robert Gaag
p+1-305-379-1222
f+1-305-379-2771
[email protected]
Georgios Ouzounidis
p+49-40-5070-5295
f +49-40-5070-5869
[email protected]
p+49-40-5070-5404
f+49-40-5070-2558
[email protected]
Director Sales
Latin America
and Caribbean
Jörg Femerling
p +1-305-379-2604
[email protected]
America and Canada
Europe, Middle East and Africa
Canada
Dan Hepworth
p +1-514-245-0143
[email protected]
BeNeLux
Rudi Preud’homme
p +32-2-752-8690
[email protected]
Dubai
Chile
Carlos Sotomayor
p +56-2-2573-7770
[email protected]
Italy
Emanuela Marabese
p +39-02-58571483
[email protected]
Russia
Lessors North America
Turkey
United Kingdom
Lydia Martin
p +1-818-232-5956
[email protected]
Fulya Türköz
p +90-212-465 55 57
[email protected]
Paul Conway
p +44-7812-091074
[email protected]
Ziad Al Hazmi
p +971-4-4057-557
[email protected]
Andreas van de Kuil
p +7-495-937-5103
[email protected]
Contacts | 31
Vice President
Corporate Sales
Asia Pacific
Gerald Steinhoff
p +65-6733-5539
[email protected]
Director
Corporate Sales
VIP & Special Mission
Director
Corporate Sales
Lessors & Banks
Wieland Timm
p +49-40-5070-2548
wieland.timm
@lht.dlh.de
Andreas Kehl
p +49-40-5070-4780
andreas.kehl
@lht.dlh.de
Line Maintenance
Worldwide
Michael Struck
p +49-69-696-69660
linemaint.agrmts
@lht.dlh.de
Affiliates & Corporations
Lufthansa Technik
AERO Alzey
Phone+49-6731-497-0
Fax +49-6731-497-197
[email protected]
www.lhaero.com
Director Sales
East Asia
Richard Haas
p+852-2846-6370
f+852-2156-0230
[email protected]
Lufthansa Technik
Brussels
Phone +32-2-752-8660
Fax +32-2-752-8673
[email protected]
brussels
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
Director Sales
South East Asia
and Australia
Robin Johansson
p +65-6733-9081
[email protected]
Asia and Australia
Australia & Pacific
Joseph Giarrusso
p +61-3-9551-9064
[email protected]
China
Steven Wang
p +86-10-6465-1593
[email protected]
Japan
Hidenori Sato
p +81-45-309-2777
[email protected]
Lufthansa Technik
Intercoat
Phone +49-4191-809-100
Fax +49-4191-2826
[email protected]
www.lht-intercoat.de
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
Lufthansa Technik
Maintenance International
Phone+49-69-696-141910
Fax +49-69-696-90942
[email protected]
ltmi
Lufthansa Technik Malta
Phone+356-2560-4000
Fax +356-2560-4190
[email protected]
www.lht-malta.com
Lufthansa Technik
Milan
Phone+39-02-585714-24
Fax +39-02-748-64924
cesare.ghermandi@
lht-milan.com
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
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
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
A never-ending story.
N O
O
N
I
I N
V
A T
Lufthansa Technik is synonymous with innovation.
Thanks to creative engineering work and cuttingedge research facilities, we constantly set new
standards. Alongside the continuous further
development of maintenance, repair, and overhaul
procedures, we develop new technologies, cabin
products, and servicing processes for aviation.
Always striving for the highest quality and safety
standards, we are able to guarantee technological
excellence.
Lufthansa Technik AG, [email protected]
Call us: +49-40-5070-5553
www.lufthansa-technik.com/innovation
More mobility for the world

- Lufthansa Technik AG

Transcription

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