Connection 2-2016 PDF
Connection 2-2016 PDF
2016 March/April
Airbus A320neo
Aircraft Base Maintenance Innovation & Technology Here for you in the Middle East
6
New Aircraft
• Airbus A320neo: 14
The A320’s future is “neo”
• Airbus A350 XWB:
EASA Part 21/J approval 24
New pneumatic test bench 25
A350 nacelle services 25
14
• Engine Parts & Accessories Repair: 21
Dedicated app for EPAR catalog
16
Categories
• News 3– 5
• Personalities 23
• Events 27
• Products & Services 28
• Contacts 30
26
Weg beim Jaeger 193 · 22335 Hamburg, Germany
Infoline +49-40-5070-5553 · Fax +49-40-5070-8860
[email protected] · www.lufthansa-technik.com
Angela Huber-Saffer · Database management
Editorial Production
Editorial office: Flightlines, Hamburg
Design: Art Works!, Hamburg
Photos: Lufthansa Technik AG, Deutsche Lufthansa AG
Printing: Beisner Druck GmbH & Co. KG
Lufthansa Technik Connection 2.2016 News | 3
C
arsten Spohr, Chairman of the Board The development and introduction of CEO. “At Airbus we are proud to support
and CEO of the Lufthansa Group, the quietest and most fuel-efficient aircraft Lufthansa’s growth over the past four
Airbus President and CEO Fabrice on short and medium distances is further decades with our partnership now span-
Brégier and the President of Pratt & Whitney evidence of the successful cooperation in ning almost the entire Airbus family, from
Robert Leduc invited 700 guests and media the aviation industry at European level. the A320 right up to the A380.”
representatives to the official delivery at “Europe has been a leader in this fascinat- “Pratt & Whitney is proud to build on its
Hamburg-Finkenwerder. Following the cere- ing industry since the early days of aviation,” long and deep history with Lufthansa and
monial handover, the first two new-type says Carsten Spohr. “Lufthansa and Airbus Airbus by together marking a new era in
airplanes were presented to the public. The have developed a trusting and productive commercial aviation with the delivery of the
first A320neo, with the registration D-AINA, 40-year partnership.” A320neo equipped with ultra-high bypass
has already flown scheduled service since “On behalf of everyone at Airbus, I con- ratio geared turbofan engines,” Pratt &
January and the second “neo” has comple- gratulate Lufthansa on being the A320neo Whitney President Robert Leduc said.
mented the Lufthansa Airbus fleet soon after. launch customer. Together, we’re opening Just in time for the adoption of the first
The first experiences with the A320neo clearly a new chapter in commercial aviation and A320neo, Lufthansa Technik is also ready
show that the 15 percent lower fuel con- I am confident that the A320neo will sup- for maintenance of the new airplane type
sumption mark – as compared to the previous port Lufthansa’s objective to raise its envi- and its systems. In the preparatory phase,
A320 generation – has not only been achieved ronmental performance. The A320neo not Lufthansa Technik has laid out all technical,
but even slightly exceeded. The significantly only cuts emissions at every operational operational and personnel foundations for
quieter engines also increase customer com- stage but also halves its noise footprint complete technical support of the
fort on board and provide relief to residents compared to previous generation aircraft,” A320neo.
near airports by reducing noise emissions. said Fabrice Brégier, Airbus President and
� Please continue on page 14
4 | News Lufthansa Technik Connection 2. 2016
Manila
Hamburg
Singapore London
www.lufthansa-
technik.com/
customer-newsletter
Lufthansa Technik Connection 2.2016 News | 5
Zurich
Manila
Hamburg
Munich
www.lufthansa-technik.
com/base-maintenance
Lufthansa Technik Connection 2.2016 Aircraft Base Maintenance | 7
L
ufthansa Technik has always been
known for its tailored products, from
a single event to a fleet solution, and
for its high quality and worldwide network
of overhaul locations. However, in recent
years the company has adapted the struc-
ture and organization of its Aircraft Base
Maintenance division so that it can contin-
ue to offer its customers the right solutions
in a challenging market as well as signifi-
cant added value.
The extensive SixToONE restructuring
program has brought the European over-
haul facilities even closer together. Struc-
tures and processes were standardized
further, sales contacts see themselves now
as network sales representatives, and
customers receive the same high-quality
services everywhere, regardless of which
Lufthansa Technik facility performs the
overhaul of their aircraft. In the process,
the effect of the program far exceeds the
European locations, since the new pro-
cesses, which have meanwhile proven
their worth, are now being transferred to
other facilities around the world.
HAM
SNN SXF
FRA PEK
BUD
SOF
MLA
BQN MNL
“is a success story,” reports Marcus “Basically we do the same thing at all our facility in Hamburg, so that the staff there
Motschenbacher, Director Network Sales sites, but not all aircraft types are handled has developed special expertise in cabin
& Customer Service Aircraft Base Mainte- everywhere. In Shannon, for example, we conversions. Manila concentrates on the
nance (see the interview on page 11). fill the growing niche for Boeing 757/767 Airbus A380 and has built up new Boeing
The standards developed in the network aircraft. We work on narrowbodies in 777 base maintenance capabilities.
“
were transferred to Shannon and at “Overall, Lufthansa Technik has the
the new subsidiary all other locations capacity to deliver over six million man-
from the very begin- We are prepared to offer except for Ham- hours of base maintenance work per
ning. Of five planned customers our free capacity this burg, and we year,” says Thomas Rueckert, Vice Presi-
lines in Puerto Rico, summer with a high level of overhaul wide- dent Production Network Aircraft Base
four were already flexibility and at attractive prices. bodies – the A330 Maintenance. “That puts us in third place
sold out when the Thomas Rueckert and A340 – pri- worldwide in terms of capacity.”
facility opened, and marily in Malta,
in the months since then, Lufthansa Technik Manila and Hamburg,” says Marcus Customers profit from synergies
Puerto Rico has already overhauled Motschenbacher, naming some examples.
eighteen aircraft for its customers Jet Blue In addition to a focus based on aircraft The individual locations exchange know-
and Spirit Airlines. types, there are business-specific special- how and expertise and help each other
ties. For example, Lufthansa Technik out with employees. For instance, the
Focal points of the global network carries out lease transitions everywhere, experts from Shannon travel the globe
but Shannon, in particular, specializes in throughout the network, supporting the
Each of the locations in Lufthansa Technik’s the business. And many modifications development of new overhaul lines. As a
network specializes in specific aircraft over the last two years were planned and result of the restructuring program, all the
types or a specific kind of business. carried out at the company’s German
� Please continue on page 10
10 | Aircraft Base Maintenance Lufthansa Technik Connection 2.2016
facilities work more closely with each other. summarizes Thomas Rueckert. Through which Lufthansa Technik offers together
The learning effect of this cooperation is this international exchange, all of Lufthansa with Inmarsat and Lufthansa Systems.
extensive – and benefits the customers Technik’s customers profit from the more The first installations of the Inmarsat
most of all. “If we discover something at than 600 events the company carries out systems, which are based on what is
one location today, all the other locations every year, and this build-up of experience currently the fastest system (Ka-band),
know about it the next day. Customers no benefits every single event, beyond the will begin over the next few months with
longer have to transfer new insights bounds of location and aircraft type. Lufthansa Technik as the official Engineering
themselves; we do that,” explains Marcus provider and installation partner (page 13).
Motschenbacher. The overhaul lines in all New technologies and aircraft And even if the first big maintenance
the facilities are meanwhile set up identi- events for the new aircraft types – such
cally and projects are controlled and But Lufthansa Technik Aircraft Base Main- as the Airbus A350 or the Boeing 787 –
organized according to a pattern. “And tenance has more goals than just greater will not take place for another few years,
that’s one of the most important factors: efficiency. The company is also focusing Lufthansa Technik is already making
the successful performance of overhaul on new technologies. One important area preparations for these new challenges.
programs depends on well-trained for innovation is the aircraft cabin. An Marcus Motschenbacher says: “We are
employees, good logistics and prepara- example of a new cabin solution is state- holding initial discussions these days on
tion and good project management,” of-the-art on-board broadband Internet, the new aircraft types.”
Lufthansa Technik Connection 2.2016 Aircraft Base Maintenance | 11
Thomas Rueckert
(left) and Marcus
Motschenbacher.
What characterizes today’s base October through March. Getting the owing to the technological challenges they
maintenance market, and what is majority of work done in just six months is present. These two trends mean that it is
Lufthansa Technik’s position in it? a challenge for the whole industry – for becoming more and more difficult to earn
Marcus Motschenbacher: Especially in customers, for us and for the competition. the same revenue at a single site in less
Europe, the market for base maintenance Thomas Rueckert: The seasonal effect is available time.
is marked by a strong and fragmented not as extreme in the Americas. If you
competition. There are highs in demand look at the profile of the workload in How is Lufthansa Technik
every five to six years that follow the waves Puerto Rico, for instance, you can see positioned for this market?
of manufacturers’ deliveries of new aircraft. that except for a few breaks around holi- Motschenbacher: Lufthansa Technik has
But if the delivery of a new type is delayed, days, capacity utilization is very constant. positioned itself strongly in the competitive
that can also lead to heightened demands Asia also suffers from lower demand in landscape, and with our network, we are
for work on older types, because then they the summer, though not as strongly as currently the largest company of this kind
stay in service longer – as we currently Europe. Beyond strong seasonal effects, in Europe. Last year we charted steady
witness on 767s and 757s. We also see an a second trend is an increasing reduction growth under our own steam – that is,
increase in seasonal effects within the year: in work density. The new aircraft types through our own investments and con-
the demand for base maintenance events mean less work for us, and the older struction projects.
is concentrated in the winter months, from types require more time in the workshop
� Please continue on page 12
12 | Aircraft Base Maintenance Lufthansa Technik Connection 2.2016
Rueckert: Today we are in a position to we need less material. I don’t believe that
operate more than forty overhaul lines dur- any other provider can currently realize
ing the winter – on all three main continents effects like these across its locations within
and at strategically and economically sig- days.
nificant locations. At the moment, we know Rueckert: And customers see the same
of no other base maintenance provider logo everywhere, since all the operations
who can offer such high and consistent are part of the same brand. They see the
product the way we can. same processes, the same structures, the
same performance and the same interfaces
What is behind the network idea? at all our sites – that is, the same look and
Motschenbacher: The network is strongly feel. At the same time, we keep a certain
dependent on an interdisciplinary and local color – not where it leads to autonomy,
geographic exchange – we help and but where it’s justified on the basis of tomers in the regions. Many of them work
support each other. There are also great special features. And we’ve standardized close to the production sites, and that
advantages when we set up a new site not just the product, but the manufacturing enables them to experience our day-to-
and can transfer our know-how and process, too. day business directly. But they’re not
expertise from other locations. responsible for just that location; instead,
Rueckert: We bring together the advantag- Does that have an influence on pricing? they see themselves as network sales
es of both worlds. Our worldwide locations Motschenbacher: Price is a challenge. employees.
mean that we are close to our customers, The competition is great and the problem
but at the same time we can draw on of unused capacity sometimes leads to How did the development of the new
synergies from the entire network. inappropriate pricing in competitive situa- site in Puerto Rico go last year?
tions. We are dealing with the topic and Motschenbacher: The set-up of Puerto
What particular advantages does the have been successful, especially through Rico in just eighteen months from first idea
customer have from the network? the synergy effects we can offer. We have to first check is a success story. We built
Motschenbacher: We learn from every several well-known low-cost carriers the new operation using a template with
one of the more than 600 events we carry among our customers as well as leasing the overall standardization as a foundation,
out each year, and we transfer these expe- companies that demand a high level of and we were able to move it to a high level
riences to the other locations. We also flexibility. This and our growth show that of quality very quickly. Performance and
commit to standards, because this is the our price structure is compatible with the customer satisfaction are both very good.
only way to learn quickly and stabilize our market and is attractive to many custom- We have delivered on time, starting with
processes – or question their usefulness. If ers in combination with our quality and the very first aircraft.
we find a solution to a technical challenge performance. Rueckert: The majority of our new
for a customer at one location, we apply it Rueckert: Our restructuring project employees were trained at our facilities in
to other events at other locations, too. That SixToONE has revealed completely new Europe. When they came to Puerto Rico,
makes us more efficient and faster, and potential. Through standardization – such they were already used to our processes,
as only preparing job cards in one location so the learning curve has been very steep.
– we have reached a much better overall Compared with the way we set up new
cost position than we used to have, and operations in the past, this is a completely
that has enabled us to be so successful in different league: much faster, much more
this market segment. We are also pre- stable and much smoother. At the moment
pared to offer customers our free capacity we have two lines in operation there, two
this summer with a high level of flexibility more will be added this year, and we have
and at attractive prices. a fifth line in preparation for next year.
Both of our customers, JetBlue and Spirit
Did the sales structure change as well? Airlines, have already requested greater
Motschenbacher: During the redesign it capacity, and in general market resonance
was important to us to retain, maintain and has been positive. In fact, we are already
continue to develop our good customer asking ourselves whether we want to
contacts. Our network sales in Europe, expand our footprint in the Americas even
Asia Pacific and the Americas are currently further.
positioned very close to customers, and
headquarters in Hamburg plays only a
coordinating role. Our employees are
deployed so that they are near their cus-
Lufthansa Technik Connection 2.2016 Aircraft Base Maintenance | 13
Why do customers come to Rueckert: Over the last two and a half
Lufthansa Technik in Puerto Rico? years, Lufthansa Technik managed to
Motschenbacher: Evidently the system complete the biggest modification project
we transferred from Europe enables us to it has ever handled in record time – with
work much more efficiently than other the entire value creation chain, from con-
providers. The exciting question for us was sulting to engineering, material and logis-
whether we could build up an operation in tics, and including installation, of course.
this region with our know-how and achieve All four of these elements from a single
this kind of efficiency, and meanwhile we source, with a single point of responsibility
know: Yes, we can. We haven’t reached – that’s not something you find often on
our goal completely, but our progress the market. But we have a high degree of
has been much faster than we thought it expertise in working with our customers to
would be. develop the right solution for them. And
Rueckert: We actually appear to have our strength in carrying out conversions in
developed an efficiency lead in Europe our network also plays a role.
that we can transfer to other locations. And
Faster than swift
that gives us the confidence to consider, To sum up one more time: What sets
Ka-band // Entertainment and
even now, how we can continue to grow. Lufthansa Technik apart from other
connectivity from a single source:
heavy maintenance providers?
With Lufthansa Technik as installa-
What’s the current significance of Motschenbacher: I think we’re way out in
tion partner, Lufthansa will be the
the integrated Total Base Maintenance front with the topics of service transparency,
first network airline in Europe to
Support (TBS®) product? performance measurement and continu-
offer Ka-band-based broadband
Motschenbacher: The core function of ous improvement. We measure and com-
internet on board its short- and
Total Base Maintenance Support – that is, pare our efficiency across check types and
medium-haul flights from early
permanent, reliable access to capacity in locations. We used to learn in a very cus-
summer 2016.
our network – has made the industry begin tomer-specific way, and now we learn from
The new service is based on the
to rethink things. Now there is a stronger every event and for every customer. We
most modern broadband satellite
focus on the long term. We have an have also developed extremely rigorous
technology from Inmarsat’s Global
increasing number of customers who buy project management and standardized it
Xpress network. Lufthansa Technik
entire seasons or even several seasons at a very high level.
will be integrating all systems
across three, four or five years. They make
and components required while
a conscious decision in favor of a single Are there plans for the near future?
Lufthansa Systems will provide
provider, and they want a network provider. Rueckert: We have further ideas that we
the technical infrastructure needed
And that brings us to the second core plan to realize in the follow-up program we
to establish a well-functioning
element of Total Base Maintenance Sup- just started. For example, we want to gen-
internet connection on board. //
port – the network. If something unfore- erate even more standardized workflows,
seen happens, our many lines ensure that so that we can move from batch produc-
we have the opportunity to react flexibly. tion, which is where we are now, to genu-
Beyond that, we have pushed forward ine serial production. Together with our
even more with the connection and inte- customers we are moreover considering
gration of our customers, for example with new models for working as partners and
the AMOS MRO IT platform. With a few growing together. This could include,
very close customers, we have even gone for example, the option of exchanging
as far as physically integrating the custom- personnel with a customer – during the FWD
er’s planning department with our own. summer we would provide support for line
maintenance, and during the winter the Upgrading to Ka-band connectivity, e.g.
What role do aircraft modifications customer’s personnel would provide sup- using a skin-mounted canoe antenna,
provides passengers access to the only
play in the division? port for us for heavy maintenance. And satcom network that guarantees a minimum
Motschenbacher: Modifications play a finally, we want to pay more attention to speed for on-board online applications.
big role, not least because of the large the leasing market and become number
conversion projects we have completed one in lease management in Europe.
for Lufthansa in recent years. Most of our
capacities were tied up by these projects,
and we weren’t very well known in the
market as a result, but that is changing now.
14 | New Aircraft Lufthansa Technik Connection 2.2016
F
ollowing the delivery ceremony, this day. The airlines within the Lufthansa A320 family amount to one-third of the
Lufthansa’s first A320neo took off as a Group have ordered a total of 582 Airbus fleets in operation around the world today
special flight from the Airbus facilities aircraft in the past 40 years. Lufthansa is – and they have become important
in Hamburg-Finkenwerder with flight the largest Airbus customer with currently members of the big Lufthansa Technik
number LH9917 with guests and media 392 aircraft from the European manufac- family, too. Currently, Lufthansa Technik
representatives on board. Another cause turer, including 284 aircraft from the A320 has about one third of the world’s A320
for celebration was the 40-year partner- family and 14 A380s. Aircraft from the fleet under exclusive component support
ship between the airline and the aircraft contracts.
manufacturer. Whether it’s the longer A321 or the
shorter A319 and A318, whether a VIP jet,
40 years of partnership government aircraft or a special mission
aircraft – as a genuine one-stop shop,
Beginning with the first Airbus airliner Lufthansa Technik has developed its port-
more than four decades ago, the Lufthansa folio for the A320 family accordingly. From
Group, especially Lufthansa Technik, has engines to components, logistics, line and
played an important role in the European base maintenance, cabin completions,
aircraft manufacturer’s success story to modifications, engineering and leasing
Lufthansa Technik Connection 2.2016 New Aircraft | 15
“Better Living”
for the aircraft cabin
As a design verification engineer, Ole Duenhaupt looks after
cabin conversions for aircraft in the Cabin Modification & Aircraft
Services unit of Lufthansa Technik in Hamburg.
W
hen it comes to cabin modifica- construction at the University of Applied
tions for commercial aircraft, Sciences of Hamburg (HAW). A university
everything must be just right. internship first brought him to Lufthansa
“The tickets are already sold so the aircraft Technik, initially in the area of new technol-
has to return to scheduled service punctu- ogies and innovations. “I really wanted to
ally,” explains Ole Duenhaupt as he describes work for a service provider because there
the responsible and at times also challeng- is a greater range of tasks and many excit-
ing side of his job. Preparation time for ing areas,” he says as he explains his choice.
the total cabin conversion of an airliner in He completed another internship and his
passenger service is just as long as for a final dissertation in Lufthansa Technik’s VIP
VIP aircraft, though the retrofit itself takes aircraft division. This is where he also start-
at most six weeks. ed his career on completion of his studies.
This means that everything has to be
planned very carefully beforehand. “The
research work is frequently very demand-
ing,” says Duenhaupt. “We have to make
sure before the layover commences that
everything fits just perfectly.” That’s why,
together with his colleagues, he inspects
the cabins when the aircraft are on the
ground for other maintenance work. And if
something does not fit perfectly during the
conversion or should unforeseen problems
arise despite the careful preparations, With training courses, additional training
“we are famous for our ad-hoc solutions”. and successful projects behind him, he
became a design engineer – and his
Growing enthusiasm dream job was already in close sight.
is responsible for the entire project. He really comfortable with my tasks and in the
works closely together with the suppliers of team.” Ole Duenhaupt has been a design
the cabin elements in this context or looks verification engineer since fall last year and
humorously adds: “We essentially create after in-house developments. All fittings can therefore also support other design
‘Better Living’ for aircraft.” Apart from cab- have to be approved by the aviation author- engineers in the area of verification man-
in modifications, he and his colleagues are ity. “70 percent of my working time is spent agement. “I can honestly say today that
also responsible for antenna fittings, instal- creating and managing documents,” he says. my passion for aviation has never ceased,”
lation of exterior cameras or the integration he affirms. “I have found my dream job.”
of the electronic flight bag in the cockpit. Dream job found Yet, he still has further plans for the future
His tasks include large as well as small and is interested in a specialist career path
projects. In terms of the large retrofit pro- Ole Duenhaupt describes his work as “very with Lufthansa Technik. “My goal is to also
grams, such as the cabin modification of varied and exciting”. Because of the high take on project management duties down
the Lufthansa long-haul fleet, for example, throughput and the different projects, he is the line as a senior engineer.” This will
which was completed last year, he is constantly learning and bears considerable require some more training courses and
responsible for part of the conversion. And responsibility for “his” cabin elements. And advanced training – and naturally also more
when it comes to small modifications, he the working atmosphere is also great: “I feel successfully converted aircraft cabins.
L
ufthansa Technik already offers its worldwide,” says Oliver C. Winter, Head of Pratt & Whitney, CFMI and IAE. To date,
Cyclean® Engine Wash in North and Engine Life Cycle Services at Lufthansa more than 40,000 engine washes have been
South America, Europe and the Technik. performed using Cyclean® Engine Wash
Middle East. Now the world standard in “Cyclean® Engine Wash not only short- worldwide. Cyclean® is the only established
engine wash services is also available in ens an engine wash turnaround time by 70 engine cleaning system on the market
Hong Kong. All common engine models percent but also allows it to be carried out which can be carried out directly at the
can be washed at the new location. An anywhere at the airport without a wash-bay gate in less than one hour. The very low
engine wash service can be carried out restriction. HAECO Line Services currently time required, the large fuel and emissions
as part of maintenance work, in the transit serves over 60 airlines and 300 transit flights savings, and the significant reduction in
period between two flights, or overnight. at Hong Kong International Airport. We engine maintenance costs make Cyclean®
The autonomous system, which does not believe that there is a great opportunity for an indispensable service.
require any external electricity or water Cyclean® to be a valuable engine wash
source, gives airline customers even solution for our customer base here. It Oliver C. Winter
more flexibility in the planning of engine shows HAECO Group’s long term commit- Phone +49-69-696-96184
washes. ment to invest in environmental-friendly [email protected]
“With this cooperation with HAECO in technologies and high-efficiency equip-
Hong Kong we are further expanding our ment,” says Raymond Leung, Vice Presi-
Cyclean® Engine Wash presence in the dent Commercial, Line Services, HAECO
Asia Pacific region. The high demand for Hong Kong.
efficient engine cleaning means that the Cyclean® Engine Wash is available for
number of stations will keep growing. all modern engine models from the major www.lufthansa-technik.
com/cyclean
We currently serve more than 40 airlines manufacturers General Electric, Rolls-Royce,
Lufthansa Technik Connection 2.2016 Engine Services | 19
In Shenzhen in China an Airline Support Team (AST® Engines) has once again demonstrated
its expertise in providing customers with ultra-efficient support. It successfully accomplished
what was previously thought to be impossible – replacement of the compressor stator eS
upport Team
lin
inlet guide vane ring assembly on the CFM56-7B without an engine shop visit. Hotline
s
Air
+49 -40 -
111
5070 -61
”
Ex
es
ten gin
s ion 2: “En
A
vulnerability was identified in the Choi – proved to be the turning point. Joshua engine shop visit also means no disruption
factory configuration in a series of Sun-Jae Choi is working on developing to operation, no transport costs, no engine
motors of the type CFM56-7B. The the AST® network in China and after leasing and avoidance of all other expenses
ring that controls the adjustable inlet guide analyzing and examining the problem was necessarily associated with this.
vanes is not sufficiently able to cope with able to confirm: Lufthansa Technik can do This example underscores the fact that
the stresses that occur during operation. A this! A proposal was made for retrofitting with its Airline Support Team, Lufthansa
breakdown can have a catastrophic effect five engines and the first trial event was Technik offers its customers a product
– for example the turbofan caught fire in carried out in November last year. Just one portfolio with really unique solutions. Safety
flight in one documented case. The manu- working day was needed in the hangar of and optimum efficiency are primary focal
facturer therefore prescribed replacing this Shenzhen Airlines by two Lufthansa Technik points. These services are of course also
ring in a Service Bulletin (SB 72-0811) in employees based in Shenzhen together available to other airlines in the Asian
order to eliminate the error. with one Chinese specialist in order to region. The catalog of on-wing and on-site
replace the component. services offered by AST® Engines includes
Lufthansa Technik can do this! every possible task to assure minimum
Substantial savings aircraft downtime and avoid costly engine
Such a replacement is generally carried out replacements.
during a planned engine shop visit. But Joshua Sun-Jae Choi comments: “The
since this issue was overlooked during a event really went very well – actually better Joshua Sun-Jae Choi
number of engine shop visits at Shenzhen than expected. The only problem was Phone +86-755-2777-3502
Airlines, it became necessary to find an dealing with the customs formalities for [email protected]
efficient solution. That is because an engine the tools that had to be brought in for
shop visit to implement the Service Bulletin working on site.” The engine passed the
would not only take the affected engine out on-wing test run carried out following
of service for 14 days – transport costs and completion of the work with flying colors.
engine leasing would drive up the overall No wonder therefore that there was also
cost even further. Following rejection by great euphoria about the success on the
the manufacturer and other service provid- part of the customer, considering the
ers, contact with the stationed Lufthansa enormous savings Lufthansa Technik can www.lufthansa-technik.
com/ast-engines
Technik Sales Manager – Joshua Sun-Jae offer with the on-site modification. No
20 | Innovation & Technology Lufthansa Technik Connection 2.2016
vation b
no
In
y
A revolution in surface coating
Lu
k
th
ni
h
f
ans
a Te c
Thermal spraying is a core element of many repair processes. Using nano powders, Lufthansa
Technik’s engineers have now developed the technology one major step further: Near-net-shape
coating improves quality and precision by more than an order of magnitude.
T
hermal coatings using either metal Supported by the Federal Ministry for The development of a sophisticated self-
or ceramic materials offer protection Economic Affairs and Energy (BMWi), the learning in-process measurement and con-
from corrosion and wear and tear, goal of the project was to develop a pro- trol technology constitutes another important
providing a smooth, hard surface and – in cess that allows thin coatings to be applied factor. Using high-resolution optics, the coat-
the case of ceramics – thermal insulation with unmatched precision and excellent ing thickness can be applied with a precision
of the base material. Used in component surface quality in an environmentally of 2.5 micrometers. At the same time, the
repair, thermal coating processes are friendly process. To identify the main surface roughness achieved is 1.4 micro
significantly more economical than the use influencing factors, parameter studies meters. Even the effects of thermal expansion
of new parts. When it comes to the appli- were initially carried out using numerous of the component during the coating process
cation of coatings with very precise dimen- variables. One of the are taken into account
sions however, the standard processes key elements for suc- and eliminated.
such as HVOF (High Velocity Oxygen Fuel) cess was the use of Project Manager Dr.
or plasma spraying have limitations. That so-called nano pow- Holger Kassner on
is why Lufthansa Technik, together with ders with particle di- the results achieved:
innovation partners Thermico GmbH, the mensions in the “The new process
Juelich Research Center (Forschungszen- micrometer range. In offers a performance
trum Juelich), RWTH Aachen and the addition, spray pow- that is between 10 to
Technical University of Braunschweig, has der containing tung- 100 times better than
launched an R&D project called “HEBe”, sten carbide was par- hard-chroming or
a German acronym for high-efficiency tially replaced with comparable conven-
near-net-shape coating process. other carbides. Test piece produced using nano powder. tional processes.”
Lufthansa Technik Connection 2.2016 Engine Services | 21
Dedicated app
for EPAR catalog
By providing the new catalog in the form of an
application program (app), Lufthansa Technik’s
Engine Parts & Accessories Repair (EPAR) has
endeavored into a new era in user-friendliness.
With this performance, near-net-shape
coating opens up new possibilities for
repair processes. The precision achieved
allows elimination of complete process
steps such as grinding – polishing a slid-
ing surface such as a landing gear leg is
enough to achieve the desired surface.
Another advantage: due to the much
improved scratch resistance and durability
of the new coating, a re-coating may not
be necessary during the entire life cycle of
the component after repair. By substituting
hard-chroming, near-net-shape coating
even improves the environmental compati-
L
bility of repair processes. Hard-chroming Download the ufthansa Technik’s Engine Parts and Accessories Repair
has come under criticism due to the use of EPAR app! has announced yet another industry first: the EPAR cata-
chromium VI. This highly toxic and carci- log can now be searched via mobile devices such as
nogenic substance is prohibited in many smart phones and tablets. Access to a PC or laptop is no lon-
business areas. ger required. This new application offers reliable information on
Thus the project goal – a highly efficient prices, turnaround times and additional information about
near-net-shape coating process – has been Google Play Store
repairs for the complex EPAR product, which involves more
achieved. Eliminating the need for grinding, than 23,000 part numbers.
near-net-shape spraying can be applied to The app’s functions are limited to the necessary basics to
components from engines, landing gears enhance its usability. Customers may enter a part number, and
and others to extend their life cycle. The the app provides price and turnaround time. If the part number
next step for Lufthansa Technik therefore is is unknown, an extended search function by e.g. ATA Chapter
to industrialize the process. Currently this App Store is available. For certain parts – especially those for which
phase is in pre-paration. But as Lufthansa Lufthansa Technik offers special repairs – further information
Technik’s engineers have already demon- such as Product Information Documents (PIDs) is provided.
strated that conventional thermal coating The new app not only offers customers faster and easier
facilities can be easily upgraded – even the access to the EPAR catalog, monthly revisions will also ensure
spray guns can be used – the next step in that its information is always up-to-date. The new app is intended
surface treatment is definitely close. to replace the classic EPAR DVD catalog before long, which
Lufthansa Technik published annually in the past. In response
Marco Teichmann to customer wishes, the app is available for iOS and Android
Phone +49-40-5070-61480 systems. To download it, please search for “EPAR Catalog” in
[email protected] your Apple iTunes or Google Play Store. Customers who prefer
www.lufthansa-
the conventional DVD catalog may still order it via the e-mail
technik.com/epar
address given below.
Dominik Giugno
www.lufthansa- Phone +49-40-5070-66408
technik.com/hebe [email protected]
22 | Component Services Lufthansa Technik Connection 2.2016
Plasma spraying
// A plasma plume with a very high temperature is created by the
gas (hydrogen) entering the burner chamber and a powerful DC
arc (between the electrode and the anode-nozzle) that strips the
gas molecules of their electrons. As the plasma ions recombine
back to the gaseous state, a tremendous level of energy is
released. The powder materials are injected into this hot gas. The
particles melted in the plasma are sprayed at high speed onto the
component surfaces to be coated and claw mechanically (with
local d
iffusion) on the surface when shrinking during cooling down.
The combination of high temperature and extremely high particle
speeds results in a highly resilient coating. This makes the process
ideal for demanding applications in the repair of engine parts. //
www.lhaero.com
A
new plasma coating system con- involve restoring housing geometries, apply- for the different coatings. Special burners
siderably increases the capacity of ing wear protective layers as well as run-in allow the coating not only of surfaces but
Lufthansa Technik AERO Alzey, the coatings.” Previously many of these com- also the inner and outer diameter of rotation-
specialist in the Lufthansa Technik Group ponents had to be sent to the manufacturer ally symmetric and non-rotationally symmet-
for regional aircraft engines, above all the for repair, which often resulted in consider- ric components that are difficult to access,
CF34 and PW100/150 types. Plasma able time losses. One of Lufthansa Technik such as shafts, housing and sleeves.
spraying is an important element of many AERO Alzey’s corporate goals, however, is Mark Johnson, Managing Director at
repair processes for engine parts since it to focus on special repairs and to also cre- Lufthansa Technik AERO Alzey, sums up:
allows metallic and ceramic coatings to be ate efficient repair options in cases where “The new system allows us not only to fur-
applied with high adhesive strength and there are only small numbers of repaired ther expand our existing service portfolio –
minimum warpage of the base material. In parts. Installation of a plasma coating sys- we can now perform repairs ourselves and
addition to the Atmospheric Plasma Spray tem therefore constitutes a logical step in therefore retain control of the components.
(APS), the flame spray and arc wire spray the ongoing development of repair capa- In the medium term this will lead to a
process were also implemented. bilities. The wait time is eliminated and the reduction in turnaround times, increased
Project Manager Thomas Breit explains engine turnaround time remains calculable. delivery reliability and cost reductions.”
the original situation: “We have a large Prior to actual coating the surfaces are
number of different components to process prepared for the process in a corundum Thomas Breit
owing to the many different engine types. blasting machine. Fully-automatic, robot- Phone +49-6731-497-372
The majority of our applications primarily controlled spraying processes are then used [email protected]
Lufthansa Technik Connection 2.2016 Personalities | 23
W
ith a degree in business said Lufthansa Technik CEO Dr. he succeeds Andreas Kaden as
administration, Constanze Johannes Bussmann. Hufenbecher’s Chief Executive Officer (CEO).
Hufenbecher has held a predecessor as Chief Executive Siddique has been a member of
variety of management positions to Finance, Dr. Jansen, retired after the Executive Board of Lufthansa
date. “Constanze Hufenbecher has fifteen years at the head of Finance at Technical Training since 2013. Before joining
been successful in a variety of indus- Lufthansa Technik, but will continue to Lufthansa Technical Training in 2013, Siddique
tries and companies outside aviation support the company with advice and was CEO of Lufthansa Flight Training Berlin and
and has the right qualifications for assistance. “Dr. Peter Jansen kept of Lufthansa Flight Training CST. He began his
developing and implementing new Lufthansa Technik on a solid financial career in aviation in 1994 when he joined the
ideas at Lufthansa Technik. We look footing for fifteen years, even when Production Planning department of Deutsche
forward to working with her,” said times were difficult. His competence Aerospace Airbus (DASA) in Hamburg. Born in
Carsten Spohr, Chairman of the Super- and commitment are valued across Frankfurt am Main, Siddique studied electronics
visory Board of Lufthansa Technik and the Group, and he has my heartfelt engineering and financial controlling at the Tech-
CEO of Deutsche Lufthansa AG. Con- thanks for his outstanding achieve- nical University of Darmstadt and the University of
stanze Hufenbecher succeeds Dr. Peter ments,” said Spohr. St. Gallen, graduating as an industrial engineer.
Jansen, who stepped down as a mem- Dr. Peter Jansen has held a number
ber of the Executive Board of Lufthansa of management positions in the Luft- Harald S chween has tak-
Technik on December 31, 2015. hansa Group since 1984. In 1994 he en over the responsibility as Head
“We welcome Constanze became head of Group Audit, of Sales & Key Account Manage-
Hufenbecher to the and in 1999 he took over the ment at Lufthansa Technical Train-
Executive Board. We leadership of both Corpo- ing. Prior to the promotion to this
have big plans for rate Controlling and position, Harald Schween worked
Lufthansa Technik, Cost Management. He on the development of Lufthansa
and I’m convinced has been a member Technik’s corporate sales organization. He was
that she can make of the Executive Board responsible for business development and key
a significant con- of Lufthansa Technik account sales in various management functions
tribution to the since January 2001 at Lufthansa Technik, Lufthansa Flight Training
development of with responsibility for and Lufthansa Cargo, among others.
the company,” Finance.
C hristian W icker has
been appointed as the new Direc-
tor Sales & Marketing of Lufthansa
Technik Landing Gear Services UK
(LTLGS). Christian Wicker started
Courtesy of BE Printers und Prinovis Ltd. & Co. KG
T
hanks to the approval granted for For example, if an aircraft’s airframe is the damage has occurred. Cabin modifi-
the Airbus A350, Lufthansa Technik damaged following a collision with a ground cations, for example, are another option
is also extending the area of autho- vehicle and the damage caused is outside offered by the Design Organizations’
rization of its Design Organization to the the tolerance range permitted in the manu- approval under Part 21/J. Lufthansa Technik
new type. This privilege accelerates the al, the operator can commission Lufthansa is already performing extensive interior
approval process significantly and can be Technik. The trained experts then immedi- modifications in the context of a “minor or
decisive in operational terms with respect ately assess the damage and, if the dam- major change”.
to departures or cancellations. age pattern permits, create a “Change/ While the design approvals of the EASA
The extended scope of approval – a Repair Approval Sheet” (CRAS) so that the Design Organization are essentially limited
routine process for Lufthansa Technik – aircraft can continue in service – usually to the scope of the EASA, they can also be
includes the complete aircraft currently still temporarily – without involving the authori- used outside of the EASA provided the
with the exception of the engines. Carsten ties or the OEM. respective national authority recognizes
Wortmann, Product Manager for the A350, The customer can in this way avoid an EASA approval. However, since this is the
explains the significance of the Part 21/J Aircraft on Ground situation (AOG) at a case in many countries, the actual impact
approval: “Aircraft maintenance is typically non-maintenance base, for example, and of the approval extends significantly
carried out in accordance with the manu- plan in advance for the repair at its home beyond the scope of the EASA.
als. However, if an MRO provider has an base. This is often very advantageous for
approval under Part 21/J, then it can inde- repairing the damage because trained staff,
pendently approve so-called minor repairs tools, infrastructure and other constraints Dr. Dagmar Elten
among others without the involvement of at the home base are much more suitable Phone +49-40-5070-64432
the respective authority.” for the repair than at the location where [email protected]
Lufthansa Technik Connection 2.2016 New Aircraft | 25
Lufthansa Technik is taking one step further in expanding its ARC® network worldwide
service portfolio for the Airbus A350 with the commissioning
The service portfolio of Lufthansa Technik’s
of a new pneumatic test bench. Airframe Related Components (ARC®)
comprise testing, repair, maintenance,
overhaul and modifications for the full range
of aircraft composites, bonded materials
T
he Component Services division of The new test bench is designed for and other structural components in use
Lufthansa Technik has commis- testing butterfly valves in ATA Chapters today. The services include comprehensive
sioned a new test bench for cold 21, 30, 36, 49 and 80. It is equipped with spare parts supply, asset management,
air valves. The test bench is designed to fast flow control valves for regulating the pooling concepts, contract management
meet the special requirements of the Air- inlet and outlet pressure. as well as engineering support. //
bus A350 components and supplements Among other things, flow rates of up
two existing systems. Two main reasons to 225kg/min (500lb/min) can be mea-
were instrumental in the new acquisition. sured. By developing special adapters
On one hand, the existing two test bench- and additional tools, Lufthansa Technik
www.lufthansa-
es have already reached their capacity can therefore test eight different compo-
technik.com/arc
limit, while on the other hand the new nents of the A350 alone. However, this
aircraft type also poses completely new only scratches the surface of the per-
requirements. As the project engineer formance scope of the testing device.
responsible for the pneumatic A350 com- Overall the test bench can test up to
ponents, Jan Poensgen comments: “Test- 100 different pneumatic components
ing the Airbus A350 components requires from various manufacturers.
much higher air flows at low pressures.
The new test bench is therefore fitted with
larger air lines – 150 mm (6 inches) in Jan Poensgen
diameter as opposed to 100mm (4 inches) Phone +49-40-5070-4990
in order to achieve such high flow rates.” [email protected]
26 | Lufthansa Technik Group Lufthansa Technik Connection 2.2016
www.lufthansa-technik.
com/lht-middle-east
L
ufthansa Technik has established East,” said Richard Haas, Director Sales Aviation District has emerged the ideal
Dubai as the location of the currently Africa & Middle East, Lufthansa Technik. venue for us to host our new facility. It will
32nd member of its global network of “Both steps are essential requisites that will put us in prime position as a leader in the
companies and affiliates. Encompassing enable us to establish a sustainable pres- aerospace supply chain sphere, and help
both workshop and office areas, various ence in the region, as well as to competitively us enhance value for our growing list of
technical services will be hosted, such as participate in one of the most important customers through offering optimized tech-
“
the repair of Airframe Related Compo- MRO markets worldwide.” nical services, including our Airframe Relat-
nents (ARC®) including flaps, radomes, Tahnoon Saif, Vice ed Component (ARC®)
reversers, inlet cowls and AOG (Aircraft President of Aviation Dis- portfolio which features
On Ground) support via a local material trict, Dubai South, said: The Aviation District aircraft maintenance,
support desk. “The Aviation District wel- has emerged the repair and overhaul
“In line with our regionalization strategy comes a leading global ideal venue for us. (MRO) services – literally
we have decided to further develop the player like Lufthansa Ziad Al Hazmi from nose to tail.”
product portfolio and the appearance of Technik. Their facilities Lufthansa Technik Middle
our current activities here in the Middle here will give the company an operational East will also offer material and spares and
edge in terms of becoming one of the first engine wash services for commercial and
international suppliers in the District. Their VIP customers locally. Further evaluation of
presence also builds on the aviation plat- additional capabilities is ongoing depending
form which we are establishing – one that on other customer r equirements. The
will match the best in the world, in line with the current company site at Dubai International
vision of His Highness Sheikh Mohammed.” Airport will be kept operational.
Ziad Al Hazmi, CEO of Lufthansa Technik
Middle East, said: “Over the past few Ziad Al Hazmi
months we have engaged very construc- Phone +971-4-4057-557
tively with our partners at Dubai South. The [email protected]
Lufthansa Technik Connection 2.2016 Events & Exhibitions | 27
I
nduction cooktops are enjoying growing turbulence. Various additional applications Expo is the launch pad for cabin pro-
popularity. Cooking with induction is fast, allow the use, for example, of a special grammes showcasing tomorrow’s
clean, safe and economical. Now it is rice cooker with different cooking settings designs, in-flight entertainment, connec-
possible on board aircraft, so that lovers of as well as a toaster. Even a wok is con- tivity and passenger services.
sophisticated cuisine can enjoy its many ceivable, so there are no limits to fresh
advantages inflight. Together with the Ulm- on-board gourmet cuisine in the future. 5 – 7 April 2016 | Dallas
based company hs2 engineering, Lufthansa Induction cooktop platforms offer many
Technik has developed a prototype of an advantages. They have excellent energy
MRO Americas
Inductive Cooking Platform. Talks are cur- efficiency and are characterized by their The MRO Americas conference and
rently underway with potential customers, extremely fast and effective heating. Up exhibition follows the tradition of bringing
flight attendants and chefs in order to to 30 percent energy savings can be together the decision-makers from air-
define the market requirements and to achieved with parboiling alone. An electro- lines and suppliers to discuss the critical
adapt the solution precisely to those needs. magnet below the glass surface creates a issues impacting the MRO industry and
The Inductive strong thermal providing insight into upcoming trends,
“
Cooking Platform field that heats regulations and best practices.
will be presented We want to savor the benefits of pre- the base of the
on the Lufthansa paring fresh food with inductive cook- pot directly but 12 – 14 April 2016 | Shanghai
Technik booth at ing above the clouds – just as you not the cooktop
the Aircraft Interi- would expect in high-end restaurants. itself. This allows
ABACE
ors Expo, which Franziska Voerner the heat to be ABACE (Asian Business Aviation Con-
runs from April 5 distributed more vention & Exhibition) is a premier event for
to 7, 2016, in Hamburg, Germany. The efficiently and faster than with a conven- the Asian business aviation community.
cooking platform has already made it onto tional hob with electric hotplates. Because The exhibition brings together a broad
the shortlist for the international “Crystal the cooking surface remains comparatively group of interested parties involved in
Cabin Award”, as a concept for the future. cool and the glass surface is only heated nearly every aspect of business aviation.
Measuring 285 x 540 x 217 millimeters and indirectly through contact with the base of
weighing not more than 13.5 kilograms, it the pot, splashes of food can no longer 9 – 12 May 2016 | Charlotte
fits into most aircraft galleys. It is an all-in- burn into the cooktop. This makes clean-
one solution including a power/heating unit ing much easier.
RAA Convention
ril 2016
and an integrated fume and odour hood. A Ap Incorporating a trade show, the Regional
7
5-
smart pot containment system covers and aft Airline Association’s (RAA) major conven-
Aircr Expo
holds the frying pan or other cooking appli- Franziska Voerner iors tion is the meeting place for US regional
ances securely in place during all phases Phone +49-40-5070-60251 Inter oth 6B80 airlines, manufacturers of products and
B o
of preparation and cooking – even during [email protected] r services and the key decision makers of
g
Ha m bu
this sector of commercial aviation.
-4
A330
A340
308
eServices A340-300
A350 Airbus A350
Lufthansa Technik’s Technical Operations Line Maintenance,
Websuite manage/m® allows operators Component Services,
to manage their technical operations via a Engine Services:
Trent XWB
web-based system.
Airbus A380
A380
Please follow this link for the com- Line Maintenance
plete MRO service portfolio and more Base Maintenance
details about Lufthansa Technik’s
Component Services
solutions for fleets of any size.
www.lufthansa-technik.com/services Engine Services: Trent 900
Completion
Lufthansa Technik Connection 2.2016 Products & Services | 29
Boeing Regionals
737 Boeing 737 Q-Series Bombardier Q400
Line Maintenance Line Maintenance
Base Maintenance Base Maintenance
Component Services Component Services
Engine Services: Engine Services:
CFM56-3 PW100, PW150
Completion
Q-Series
737
737 NG Boeing 737NG CRJ Bombardier CRJ
Line Maintenance Line Maintenance
Base Maintenance Base Maintenance
Component Services Component Services
Engine Services: Engine Services: GE CF34
CFM56-7B
Completion CRJ 700
737NG/MAX
747 Boeing 747 E-Jets Embraer
Line Maintenance E-Jets 170/175, 190/195,
Base Maintenance Line Maintenance
Component Services Base Maintenance
Engine Services: JT9D, Component Services
PW4000, CF6-80C2 ERJ 190 Engine Services: GE CF34
Completion
747-8
757 Boeing
757
Line Maintenance
Base Maintenance
Component Services
Engine Services:
RB211-535
Completion
757
767 Boeing 767
Line Maintenance
Base Maintenance
Component Services
Engine Services:
PW4000-94, CF6-80C2
Business Jets
Completion
767
777 Boeing 777 Airbus Corporate Jets ACJ
Line Maintenance Line Maintenance
Base Maintenance Base Maintenance
Component Services Component Services
Completion Engine Services:
Boeing 777-9X
vorläufige Zeichnung
CFM56, V2500-A5
Completion
777
777X Boeing 777X Boeing Business Jet BBJ
in preparation Airbus Corporate Jetliner Line Maintenance
Base Maintenance
Component Services
Engine Services:
CFM56-7B
Completion
Vice President
Corporate Sales
Eastern Europe
and CIS
Dmitri Zaitsev
Vice President Vice President p +49-40-5070-5404
Corporate Sales Corporate Sales [email protected]
USA and Canada Europe
Sahib Ajjam Georgios Ouzounidis
p +1-305-677-5199 p +49-40-5070-5295
[email protected] [email protected]
Vice President
Vice President
Corporate Sales
Corporate Sales
Middle East and Africa
Latin America
Richard Haas
and Caribbean
p +49-40-5070-3053
Jörg Femerling
[email protected]
www.lufthansa- p +1-305-379-2604
technik.com/sales [email protected]
Lessors North
America Italy Turkey
Lydia Martin Emanuela Marabese Fulya Türköz
p +1-818-232-5956 p +39-02-58571483 p +90-212-465 55 57
lydia.martin@ emanuela.marabese@ fulya.tuerkoez@
lht.dlh.de lht.dlh.de lht.dlh.de
Lufthansa Technik Connection 2.2016 Contacts | 31
N I N
N O
I O
V
A T
Lufthansa Technik is synonymous with innovation.
Thanks to creative engineering work and cutting-
edge 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.