- Lufthansa Technik AG

Transcription

The Lufthansa Technik Group Magazine
4.2015 July/August
Component Services
“Reliability and
strength for the future”
Airbus A350 Services
Major component
contract
Aircraft Systems
“Committed to
preserving value”
Cabin Innovation
New personal
IFE solution
2 | Content
Lufthansa Technik Connection 4.2015
8
“Reliability and
strength for the future”
Photo: Airbus S.A.S. 2014
Harald Gloy, Senior Vice President Component Services, explains why
Lufthansa Technik is a global market leader for component support.
A350 contract
Finnair has awarded Lufthansa Technik a comprehensive
Total Component Support (TCS®) contract.
16
18
New personal IFE solution
In cooperation with Qantas Airways, Lufthansa Technik
has developed a new tablet-based IFE concept.
22
“Committed to preserving value”
Andreas Tielmann, Vice President Aircraft Systems, speaks
about composite repairs and landing gear overhaul trends.
Lufthansa Technik
• Cooperation with GE Aviation: 3
New engine overhaul joint venture
Innovation & Technology
• Lufthansa LEOS eSchlepper:
6
Heavyweight with electric traction
• Cyclean®: Hot solution for cold wash 14
• Joint development with Qantas:
18
Component Services • Interview with Harald Gloy:
8
“Reliability and strength for the future”
Laboratory Services
• Analytical methods:
11
Material detectives at work
Customer Portrait
• Aerolineas Argentinas:
12
Shop visits à la carte
eServices
• New features for m/material: Online 15
material offers anytime, anywhere
New Aircraft
• TCS® contract:
16
A350 component support for Finnair
Engine Services
• APU inspection:
20
Voice control improves data entry
• Technical service provision
21
for engine lessors
Aircraft Systems
• Interview with Andreas Tielmann:
22
“We’re committed to preserving value”
• Trent 500 and Trent 700:
25
High-class repair of acoustic panels
Logistic Services
• Hamburg: New storage system
26
• Middle East: Easy IT system
27
for warehouse management
Categories
• News
4– 5
• Events 27
• Products & Services
28
• Contacts
30
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
Lufthansa Technik | 3
New engine joint venture with GE
Lufthansa Technik and GE Aviation will create a new, state-of-the-art engine overhaul facility
in Europe to service GEnx-2B and GE9X engines. Subject to receipt of the required regulatory
approvals, the new joint venture is expected to be operational in 2018.
T
he MoU was signed at the Paris Air
Show by GE Aviation President and
Chief Executive Officer David Joyce,
Deutsche Lufthansa AG CEO Carsten Spohr,
GE Aviation Services President and CEO
Kevin McAllister, and Lufthansa Technik
CEO Dr. Johannes Bussmann. The new
joint venture will be equipped to perform the
full range of engine maintenance services
for the GEnx-2B and the GE9X, powering
the Boeing 747-8 and Boeing 777X,
respectively. The partners will continue to
collaborate on repair development and
mobile support services.
“We are committed to building a worldclass facility that will help meet future
demand for GEnx-2B and GE9X overhauls,”
said Kevin McAllister, President and CEO of
GE Aviation, Services. “Lufthansa Technik
has an excellent reputation for engineering
expertise and customer service, and we
are pleased to extend our long-standing
collaboration with the formation of this new
facility.”
“Signing the agreement for this joint
venture expresses our determination to significantly expand our long-standing and
proven partnership for the technical support
and development of state-of-the-art wide-
body aircraft engines,” said Carsten Spohr,
CEO of Lufthansa. Lufthansa Technik’s CEO
Dr. Johannes Bussmann added: “The combination of the know-how of a leading manufacturer and the extensive experience of
one of the world’s leading maintenance
organizations will mean the highest in quality
and cost advantages for our airline customers.”
For forty years, Lufthansa Technik has
provided technical support for GE engines.
Lufthansa Technik has already developed
the skills and knowledge needed for fast,
smaller repairs to the GEnx-2B engines
used in the Boeing 747-8. The first two of
these maintenance events – known as
“quick turns” – are in progress and will conclude by the end of June. Lufthansa is the
largest operator of the GEnx-2B-powered
Boeing 747-8, and is the launch customer
for the Boeing 777-9X aircraft, with 34
aircraft on order and deliveries scheduled
to begin in 2020. More than 400 GEnx-2B
engines are in service, and the fleet has
accumulated 1.7 million flight hours and
300,000 cycles with outstanding performance. Compared to GE’s CF6 engine,
the GEnx engine offers up to 15 percent
better fuel consumption, which translates
to 15 percent less CO2.
The GE9X engine will be in the 100,000
pound thrust class. Key features include a
134-inch diameter composite fan case and
16 composite fan blades, a next-generation
27:1 pressure-ratio 11-stage high-pressure
compressor, a third-generation TAPS III
combustor for high efficiency and low
emissions, and CMC material in the combustor and turbine. Almost 700 GE9X
engines have been ordered by customers
since it was launched on the Boeing 777X
aircraft last year. Engine certification is
scheduled for 2018.
Signing the MoU (from left): GE Aviation Services
President and CEO Kevin McAllister, GE Aviation
President and Chief Executive Officer David Joyce
with Lufthansa CEO Carsten Spohr and Lufthansa
Technik CEO Dr. Johannes Bussmann.
4 | News
London
Athens
Berlin
Supply for
Aegean Airlines
Component Support // Aegean
Airlines has extended the contract with Lufthansa Technik to
supply materials for their A320
family and the Q400 fleet of the
airline’s subsidiary Olympic Air.
Under the agreement, Lufthansa
Technik is to supply both fleet
types with components for
another six years.
Dr. Dimitris Gerogiannis, CEO of
Aegean Airlines, said: “We are
pleased to extend our cooperation with Lufthansa Technik, a
trustful, dependable and innovative partner, on component support for our A320 and Q400 fleet.”
Lufthansa Technik has been
looking after Aegean Airlines
A320 family fleet since entry
into service in 2007 and after
Olympic Air’s Q400 fleet since
start of its operation in 2009.
Lufthansa Technik’s Chief Executive Product and Services, Dr.
Thomas Stüger, explained: “We
are very pleased and honored
to be able to further expand our
cooperation with Aegean Airlines. Over the past years we
have established a trustful and
reliable partnership. We are
convinced that Aegean’s operational needs and requirements
will be strongly supported by
Lufthansa Technik also in the
future.” //
7800-landings check
on CL-604
LBAS // Lufthansa Bombardier
Aviation Services has performed the first 7800-landings
inspections on Swiss Air Ambulance’s (Rega) fleet of three
Challenger 604 aircraft. Industrywide, this is the first time an
inspection of this type was ever
performed.
As one of the largest scheduled
maintenance events on the
Challenger 604 aircraft, the
7800-landings inspection is
comparable to the D-check of
a large commercial airliner.
Together with Bombardier, the
manufacturer of the Challenger
604, Lufthansa Bombardier
Aviation Services set up a dedicated team for this special
inspection. Unlike any other
inspection on a Challenger
604, this check includes extensive non-destructive inspections
as well as x-ray testing of the
aircraft structure.
Ernst Kohler, CEO of Rega
underlines: “We were in need
of a reliable and competent
partner to perform maintenance
on our ambulance jets. Aircraft
downtime along with quality
and budget are the critical elements for us. Our experience
with Lufthansa Bombardier
Aviation Services during the
96-months inspection performed 4 years ago was the
key to selecting them for the
7800-landings inspection.
Again, we are delighted about
the services we received.” //
Former CEO receives
award for life’s work
August Wilhelm Henningsen //
Chairman of the Executive
Board of Lufthansa Technik
through April 2015, August
Wilhelm Henningsen was honored at an event in London by
the industry publication Aircraft
Technology, Engineering &
Maintenance (ATE&M) for his
life’s work. The jury commended Henningsen’s lifelong and
successful commitment to the
aviation industry worldwide.
On occasion of the awards
ceremony, Henningsen said:
“I am extremely honored to
have been nominated and
selected by the jury to receive
the esteemed ATE&M Lifetime
Achievement Award. I would
like to dedicate this award to
the 26,000 highly qualified and
motivated Lufthansa Technik
employees in more than 30
companies around the world.”
Dr. Johannes Bussmann, who
succeeded Henningsen as
CEO of Lufthansa Technik,
commented: “Under the leadership of August Wilhelm Henningsen, Lufthansa Technik
rose to the top of the world’s
MRO industry. His outstanding
achievements for the good of
the company and the industry
are a strong motivation for me
and the entire Lufthansa Technik
management team. We are very
grateful to him for the strength
of his commitment over so many
years.”//
Geneva
Elite VIP completions
for ACJ319
EBACE // Building on the success story of the ACJ318 Elite,
with 19 deliveries to date, and
based on market demand, Airbus Corporate Jets (ACJ) and
Lufthansa Technik will expand
their successful co-operation
in pre-defined VIP cabin completions by offering the Elite
concept on the ACJ319. The
new ACJ319 Elite product was
officially launched at EBACE
2015 in Geneva.
The baseline configuration of
the ACJ319 Elite consists of a
crew-rest/entourage area, a
spacious executive lounge with
full-flat club-seating and berthable divans, followed by a midcabin lavatory. Behind this area
the baseline concept features a
private office that converts to a
bedroom and a master bathroom, including a shower option.
In order to experience the look
and feel of their VIP interior in
the most realistic way possible,
customers can use the ACJ319
Elite App available for iPad.
Numerous layout options and
color schemes can be selected
and viewed in real-time,
including ultra-realistic moving
3D-views of the interior. //
News | 5
Stuttgart
Dublin
Hannover
Letter of Intent
with TUI Airlines
Overhaul Services // Lufthansa
Technik becomes technical service partner for the aircraft fleet
of TUI Airlines. TUI Airlines and
Lufthansa Technik have negotiated and signed an appropriate
Letter of Intent (LoI). The holiday
airlines of the worldwide largest
travel company TUI operate a
fleet of about 140 medium- and
long-range aircraft, mainly the
types Boeing 737, 757, 767
and 787.
In the future, Lufthansa Technik
will support the internal overhaul
and maintenance business units
of the holiday airlines as their
new service provider for aircraft
overhaul services. In case of
reaching the capacity limits
within its own organization, the
holiday airlines of TUI will utilize
the worldwide leader Lufthansa
Technik. The air traffic of a holiday travel company like TUI is
significantly seasonal. For example, Lufthansa Technik can
ideally support the TUI airlines
to absorb seasonal peaks. //
Cooperation with
Mercedes-Benz Style
VIP & Executive Jet Solutions
// Mercedes-Benz Style and
Lufthansa Technik will jointly
develop an entirely innovative,
luxurious and integrated cabin
concept for short- and mediumhaul aircraft. The dynamic
layout is characterized by the
aesthetic appeal of state-ofthe-art luxury embodied in the
Mercedes-Benz brand.
“It was an inspiring challenge
to transfer our design philosophy
of sensual purity into the area
of aeronautical engineering.
The spectacular architecture of
the interior shows creativity
and modernity. Sensual surfaces
and clear forms, combined
with intelligent high-tech
features and perfectly shaped
modern luxury are the characteristic features of MercedesBenz design,” says Gorden
Wagener, Vice President Design
Daimler AG.
“The purpose of our cooperation with Mercedes-Benz Style
is to unite the two companies’
innovative expertise in the areas
of design and technology. Our
goal is to offer a highly discerning global clientele a standard
of interior design that leaves
nothing to be desired,” said
Walter Heerdt, Senior Vice President VIP & Executive Jet Solutions of Lufthansa Technik. //
With a focus on smart.life
Engine Technical & Cost
Workshop for Lessors // With
this event the Lufthansa Technik
Corporate Sales department for
Lessors & Banks and the Product
Sales department for Engine
Services & Lease intended to
provide the members of this
customer group in the region
with current information about
the latest developments in the
engine overhaul sector. Cost
management of engines operated in difficult climatic conditions was among the important
items of the afternoon. The
Lufthansa Technik specialists
highlighted the operational risks
and pointed to items to look for
as engine owner.
The presentation of smart.life
was another key element of the
workshop. Lufthansa Technik’s
Engine Services division has
developed smart.life for managing older engine models.
The goal is to handle engines
which have already reached
the second half of their life cycle
in such a way that – until they
are retired from flight operations
– excessive maintenance work
is avoided and costs are minimized accordingly. Complex
repair procedures, for example,
can be rejected in favor of
simpler procedures, and the full
replacement of modules and
engines can be avoided.
Another key aspect relates to
leasing models, with particular
value assigned to flexibility in
supporting customers in the
purchase and sale of engines
as well as to the warehousing
of the customer’s own replacement engines, assemblies, and
components.
Participants of the workshop
enjoyed the opportunity for
questions and an open exchange
of thoughts. Based on the success of this first Engine Technical
& Cost Workshop for Lessors,
Lufthansa Technik’s Corporate
Sales department Lessors &
Banks plans to have further
events in the future, intended
to introduce important issues
to this customer segment. //
Andreas Kehl
Phone +49-40-5070-4780
[email protected]
vation b
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The heavyweight
with electric traction
no
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In
6 | Innovation & Technology
a Te c
h
Pulling a widebody aircraft over several kilometers running on electric power alone – that’s no
contradiction for the eSchlepper. The world’s first towbarless electric tractor for large aircraft is
currently being tested at Frankfurt Airport and under certification tests for various aircraft types.
Innovation & Technology | 7
for towing aircraft to the hangar and repositioning large long-haul aircraft – also
over longer distances of five to seven kilometers. It is part of E-PORT AN, the electric
mobility project at Frankfurt Airport.
Green and economical
Lufthansa LEOS has been investigating
technology concepts for alternative forms
of propulsion on the ground since 2007.
Together with KALMAR Motor AB from
Sweden, the aircraft handling specialists
have been working on the development
of the innovative eSchlepper since 2013.
The electric propulsion significantly reduces fuel consumption as well as noise and
pollutant emissions on the ground. The
maintenance overhead is also much more
favorable with pure electric propulsion
compared with conventional diesel-powered tractors, delivering cost reductions of
around 50 percent. The eSchlepper also
emits 75 percent less CO2 in comparison
and drives very quiet.
Powerful battery pack
The new eSchlepper is capable of pulling
even the largest widebody aircraft.
Standing in front: Gerhard Baumgarten,
Head of Innovation at Lufthansa LEOS.
T
he specification was extremely challenging: “The eSchlepper was to be
able to pull a fully prefuelled A380
weighing more than 400 tons over a distance of seven kilometers without activating the emergency power system,” explains
Gerhard Baumgarten, Head of Innovation
at Lufthansa LEOS. The success achieved
in this respect is exactly what he and his
colleagues can now test at Frankfurt Airport. The first “TBL800 Towbarless Tractor”
was supplied recently to Lufthansa LEOS.
The eSchlepper is an electrically powered, towbarless aircraft tractor, which is
more environmentally friendly and more
economical than the diesel-powered tractor.
The eSchlepper is to be used in particular
The eSchlepper is a plug-in hybrid vehicle
with lithium batteries and built-in range
extender. “The battery pack is enormous,
triple the power of the latest Tesla,” explains
Gerhard Baumgarten. “The eSchlepper
does not move as fast as a sports car, but
it needs sufficient power in order to be
able to pull heavy loads.” The integrated
diesel motor, known as the range extender,
is used exclusively for backup purposes –
the risk of the tractor coming to a standstill
during a towing exercise is therefore
excluded. The batteries are charged
Technical data
Weight 35 t
Max towing speed (A380) 25 km/h
Max speed solo
32 km/h
Cradle lifting capacity 60 t
Power Electric drive
Front axle 400kW, Rear axle 300kW
Battery capacity
180 kWh / 820 Volts
Input for onboard battery chargers
240V / 63A / 50 Hz (mains) or
115V / 90A / 400 Hz (aircraft power)
Hybrid charging Diesel Engine
Cummins QSB 6,7 (Tier 4 Final)
175kW / 820 Volts
during operation by means of a generator
or during downtime at a charging station.
The eSchlepper can be used for the
aircraft types Airbus A330, A340, A350,
A380 and Boeing 777, 747, 787 as well
as the DC-10 and MD-11. Comprehensive
tests have to be carried out for certification
for every aircraft type. These tests measure
the forces acting on the nosewheel during
various activities, for example pushbacks
or maintenance towing operations.
“We want to gather experience so that
we can incorporate further improvements
if possible,” says Gerhard Baumgarten.
Once an aircraft type has been certified,
the eSchlepper is then used during normal
ground operation. That’s when the heavyweight with the battery heart can prove its
strengths under real working conditions.
Gerhard Baumgarten
Phone +49-69-696-95282
[email protected]
8 | Component Services
„Reliability and strength
for the future“
Thanks to a flexible portfolio of in-house repairs, partnerships, and surplus parts options as well
as a rapidly growing regional presence, Lufthansa Technik is today a global market leader in
material supply. Harald Gloy, Senior Vice President Aircraft Component Services, explains the
special qualities that make the company attractive in the long term for customers of any fleet size.
Component Services | 9
How would you characterize
the market for component support
currently and how is Lufthansa
Technik positioned?
Harald Gloy: The business segment is
becoming increasingly broader and more
diversified – as are we in terms of what we
offer. This applies equally for our products
and for our commitment in the regions. We
are taking our claim of being a worldwide
provider more seriously than ever.
How important is the topic of regional
presence for the Component Services
product division?
Despite all digitization and networking
deliberations, we are taking into account a
persistently strong call from our customers
for a local presence. We are therefore represented by more and more of our business
segment’s functions in the regions and have
gained significant momentum through our
global presence. In the U.S., for example,
we offer a number of functions with
Lufthansa Technik Component Services
(LTCS) – not just repair workshops, but also
customer service roles, product sales, material control, and a dedicated AOG Desk.
We are actively represented by Lufthansa
Technik Shenzhen in the Asia-Pacific region
with repair workshops, customer service,
and product sales in Hong Kong and Singapore. Then we have Lufthansa Technik
Services India (LTSI) in the Indian market.
And we are also excellently positioned in
Moscow for the Russian market.
How has the product portfolio of
Lufthansa Technik Component Services
changed compared with a couple of
years ago?
In addition to our “classic” product world
with integrated products, such as TMO®,
TCS® and TCM, and individual repairs (Single
Component Maintenance), product combinations are also increasingly in demand.
This was and is of course also a mandate
to us to continuously develop our products.
What role do consumables and
expendables play in the portfolio?
The supply of C&E is another good example
of how the market has become more diverse
and how we are positioned to deal with
this. LRU and C&E were formerly two sepa-
Finnair has just recently purchased
comprehensive component support
from Lufthansa Technik for its A350
fleet. What are the motivating factors
that lead airlines to place new aircraft
types in the hands of Component
Services?
There must be strong logistics
Airlines like Finnair, who are adding a new
behind the claim of being a world
fleet to their operations, want to work with
market leading provider.
a sustainable supply concept from the
Yes, that’s right. This is a very important
outset and beyond manufacturer guarantopic for us. That’s because in addition to
tees and have a competent partner at
component repairs and pooling, customer
their side. A partner who, for example,
perception of our product is especially
will take over war
determined by our
ranty handling when
logistics service
Our ability to choose the best
components fail. As
quality – this is a
alternative for every part stands
Lufthansa Technik we
critical feature of
out from the competition.
look after the entire
our products. That
processing with the
is also why we are
Harald Gloy
OEMs, which an
very closely netairline would otherwise have to do itself.
worked with Lufthansa Technik Logistik
Furthermore, an a
irline gets comprehenServices. Recent developments provide
sive technical and consulting know-how
further proof of this – the new Distribution
with us thanks to the wealth of our inCenter Europe in Frankfurt is the cornerhouse engineering and troubleshooting
stone of the fast and reliable supply for airexpertise. The entry-into-service-phase for
line customers around the world. We have
new aircraft therefore loses its fear factor.
furthermore bundled and consolidated our
We tackle new component technologies
activities – components, C&E, and logistics
from the outset.
– in North America and also do address
the topic of warehouse locations in the
Are there further arguments
Americas. And we have an efficient logisapart from technical expertise?
tics business unit in Shenzhen in China for
Our price/performance ratio is very good.
the region, which is supplemented by a
It’s not just about the price per se, rather
logistics center in Singapore.
that we offer the operative experience
when it comes to introducing new aircraft
Where do you see Lufthansa
types. We have demonstrated this continTechnik’s key differentiators in the
uously over the years. What we understand
area of component supply?
of airline needs and have integrated in our
Reliability and strength for the future – these
expertise represents a wealth of experience
are the two main features that are attributed
that an aircraft manufacturer simply canto us first off in discussions with customers.
not have without the influence of the operReliability simply means that we also do
ations side. This can be seen, for example,
what we say we will. And this is based today
in manufacturer recommendations for
as ever on our technical expertise, in other
stocking spare parts. We can save investwords technical reliability. This business
ment here on the part of the airlines
practice is evident for our customers, for
through realistic r ecommendations. Last
example when they have queries or when
but not least, the above-mentioned logistiour engineers meet customers. And also if
cal capability is also one of the arguments
there are ever complaints. We notice a great
in favor of material supply. All international
confidence in us to also deal professionally
destinations can be accessed quickly and
with discrepancies. This shapes our image
at high frequency from our global distribuand these are qualities we have to demontion centers.
strate over and over again. Our strengths
also have to remain strong in the future
and will be added by new features as well.
Please continue on page 10
rate worlds with very few lines linking the
two in the market also. However, we are
now noticing an increasing interest on the
part of customers here and increasingly a
combined demand.
“
�
10 | Component Services
What is the status of component supply for other
new types, especially the A320neo and 737 MAX
volume models?
We are active to the same extent for these types and will
supply them with services and capabilities in the same way
as the preceding models. Preparations are in full swing
for both types and as soon as the first aircraft are to be
supplied this is what we will also do.
What is the situation regarding cooperation
with the e
quipment manufacturers in terms of
the new aircraft types?
Our cooperation with Honeywell on the A350 is a good
example. We can benefit mutually from this. The manufacturer wants to learn from Lufthansa Technik’s capabilities
and anticipates an improvement in components from the
operations side in relation to the repair processes. And as
Lufthansa Technik, we are familiar very early on with the
entire range and are in contact with the manufacturer’s
engineers regarding maintainability. We can establish full
capability here in good time, utilize our strengths, and support customers with cost-efficient maintenance procedures.
Finally, what is the situation regarding component
supply for the so-called sunset types, such as
the 737 Classic, in other words types reaching the
end of their product life cycle?
We make much more conscious decisions in our production
processes today as to whether we will repair a component
in-house or outsource it to specialists. As a third production
alternative, we also have the option of using surplus com
ponents. We are meanwhile increasingly performing teardowns, for example with Lufthansa Technik Component
Services in Tulsa for the 737 Classic, the MD-11, and the
747. As Component Services, we can essentially cover all
needs optimally with these three alternatives. This ability to
choose the best alternative for every part from within our
own operations and therefore serve the needs of customers
optimally at the same time means that we stand out from
the competition.
Harald Gloy
Harald Gloy is Senior Vice President
Aircraft Component Services of
Lufthansa Technik. Harald Gloy
holds a degree in engineering
and management. He came to
Lufthansa Technik in Hamburg in 1999. Following a
tenure as Director Production Aircraft Base Maintenance
he took over Component Maintenance Services as Vice
President and thereafter Gloy became Vice President
Engine Overhaul in November 2012. //
A
ircraft materials are not expected
to fail, unfortunately sometimes this
does happen. Usually diagnosed
in the responsible Lufthansa Technik workshop, the specialists of the Lufthansa
Technik central materialography laboratory
in Hamburg are consulted to identify the
causes for complex failure issues and for
cases subject to insurance claims or mandatory reporting.
The laboratory is equipped to carry out
manufacturer-standard inspections and
failure analysis of all aircraft components
from all materials. Each inspection starts
with a material component analysis. As
manufacturing data are sometimes
unavailable, the material basis for every
component to be inspected has to be
determined. The material specialists use,
for example, spectroscopic techniques
such as X-ray fluorescence spectroscopy,
where the sample is subject to radiation
and the resultant spectral lines reveal
information about the constituent materials.
After the materials have been determined,
the individual failure can be analyzed.
Failure analysis is modelled on the VDI
3822 guidelines. This standard makes it
Laboratory Services | 11
Placing a material sample in the electron microscope.
Material detectives at work
To identify the causes of failures, analytical investigations are performed in Lufthansa Technik’s
central materialography laboratory. A comprehensive range of analytical methods is available
advising on the failure mechanism and on future damage prevention.
possible to compare the results obtained
at different sites, thereby fulfilling the basic
prerequisites for reliable documentation.
The component or a small sample from
the component is initially considered macroscopically, i.e. as a whole and in parts
with a stereo microscope. Parts exhibiting
features of wear or a fracture origin are
then inspected for fracture characteristics
using a scanning electron microscope
(SEM). This can be combined with highresolution energy-dispersive X-ray spectroscopy (EDX), enabling to determine the
composition of nano particles.
In addition, the metallography laboratory
also conducts measurements of the hard-
ness of the metal matrix, of the paint and
surface coatings along with macro-hardness tests on larger components. Further
test equipment enables the experts to test
tensile strength and ductility of materials.
Findings, for example metal debris found
on magnetic chip detectors, oil filters or
within the hydraulic fluids during A/C operation can quickly be examined.
The test results enable the experts to
advise not only on the failure mechanism,
but also on future damage prevention or
MRO process optimization. The material
detectives from Laboratory Services thus
form an important element in Lufthansa
Technik’s self-improvement chain. The
material laboratory not only handles tasks
from Lufthansa Technik Group on a routine
basis. As the laboratory’s independence
and experience make its work highly
regarded by external customers, airline
customers or authorities continue to place
orders for consulting, independent assessments or failure analysis. The central
materialography laboratories are therefore
increasingly involved in joint assessment
procedures with airline customers, manufacturers, and authorities.
Dr. Christian Siry
Phone +49-40-5070-4299
[email protected]
12 | Customer Portrait
Shop visits à la carte
The newest contracts with Aerolíneas Argentinas are radical service offerings precisely tailored to
the requirements of the customer. They crown a special partnership between the Argentinian national
carrier and Lufthansa Technik which started almost two decades ago.
T
he Aerolíneas Group is one of the
major carriers in South America.
From its headquarters based in the
Jorge Newbery and Ezeiza International
Airports in Buenos Aires, Aerolíneas
Argentinas flies to 24 international destinations in America, Europe and the South
Pacific. The local Austral Lineas Aereas,
belonging to the group, operates flights to
35 destinations in Argentina.
For about 20 years the Argentinian airline relies on technical services provided
by Lufthansa Technik with various products, among them engine and component
support. To name only a few recent examples: In 2012 and 2013 Lufthansa Technik
AERO Alzey and Aerolíneas Argentinas
signed contracts for the engine types
CF34-10 and CFM56-7. Also in 2013, a
local base for the mobile Airline Support
Aerolíneas Argentinas
• National airline of Argentinia
• Member of the SkyTeam alliance
• Founded in 1950
• Headquarted in Buenos Aires
• Fleet of 57 aircraft
• 18 international and
35 national destinations
• Ambitious program of fleet renewal
Customer Portrait | 13
Fort Lauderdale
Miami
Mexico
MEX
BQN
Belize
Guatemala
El Salvador
Lufthansa Technik offers a broad portfolio of tailored services
for the airline industry in Latin America. The integration of local
sales offices and maintenance stations with global production
capacities provides efficient MRO solutions. The increasing number
of Cyclean® engine wash stations in the area are but one example of
a comprehensive support.
Puerto Rico
Honduras
Nicaragua
Costa Rica
Venezuela
Panama
BOG
● Regional Sales Offices
● Lufthansa Technik Subsidiary
● Lufthansa Line Maintenance Stations
● Cyclean® Customer Lease Station
Guyana
Suriname
Guyane
Colombia
Equador
Brasil
Teams (AST® Engines) has been set up.
Lufthansa Technik and the engine experts
of Aerolíneas Argentinas together handle
AST® services for Latin America directly
from Buenos Aires.
Divided work
Photo: sunsinger – Fotolia
Two new engine contracts verify the special relationship between the two companies, which not only relies on service
agreements between customer and provider, but is a real partnership. For the first
time the overhaul of 54 CFM56-7B and 28
CFM56-5C engines will be carried out
within the framework of newly defined
contracts that envisage dividing the work
between airline and MRO provider.
Under the Joint Shop Visit Program
Aerolíneas Argentinas will tear the CFM567B engines down into modules in Buenos
Aires, while the repairs will then be carried
out in Hamburg. After the overhaul, the
modules will be sent back to Buenos Aires
for reassembly of the engine.
Hernán Flombaum, Components and
Engines Provisioning Manager at Aero
líneas Argentinas, comments: “The tailored
solution to improve the capabilities in our
shop and a competitive commercial offer
made Lufthansa Technik the best solution
to support the engines of our growing
Boeing 737NG fleet.”
Tailored support package
LIM
Perú
Bolivia
To enable the agreed division
CNF
of labor to be implemented efficiently, a tailored support package
GIG, SDU
GRU
Paraguay
was agreed for Aerolíneas ArgenChile
tinas. The company, which already
has qualified engine mechanics –
in the past JT8 engines used to
Enhanced Perforbe maintained here – will be supmance ImproveSantiago de Chile
SCL
ported with a variety of measures.
ment workscope in
EZE
Uruguay combination with indiOne fundamental element of this
Buenos Aires
is staff training for the new engine
vidual customized Life
types. In addition, Lufthansa
Extension
workscopes, will
Argentina
Technik will provide assistance
reduce the long-term maintewith the sourcing of shop
nance cost per flight hour and the
equipment. And finally the
fuel consumption as well as optimize
MRO provider will also oversee
the workscoping.
the setting up of the new shop:
As with the CFM56-7B contract,
companies in the Lufthansa
Lufthansa Technik will create
Technik Group will assist with
potential work for the engine
the equipment layout, the creshop of Aerolíneas Argentinas.
ation of the basic infrastructure
The typical Life Extension shop visand establishment of the processes
its require only a partial disassembly of
down to the necessary logistics.
the engine, which will be performed at the
Additional training for staff authorized to
airlines’ engine shop: The top case repair
issue certification will take place at the
to access the High Pressure Compartment
engine manufacturers. The training of the
(HPC), the Low Pressure Turbine (LPT)
mechanics took place at Lufthansa Technik
removal for overhaul at Lufthansa Technik,
in Hamburg and Frankfurt. Moreover, a
and all necessary work in the fan major
technical adviser of Lufthansa Technik will
module and gearboxes. At the same time,
be permanently on site in Buenos Aires to
Cyclean® Engine Wash equipment will be
ensure that the overhaul program runs as
allocated at Aerolíneas Argentinas.
smoothly as possible. In the long-term a
The new solutions based on division of
local repair capability may be built up as well. the overhaul tasks are a genuine win-win
situation for both the Argentinean carrier
CFM56-5C Performance Program
and Lufthansa Technik. Last but not least,
they also are a manifestation of the truly
The second new contract about the 28
collaborative approach the Hamburg comCFM56-5C engines of Aerolíneas Argentinas’ pany offers its long-standing customer and
A340-300 fleet was signed in February
partner.
2015. Lufthansa Technik will support the
airline with a Performance Program for this
Jörg Femerling
engine type until the phase-out of the fleet.
Phone +1-305-379-2604
The concept, based on Lufthansa Technik’s [email protected]
14 | Engine Services
For more information:
www.lufthansa-technik.com/cyclean
Visual check of
nozzle spray pattern.
Hot solution for cold wash
Cyclean® can now also be used at sub-zero temperatures. This considerably increases the
scope of application of the flexible and highly efficient wash system for aircraft engines.
T
he success story of the Cyclean®
engine wash system developed by
Lufthansa Technik specialists continues
to evolve. In the past the system could only
be used at outside air temperatures of higher than plus 5 degrees Celsius so as to prevent any danger of icing in the engine as a
result of spraying with cleaning water. This
resulted in specific restrictions, for example
in North America and Russia.
Engineers at Lufthansa Technik responded by developing a solution that also allows
engine washes to be performed safely at
lower temperatures, thus extending the scope
of application considerably. The latest generation of Cyclean® wash units is now
equipped additionally with an integrated
glycol mixing system, which allows the dispensed admixture of antifreeze agent to be
added to the water. The result is a considerable extension of the operating limit down to
below zero: Engine washes up to minus 10
degrees Celsius are now possible with the
new system.
The first new system is already in use in
London Heathrow (UK). A further system is
likewise available in Zurich (Switzerland) and
the third one is to be used at the new Cyclean®
service station in Montreal (Canada) from
the middle of the year. Customers gain more
benefit from the advantages of Cyclean®
with the new system. The cleaning system
can wash an engine directly at the gate in
less than one hour. The process frees the
engines, in particular the fan and compressor
blades, from dirt such as sand, mud, salt,
dust and pollen. Once cleaned, the engines
are more thermally efficient in operation and
use up to one percent less kerosene for the
same level of performance, reducing costs
and the environmental impact.
Cyclean® is used daily today in 21 countries on four continents. The appropriate
washing spray adapters are meanwhile
offered for 37 engine types, including the
new GEnx engines, the GP7200 and all
Trent engine types including the XWB for
the A350.
Oliver Winter
Phone +49-69-696-96184
[email protected]
eServices | 15
Online material offers
anytime, anywhere
Lufthansa Technik’s online shop for rotables and consumables
now offers new features with even greater user-friendliness.
T
ime is money and during an AOG,
things need to happen quickly. Customers now enjoy an even higher
standard in comfort and convenience when
they use m/material, the manage/m®
application that manages all aspects of a
customer’s material contract with Lufthansa
Technik. A brand new function within
m/material allows customers to request an
offer for non-contracted material online –
efficiently and easily. All a customer has to
do is enter the “fast lane” within m/material,
select the new function “offer”, and choose
between “sale”, “loan” and “exchange” as
well as stating the urgency of the request. If
AOG is selected, customers will receive the
desired material as soon as possible.
Short response times are a dominant
feature of the new system. “The offer for
C&E material is available in an average of
only thirty seconds. For components it usually takes between two and twenty minutes
until an offer is generated, and the customer
receives it via the system,” explains Georg
Pelda, the responsible IT project manager
at Lufthansa Technik.
The most significant improvement is
that an offer can be requested via just one
channel – m/material – and the customer
only has to deal with one digital workflow.
No additional e-mails, faxes or calls are
required. “We offer this as a fast, easy and
reliable service to any Lufthansa Technik
customer. The speed with which an offer is
generated is incredibly high, since the
inquiries are handled directly by the AOG
desk. In addition, you can also request
several part numbers within a single offer,
which speeds up the whole process even
more,” underlines Soraa Kim, Lufthansa
Technik project manager for Single Component Availability. m/material, Lufthansa
Technik’s innovative, comfortable approach
to submitting material requests, is already
in use by nearly 170 customers. The customer roll-out of the new system will start in
July for American customers, with all others
being able to profit from these improvements
by the end of the year.
Jamila Jadran
Phone +49-69-696-37386
[email protected]
Project managers Soraa Kim and Georg Pelda show the new function of m/material.
Automated interface
All offers are presented in a standardized
format that includes information on prices or
rates, serial numbers, and attached certificates such as an EASA Form 1 or a workshop report. “An automated interface with
the manage/m® module m/archive provides
the relevant documents for material ordered
via m/material,” says Pelda. “The customer
consequently receives all the important data
needed to decide whether to accept the
offer, and can choose between a sale, a
loan and an exchange.”
www.manage-m.com
16 | New Aircraft
A350 component
support for Finnair
Finnair, the first European airline to operate the Airbus A350 XWB, has awarded
Lufthansa Technik a comprehensive Total Component Support (TCS®) contract for
the new aircraft type.
L
ufthansa Technik is one of the leading providers
of technical services for the aviation industry,
and the agreement with Finnair is the company’s
first contract for A350 XWB component support. “The
new A350 XWB aircraft form the backbone of our
growth strategy, and component support agreement is
one part of our thorough preparations for the aircraft’s
arrival,” says Jari Huhtinen, Vice President, Finnair
Technical Operations. “We are pleased to sign this
contract with Lufthansa Technik. World class technical
competencies, high reliability of repair service and
overall cost competitiveness were key factors in our
decision,” Huhtinen says.
“This first contract for component support for the
newest Airbus aircraft is a terrific vote of confidence
from our customer Finnair,” says Dr. Johannes Buss-
mann, CEO of Lufthansa Technik. “It also underscores
once again our many years of expertise in ensuring a
smooth introduction of new aircraft types.”
The exclusive Total Component Support (TCS®)
contract covers the availability and repair services of
A350 XWB components. Finnair already has an
agreement with Lufthansa Technik on engine related
component services for V2500 engines and APU
services for APS3200. Finnair’s own maintenance
organisation at the Helsinki Airport is responsible for
the line maintenance of Finnair’s current fleet and the
new A350 XWB fleet. Finnair has firm orders for 19
A350 XWB aircraft, the first four of which are expected
to arrive in the fleet in the second half of this year, with
another seven in 2016 and 2017. The complete order
will be fulfilled by 2023.
New Aircraft | 17
Photo: Airbus S.A.S. 2014
About Finnair
// Finnair flies between Asia, Europe and North
America with an emphasis on fast connections
via Helsinki, carrying more than nine million passengers annually and connecting 15 cities in
Asia with more than 60 destinations in Europe.
The airline, a pioneer in sustainable flying, is the
European launch customer of the next-generation, eco-smart Airbus A350 XWB aircraft and is
the first airline listed in the Leadership Index of
the worldwide Carbon Disclosure Project. The
only Nordic carrier with a 4-star Skytrax ranking,
Finnair has also won the World Airline Award for
Best Airline Northern Europe for the past five
years running. //
18 | Innovation & Technology
vation b
ans
ni
f
th
k
Lu
Franziska Voerner and Hauke Fleischer
developed the dedicated housing, which
eliminates the seat back screen.
no
y
In
In cooperation with Qantas Airways, Lufthansa Technik has developed a new concept for
in-flight entertainment. A tablet in a dedicated housing replaces the traditional seat back
screen, enabling customers to use the mobile device during their entire stay on board.
a Te c
h
Innovation & Technology | 19
Due to the snap-fit, inserting the PED case into the utility shelf is a matter of seconds.
I
t’s not just on the ground that the popularity of mobile devices such as smartphones and tablets keeps on growing;
they are also gaining the upper hand for
use in flight, replacing more and more
integrated in-flight entertainment system
(IFE) solutions. Whilst many providers continue to rely on fixed monitors integrated
in the aircraft seat, Lufthansa Technik and
Australia’s largest airline, Qantas Airways,
have cooperated to develop a new IFE
concept that makes it possible to use the
tablet in the seat back throughout the entire
flight (gate-to-gate IFE). After the successful completion of all tests necessary for
approval (including the test for Head Injury
Criteria), Qantas will initially make the
concept available in the Business Class
on its two-class Boeing 717 fleet.
The new IFE concept provides wireless access
to films, TV and music, whilst passengers still have
their hands and tray tables free.
Working closely together with aircraft
seat manufacturer ZIM Flugsitz GmbH, the
first stage was the development of a system enabling the device to be mounted in
the seat. The mounting is flexible enough
to be used for other smartphones, tablets,
e-readers and even books. ZIM integrated
this so-called “Utility Shelf” in the backrest
of the seat.
The next step involved Lufthansa
Technik and Qantas working together to
develop the Personal Electronic Device
(PED) Case, a tablet enclosure that fulfils
the requirements for flight approval.
Installed in the PED Case, the iPads made
available by Qantas for the duration of the
flight are snap-fitted into the Utility Shelf
and can be used like a traditional monitor
throughout the flight.
Latest hardware on board
This IFE concept provides passengers with
the latest hardware for on-board entertainment in all phases of flight including taxi,
take-off and landing. It provides wireless
access to films, TV and music, whilst
passengers still have their hands and tray
tables free. Airline customers can save
on the extensive costs associated with the
installation, maintenance and repair of
fixed seat back monitors.
The PED Case can be retrofitted into
any seat of any aircraft and can be modified to suit other manufacturers’ tablets.
Lufthansa Technik not only played a key
role in the development of the product; we
also offer the highest level of competency
in the integration, installation, approval and
maintenance of the latest communications
solutions and modifications for the aircraft
cabin. Lufthansa Technik can draw on many
years of experience in the fields of cabin
and seat modification. At the Hamburg
site alone, more than 200 highly qualified
employees in the various workshops
implement optimal modification solutions
for VIP customers and commercial airlines.
These solutions range from new seat
covers and upholstery to complete electronic refits of existing configurations.
Alexander Gössel
Phone +49-40-5070-5436
[email protected]
20 | Engine Services
Guided by computer commands, the
technician focusses on his inspection task.
Voice control improves data entry
Lufthansa Technik is introducing voice-controlled data entry for initial inspection and
table inspection of APUs. The Honeywell Vocollect Voice Maintenance & Inspection Solution
provides improved process reliability and cost-efficiency.
W
hether an initial inspection or a
table inspection is required,
inspecting an APU is a demanding task for mechanics. In the past, a worker
had to read the required inspection task on
the computer and then go to the APU to
perform the task. After completing it, he had
to return to the computer to enter the result.
A considerably more expensive alternative
was to use two workers who would split the
task. Vocollect, a voice-controlled data collection and analysis system, simplifies the
task so that it can be performed quickly and
easily by a single worker. The mechanic
performing the inspection communicates
with the computer using a headset through
which he receives the inspection tasks from
the computer. In this way, the inspector is
guided through the inspection program
step by step and provides the appropriate
responses depending on his findings. And
since the inspector has both hands free,
performing the inspection tasks is much
easier than it was in the past. Free-text
responses can be spoken as well, but
require the worker to check and, if necessary, correct the responses afterwards.
Engine Services | 21
Technical service provision
for engine lessors
Technical service provision by Lufthansa Technik is a service
product designed to handle the engine lease return event
for the lessor, ensuring a smooth and hassle-free transition
of the leased engine.
By introducing this cutting-edge system,
Lufthansa Technik is once again taking on
a pioneering role; it is the first aviation
company among Honeywell’s customers to
use the Vocollect system. Previously,
Vocollect was used internally at Honeywell.
Lufthansa Industry Solutions provided support for adapting the system to the requirements of an MRO company. That meant
the inspection task had to be painstakingly
analyzed and restructured. The end result
was a long list of questions and all appropriate responses, which the computer
“reads aloud.” In the first step, the system
was designed for the APS 3200 APU. Its use
with the HGT1700, the APU for the Airbus
A350, is in preparation.
Using Vocollect has clear benefits. Boy
Peter Carstensen, consultant at Lufthansa
Industry Solutions, says: “Vocollect simplifies inspection tasks and boosts worker
performance. The time required for paperwork can be reduced by nearly one-third.
In addition, process standardization strongly
supports the goal of a lean process.”
For the next innovation, Vocollect is
working on the integration of a camera
so photos can be directly incorporated into
reports to document findings. That will
shorten the processes even more.
Ole Gosau
Phone +49-40-5070-3868
[email protected]
A
n engine returning from lease
may contain many unknowns
and associated risks. Available
for a large variety of engine types,
Lufthansa Technik’s dedicated Technical
Service Provision (TSP) is precisely tailored to adress these. The service range
starts with record review and generation.
Accurate documentation of the engine
status is of the utmost importance, as
rectifications required at a later stage will
inevitably require significant effort.
Experienced Lufthansa Technik personnel analyze and reorganize all engine
records, generating a discrepancy report
for the engine lessee. Every document is
meticulously checked and verified.
In a second step, engineering work
scoping and support is provided. Experienced Lufthansa Technik engineers
analyze the engine status and develop
the required workscope which is then
sent to the selected MRO facility. This
workscope ensures that all necessary
inspections and modifications are
performed, keeping the engine in peak
condition; maximizing the engine value.
The final task comprises the housekeeping services. Lufthansa Technik
offers MRO/housekeeping services for
engines in approved facilities located in
Hamburg, Frankfurt, Alzey and Shenzhen.
Here the workscope is performed and
resulting documentation sent to Lufthansa
Technik’s Technical Service Provision
team who check and verify them. On
completion of this review an engine brochure is produced detailing the engines
current status. This brochure is the
perfect tool for re-marketing the engine
for potential new leases.
Lessors are free to choose other
MRO providers for the housekeeping
task, with Lufthansa Technik TSP providing all other services as outlined above.
All lessors are unique, so all services
are flexible and can be tailored to suit
individual specific requirements.
Robin Schmitz
Phone +49-40-5070-64678
[email protected]
Lessor advantages
•EASA 145-approved
•Maximized engine value
•Perfect engine condition
•Lufthansa Technik quality
•Smooth engine transition
•Fast housekeeping event
•Optimized asset utilization
22 | Aircraft Systems
Aircraft Systems | 23
“We’re committed to preserving value”
At Lufthansa Technik, Landing Gear Overhaul and Composite Repairs (Airframe Related Components, ARC®) were integrated into the Product Division Aircraft Systems. Connection spoke with
Andreas Tielmann, Vice President Aircraft Systems, about trends in his field of responsibility.
There are two product groups
integrated in the Product Division
Aircraft Systems that don’t appear
related at first glance. What is the
connection between these?
Andreas Tielmann: A characteristic of
landing gear and nacelles is the great
importance of spare units. They represent
a significant investment, so asset availability for both products is generally
ensured by the MRO company. An aircraft
needs such a part every eight to ten years.
In the past this mainly applied for landing
gear, but the reliability of the latest
generation of nacelles has also improved
considerably.
An important point from the customer
perspective is also the size of the components; transporting them is a major effort
and not easy to organize.
Spare units are becoming
considerably more expensive.
How are you reacting?
We want to offer a good solution for this
problem as well. Because of the rising
prices for spare units and the increasing
reliability, the pressure to get the most out
of the investment is also rising. Because
of our size and broad customer base,
we’re able to offer our customers a true
benefit because we make that kind of
investment and can amortize it through
appropriate utilization by many customers.
That results in much lower expenses for
our customers than if they kept the components in their own inventories.
What is your assessment of future
trends for repair processes?
There are two opposing effects at work
here. On the one hand, increasing reliability means less need for repairs. But when
the price of an individual part increases,
in principle the need for repairs becomes
more significant since the alternative –
replacing thus scrapping the part – is
increasingly expensive.
So I think that for the new aircraft types,
which have reached the market with considerably higher prices for replacement
parts, repairs will be an especially interesting business. These repairs will be performed less often, but since the value of
the components has increased considerably, I’m certain that the trend for repairs
will be to gain in importance.
How has the expertise in repairs for
the Airbus A380 and the Boeing 787
progressed?
Developing our own repair capability is an
important issue for us. Lufthansa Technik
seeks an ideal solution for its customers,
in various degrees of cooperation with the
manufacturer. Our cooperation with UTAS
is off to a good start. We’re learning from
each other for the 787 customers and
we’re learning how its nacelle behaves in
flight. We’ve already repaired the first 787
nacelle components from different customers from all world regions.
Bonding repairs are ideal for fiber composite materials and we see increasingly
new composite applications on new aircraft. For a lot of those no bonding repair
exists as of today. So we’re working hard
on the development of repair techniques
to enlarge our portfolio of possible repairs.
Another area of development is automation.
In this field a robot for preparing scarf
joints is in testing and will soon be put to
use in our workshop.
What other effects does
increased reliability have?
Increased reliability is good for the airlines,
but it means reduced capacity utilization
for the shops. That’s why customer focus
and growth are so important for us. We’re
seeing that airlines are doing less and less
to supply such components internally, so
�
Please continue on page 24
24 | Aircraft Systems
our realignment toward supplying customers with spares is the right way to go.
And of course on the recently introduced
types, we’re getting prepared for more
serious damage and the repairs it calls
for. That’s why it was very important when
procuring the autoclave to make certain
that it was big enough to accommodate
components from even the biggest
engines.
How important will the mobile repair
teams, the Airline Support Teams,
be in the future?
For landing gear, use of the mobile repair
teams is limited, even though there are
definitely applications. Instead, for landing
gear the shop visit for the scheduled
overhaul is the vast majority of MRO work
to do.
For composite repairs, the importance of
these mobile repair teams is increasing –
a consequence of the rising prices for
spare parts. The benefit when a part can
be repaired on-wing is of course also that
no spare parts are needed to cover the
duration of a shop visit. The more expensive the spare part is, the bigger the
benefit we can offer the customer with a
mobile repair solution. Work done by the
AST® team during an aircraft layover has
already been of considerable benefit to
our customers as well.
What does the future hold
for Aircraft Systems?
Lufthansa Technik is a global business,
and we plan to be active in the important
regions. The most visible example is the
nacelle business. We’ve doubled our shop
capacity at Lufthansa Technik Shenzhen
and successfully performed the first repairs
on Boeing 787 nacelle components.
And we’re currently deliberating about how
the right setup could look for the Middle
East region. At Lufthansa Technik Middle
East Services in Dubai, we have a small
workshop to provide solutions locally.
That’s still a small setup today, but we
have plans to get bigger in local repair
services there.
Our business is characterized by highquality, high-reliability parts. Supply and
repair call for true specialists. That’s what
we are, with lots of experience and a broad
customer base. Our customer focus combined with Lufthansa Technik’s commitment
to repairs ensures that our customers
always have a good choice.
Aircraft Systems | 25
High-class repair of acoustic panels
Acoustic panels in the air intake cowl of engines are susceptible to failure. Lufthansa Technik
offers efficient repairs for Trent 500 and Trent 700 panels. As the acoustic qualities are not
impaired by the processes, they are suitable for large area repairs – another smart alternative
to scrapping.
L
ufthansa Technik’s business unit Airframe Related Components (ARC®)
offers an approved repair of the
acoustic panels in the air intake cowl of
the Trent 500. The intricate procedure
starts with the complete removal of the
wire mesh and the cleaning and degreasing of the repair area. The wire mesh is
then pre-fit and cut as required as well as
chemically pre-treated. After the adhesive
has been sprayed onto the repair area, the
wire mesh is applied. To ensure a strong
bond, the mesh must be in perfect contact
with the adhesive on the repair area.
It is here that the experienced hands of
the Lufthansa Technik composite specialists are an absolute necessity, as the task
requires absolutely perfect handling of the
delicate woven wire. After vacuum bagging
and curing in an autoclave, the final check
is performed before the component is
rendered serviceable.
Restoring acoustic properties
The repair of the Trent 700 engine inlet
cowl acoustic panel is more complex.
Here the disbond often occurs between
the s o-called brochier weave, a woven
carbon fiber perforated sheet, and the
honeycomb core. The OEM repair – cutting out the damaged section and application of non-acoustic carbon fabric –
Trent 500 repair: Application of wire
mesh to acoustic panel.
means that the acoustic properties of the
affected panels are affected and therefore
limited. Lufthansa Technik has developed
an alternative which restores the acoustic
qualities of the panel.
The repair process – approval pending –
involves removing the facing wire mesh
and the complete brochier weave of the
affected acoustic panel. First the wire
mesh will be removed and scrapped.
Afterwards the brochier weave is removed,
cleaned, inspected and stored for later
installation.
After removal of the acoustic skins all
damaged or disbonded honeycomb core
will be replaced by new core according to
the original specification. Finally the honeycomb core, the previously removed brochier
weave and on top of that the new wire
mesh will be bonded in the autoclave in
three subsequent steps.
This repair will fully restore the acoustic
quality of the inlet panel. This means that
even large damaged areas in a Trent 700
acoustic panel must not result in a scrapped
part – another example of efficiency as
understood by Lufthansa Technik.
Henrik Radzanowski
Phone +49-40-5070-66280
[email protected]
Trent 700 repair: Blue adhesive has been
applied to the honeycomb structure. Brochier
weave bonded to honeycomb: Traces of the
adhesive are visible.
26 | Cockpit & Cabin Products
Overall view of the new
auto storage rack system.
New storage system
Lufthansa Technik Logistik Services (LTLS) has put a new auto storage
rack system for small parts into operation in Hamburg.
“A
utoStore” is an innovative, automatic storage and retrieval system in which plastic containers
are stacked one on top of the other. At
Lufthansa Technik Logistic Services, 19
robots move on an aluminum base frame.
They retrieve items from stock and transport them to seven picking stations. 75
stock inputs and up to 200 stock outputs
are possible per hour.
The “AutoStore” system covers an area
of 700 m2, with 24,000 containers accommodating 215,000 batches. The compact
storage concept thus enables space savings of more than 50 percent compared
with the legacy system. Capacity and
speed can be enhanced almost infinitely
during operation.
Optimized logistics
“The new system represents a major step
toward forward-looking, innovative, and
ergonomically optimized logistics,” said
Lufthansa Technik CFO Dr. Peter Jansen
at the official opening. Andreas Meisel,
Managing Director of Lufthansa Technik
Logistik Services, added: “Lufthansa Technik
Logistik Services invested a good three
million euros in the ‘AutoStore’ system in
the last 24 months and consequently in
the efficient deployment of employees.
At the same time this allows us to further
improve working conditions. We have thus
successfully moved away from the ‘person-to-goods’ approach formerly adopted
to a more modern ‘goods-to-person’
retrieval principle.”
The investment in the new logistics system
is a further step in Lufthansa Technik’s modernization program at the Hamburg location.
Following the construction of a new engine
overhaul center, a separate building for the
new “Original Equipment Innovation” business unit, and considerable investment in
the area of composite material repairs, a
building has recently been constructed that
includes a completely new chemistry lab
among other facilities. Lufthansa Technik
has quadrupled its investments in research
and development in the past year.
Ribbon-cutting during the opening ceremony of the new storage system.
Events & Exhibitions | 27
Easy IT system for
warehouse management
Meet us at...
25 – 30 August 2015 | Moscow
MAKS
Lufthansa Technik Middle East Services (LTMES) in Dubai is the
first user of the new self-explanatory warehouse management
system “web.control” from Lufthansa Technik Logistik Services (LTLS).
The new software was installed at the beginning of March.
Held in the town of Zhukovsky at the
airfield of the major national testing
facility, the International Aviation and
Space salon MAKS occupies a leading position in the ratings of major
world aviation forums.
6 – 8 October 2015 | Munich
inter airport Europe
“M
any smaller airlines are still
using paper or Excel tables to
manage their inventories,”
says Dr. Maik Speel, Head of Service Centers Logistic Solutions at Lufthansa Technik
Logistik Services. “Extensive and complex
software solutions are much too expensive
and tend to discourage customers rather
than increase their appetites for logistics.”
And so the idea to develop a warehouse
management system for small to mediumsized companies was born.
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
Self-explanatory picture elements facilitate use of the
new web.control warehouse management software.
Self-explanatory software
The software is self-explanatory and primarily works with picture elements so that
employees can get to grips with it quickly
and reliably on site. It is used primarily to
document goods receipt and goods output. As much data as possible is generated
automatically from the master data in
goods receipt. The goods receipt document and what is called the PickSlip,
which contains all of the information for
the physical storage, are then provided
online for printing from the system. The
packaging unit can be selected additionally
in the case of goods output, while the
shipping documents are then also available
online, thus allowing the overall process
to be completed more quickly and easily.
“Other features can be purchased
additionally like in a modular system,”
explains Laura Andersch, project employee
at Logistic Solutions. “This is therefore a
management system for inventories that
indicates when stocks have fallen below a
critical level. Inventory management can
be used to manage the entire inventory.
The storage compartment view indicates
the utilization of the storage bins in the
warehouse.”
“web.control” is a stand-alone solution,
which means that connection to an expensive system landscape is not necessary.
The data is made available in a cloud and
can therefore be accessed from all Internetenabled laptops, even from smartphones
or tablets. The customer dials into the
Internet via a link using a password and
can access his or her inventory as well as
perform all warehouse operations and
shipping activities.
The new software is primarily suitable
for customers who currently only use basic
IT support or proprietary developments. In
addition, the new warehouse management
system is also to be offered to new customers as a supplementary component to
reduce logistics costs.
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
The Regional Aviation Association of
Australia (RAAA) Convention is highly
regarded as a premier annual aviation
event of the region.
Preview
Highlights of the next issue:
• Airline Support Teams going global
• Aircraft Overhaul
• 20 years of GuideU
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™)
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
• Logistics & Training
A320
A319
A321
A320neo
A321
Hotline
24/7
k
AOG des
eServices
Lufthansa Technik’s Technical Operations
Websuite manage/m® allows operators
to manage their technical operations via a
web-based system.
www.lufthansa-technik.com/services
308
H otl i ne
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)
• Aircraft Leasing & Trading Support (ALTS®)
• AOG Services
- 4 0 - 5 0 70
49
• Surface treatment
Cabin & IFE Products
Lufthansa Technik has successfully
established a line of cabin products.
• Cabin Management & IFE Systems
• Aircraft & Cabin Equipment
• Connectivity
• Patient Transport Solutions
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
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
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]
www.lufthansa-technik.com/
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
Around the clock.
No matter what.
Our worldwide Total Component Support TCS® for
your Boeing 787. The success of an aircraft’s daily
operations depends on flawless component support when needed. With decades of experience
spanning hundreds of aircraft, Lufthansa Technik’s
component team has successfully established an
optimum supply process for 787 operators. Wherever you need us, we are happy to be of service.
Lufthansa Technik AG, [email protected]
Call us: +49-40-5070-5553
www.lufthansa-technik.com/787
More mobility for the world

- Lufthansa Technik AG

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