- Lufthansa Technik AG

The Lufthansa Technik Group Magazine

5.2015 September/October

From Guideline® to GuideU

Leading the way for 20 years

Lufthansa Technik in Europe

“Best value for money”

Maintenance international

Fleet Exit Services

Thumbs up in Frankfurt

Carefree final years

2 | Content

Lufthansa Technik Connection 5.2015

“Best value for money” Georgios Ouzounidis, Director Sales Europe, about Lufthansa Technik’s strength in its home market.

6 8 “Thumbs up” for United Airlines A photo story about Lufthansa Technik Maintenance ­International’s daily support for the US carrier in Frankfurt.

From Guideline® to GuideU The latest-generation emergency floor path marking system offers unrivaled features.

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Corporate Sales • Interview with Georgios Ouzounidis:  6 “Best value for money” Aircraft Services • Maintenance in Frankfurt: 8 “Thumbs up” for United Airlines • Lufthansa ­Technik Milan: 13 easyJet increases work volume • Aircraft Base Maintenance: 16 Start of operations in Puerto Rico Innovation & Technology • Fleet Exit Services project: 10 Carefree final years Original Equipment Innovation • Non-electric floor path marking: 14 From Guideline® to GuideU • Patient Transport Compartment: 26 Intensive care unit on all long-haul routes Component Services • Airframe Related Components: 18 Extending operational limits of CFRP • Begin of construction: 19 New wheels and brakes shop • Lufthansa Technik Intercoat: 22 Epoxy repair of metal parts Employee Portrait • Sabrina Hornig: 20 “Prepared for the impossible” Engine Services • Airline Support Teams – AST®: 24 Threefold power for on-site support Categories • News 3– 4 • Personalities 5 • Events 27 • Products & Services 28 • Contacts 30

“Prepared for the impossible” Employee portrait of Sabrina Hornig who has completed the first part of her training as Fleet Manager.

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Lufthansa Technik Connection is a complimentary information service for Lufthansa Technik’s family and friends. Published every two months. This and earlier issues can be downloaded from our website www.lufthansa-technik.com/connection Publisher Lufthansa Technik AG Tilman Tesseraux · Marketing · HAM TS1/M Weg beim Jäger 193 · 22335 Hamburg, Germany Infoline +49-40-5070-5553 · Fax +49-40-5070-8860 [email protected] · www.lufthansa-technik.com Editorial Production Editorial office: Flightlines, Hamburg Design: Art Works! Werbeagentur, Hamburg Photos: Lufthansa Technik AG, Lufthansa AG Printing: Beisner Druck GmbH & Co. KG

News | 3

Lufthansa Technik Connection 5.2015

For more information: www.lufthansa-technik.com/tcs

TCS® for Air Europa’s 787 fleet The Spanish private airline Air Europa has put the integrated component support for its future 787 fleet into the experienced hands of Lufthansa Technik. The contract will start with the arrival of the first Dreamliner in March 2016.

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he long-term Total Component Support (TCS®) agreement with Air ­Europa covers airframe and engine related component overhaul, engineering services as well as pooling and Home Base Lease. The component supply will be ­realized via Lufthansa Technik’s German ­facilities in Frankfurt and Hamburg. “For Air Europa, assurance in quality and flight safety is a key topic,” said Alberto Linés, Maintenance & Engineering Director from Air Europa. “In the past we made good experience with Lufthansa Technik’s support in different technical services. This is the reason why we have decided to expand our partnership with Lufthansa Technik to component services for our new Boeing 787 fleet, the future core of our long-haul operation.” “We are extremely proud that Air Europa has put its trust in our capabilities to deliver

the optimal component services for the new Boeing 787 fleet, making the airline our first 787 customer in Europa,” said Georgios Ouzounidis, Director Sales Europe, at

Air Europa Founded in 1986, Air Europa is the airline of Globalia Corporacion Empresarial, one of the largest touristic groups in Spain with its headquarter in Palma de Mallorca. Air Europa is full member of the Sky Team alliance and operates over 170 daily flights on domestic, European, North African and Transatlantic routes with Madrid as its major hub. Its fleet comprises of 14 Airbus A330, 20 Boeing 737NG, 11 Embraer 195 ­aircraft and will add 22 new Boeing 787 from 2016. //

L­ ufthansa Technik. “This contract signature is the latest milestone in our long-lasting partnership which started in 2002. We will do our best to help ensure that Air Europa continues to meet its customers’ expectations of providing a highly reliable product.” Since 2002 Air Europa has contracted Lufthansa Technik with different maintenance, repair and overhaul services. Currently, Lufthansa Technik is providing landing gear services for the airline’s Boeing 737NG and Airbus A330 fleets and is also executing overhaul services for a certain number of CFM56-7 engines. Lufthansa Technik Aero Alzey is overhauling the CF34-10 engines of Air Europa’s Embraer 195 Fleet. Markus Salzig Phone +49-40-5070-4096 [email protected]

4 | News

Lufthansa Technik Connection 5.2015

Hamburg

Berlin

Manila

Hangar expansion on track Lufthansa Technik Philippines // Six months after the Manilabased aircraft maintenance, repair, and overhaul (MRO) provider broke ground in January to extend its main hangar, Lufthansa Technik Philippines’ hangar extension is on track. “With the rising opportunities presented by regional growth, we have been building up our capabilities. This hangar expansion project is the latest in our continued efforts to meet different aircraft requirements and stay competitive in the market,” says Dr. Burkhard Andrich, President and CEO of Lufthansa Technik Philippines (LTP). The construction expands two existing bays equipped with versatile docking systems that can accommodate current widebodies and newer models of the Airbus A350, Boeing 777-9X, and 787. This will also be Lufthansa Technik Philippines’ second line for A380 base maintenance and its entry into Boeing 777 base maintenance. The development is expected to expand the company’s yearly capacity by 200,000 manhours. //

Extension of contract with FedEx Lufthansa Technik Logistik Services // Federal Express (FedEx) recently extended its existing transport contract with Lufthansa Technik Logistik Services (LTLS). FedEx is a logistics service provider that offers worldwide courier, express and parcel services (CEP) among others. Lufthansa Technik Logistik Services’ central transport procurement division in Hamburg negotiated the Lufthansa Technik Logistik Services import and export rates as well as the freight tariffs for Lufthansa Technik Component Services (LTCS)/ Lufthansa Technik Logistik America (LTLA). The logistics division of Lufthansa Technik Component Services is responsible for integrated transport and warehouse solutions and is an integral part of the global Lufthansa Technik Logistik Services logistics network. Transport costs were reduced significantly as a result of the central freight negotiations, resulting in an enhanced competitive edge for Lufthansa Technik. Ingmar Bergman, Vice President Sales at FedEx, said: “We operate an airline ourselves and are part of this sector. We know only too well what is important for aviation companies in terms of their transport – whether especially fast transit times for urgently needed spare parts, customs clearance or documentation. We are all the more pleased therefore to continue the shared success story with Lufthansa Technik Logistik ­Services into the future.” //

Beijing

V2500 capability approved Ameco Beijing // On June 30, 2015, Ameco’s capability application of IAE V2500-A5 series engines has been approved by the Chinese CAAC as well as by the US aviation authority FAA and the European EASA. Thus, Ameco has been authorized to provide overhaul and modification on V2500-A5 series. The service on V2500-A5 engines as a new product will help promote Ameco Beijing’s market competitiveness and support it to serve more customers at home and abroad. The first engine for overhaul was planned to the workshop in July. In addition to V2500-A5 series, the Beijing-based MRO provider overhauls PW4000 series and RB211-535E4 series, also provides QEC kit and module change on CFM56 series. //

Expanded cooperation with OHS Lufthansa Bombardier Aviation Services // ­OHS Aviation Services, the specialist for interior design of business jets, and Lufthansa Bombardier Aviation Services (LBAS), a Lufthansa Technik joint venture and leading maintenance facility exclusively for Bombardier business jets, now offer more services from a single source. “We now want to expand our successful cooperation in the form of joint customer acquisition abroad and rely on combined refurbishment and maintenance product packages,” says Christoph Meyerrose, CEO of Lufthansa Bombardier Aviation Services. For the customer, refurbishment services are attractively priced and optimally integrated into a forthcoming check. Even short-term requests are served. OHS has also expanded its engineering sector: besides “Minor Changes”, the EASA Part 21J-certified Design Organization can now permit “Major Changes” and Supplemental Type Certificates for all aircraft categories. At Berlin Schönefeld airport, LBAS and OHS offer a comprehensive maintenance and refurbishment program, including engineering services. The close proximity of both companies allows a straight forward common customer care which has proven to be very efficient over the years. //

Personalities | 5

Lufthansa Technik Connection 5.2015

Robe rt Gaag has been promoted to the position of Vice President Corporate Sales EUMEA. As of October 2015, he will take over this responsibility from Wolfgang Weynell, who held this position together with the office of SVP Corporate Sales & Marketing. With a Master’s Degree in Aeronautical Engineering from the Technical University of Munich, Robert Gaag started his career as Project Engineer for MTU Munich in 1986. He joined Lufthansa in 1989 as Project Manager in the aircraft/ engine evaluation team in Hamburg. After an assignment as Resident Representative for Lufthansa at the Boeing Company in Seattle, he returned to the Technical Directorate of Lufthansa Passenger ­Airline Services in Hamburg in 1995 as Boeing 747 Fleet Manager. Robert Gaag joined Lufthansa Technik in 2000 as Manager Key Accounts Lufthansa Group before he was assigned the position of Sales Director Central Europe in June 2002. Before his latest p ­ romotion he served as Vice President Sales North America.

Sahib A j jam has been appointed Regional Director Sales North America, succeeding Robert Gaag. Effective October 1, Sahib Ajjam will be leading Lufthansa Technik’s sales activities in the USA and Canada together with his team in Miami and the affiliated sales organization in North America. Sahib Ajjam possesses a wealth of MRO experience. After earning a degree in mechanical engineering at the University of Braunschweig, Germany, he started his career as a Key Account Manager for Schott Glass in 1994. He joined Lufthansa Technik in 1996, working as a project engineer in the engine MRO division. Further responsible positions with Lufthansa Technik included Project Director Airbus A318 Elite, Director of Narrowbody VIP-Programs and, since 2008, Director of Aircraft Maintenance Munich.

Thomas Kuhn has been named new President and CEO of BizJet International. He succeeds Manfred Gärtner, who has been leading BizJet International since 2013. Thomas Kuhn studied aeronautics and completed his education with a diploma. In 1989 he joined Lufthansa Technik, holding various management functions during the following years. In 2008, Kuhn became Sub-Division Manager Overhaul at Ameco Beijing, the Lufthansa joint venture with Air China. Prior to his latest promotion, Thomas Kuhn served as Director Engineering Services in Lufthansa Technik’s VIP & Executive Jet Maintenance Business Unit in Hamburg.

Holger Beck has been appointed Director Business Development, Sales and Customer Services of Lufthansa Technik Maintenance International (LTMI). Holger Beck is an electronics engineer, holds a Master’s degree in Technical Management and a Senior degree in Airline Management. Since joining Lufthansa ­Technik in 1989 he has held numerous responsible positions, among them Managing Director at Lufthansa LAN Technical Training in Chile and General Manager at Lufthansa Technical Training Philippines. ­Prior to his latest promotion he was Director Finance and Key Account Management at Lufthansa Technik Maintenance International.

Andr eas van de Kuil has taken over the position of Chief Executive Officer (CEO) at Lufthansa Technik Vostok Services in Moscow effective September 1, 2015. Andreas van de Kuil studied at the Northeastern University, Boston and the European School of Business (ESB Reutlingen), where he acquired a Master in International Business Administration. He joined the Lufthansa Technik sales team in 2009 as Project Manager Sales Support. Before being promoted to his current position, he served as General Sales Manager Russia & CIS located in Moscow.

S andr a E ckstein has taken over the position of Managing Director of Lufthansa Technik Landing Gear Services in London, UK. Sandra Eckstein can look back on more than a decade of experience in aviation, launching her carreer at Lufthansa CityLine. With numerous trainings in project management, leadership competence and others she soon aquired responsible management positions. She joined Lufthansa Technik in 2007, working in Strategy and Product Management, as team leader Key Account Management and as manager c ­ ontract controlling. In 2013 Sandra Eckstein was given the responsibility of CFO of Lufthansa ­Technik Landing Gear Services UK Ltd, the position she held before being promoted to her current field of work.

C hr istian L anger has been appointed as Managing Director of Lufthansa Technik Logistik Services (LTLS) with effect from September 1, 2015. Christian Langer has earned a PhD from the WHU – Otto Beisheim School of Management and a Master’s Degree in Computer Science from the University of Koblenz. He joined Lufthansa Technik in 2004, being responsible for the introduction of lean production principles in the Aircraft Maintenance Division in Frankfurt. In October 2007 he was appointed as Head of Lean Production Management for the Lufthansa Technik Group. In 2012 he additionally took over responsibility for a restructuring project of the administrative body of Lufthansa Technik. Since July 2013, Christian Langer has been Managing Director of Lumics, the joint venture between Lufthansa Technik and McKinsey & Company.

6 | Corporate Sales Europe

Lufthansa Technik Connection 5.2015

“Best value for money”

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In the run-up to this year’s MRO Europe in London (October 13 – 15) Connection talked to Georgios Ouzounidis, ­Director Sales Europe at Lufthansa Technik, about the supporting pillars that will enable the MRO provider to remain market leader and a partner for airlines in every ­ market segment in the future.

MRO e p Euro 426 Booth n Londo

What’s the current situation of the MRO industry in Europe? Georgios Ouzounidis: We have a market of 6,000 aircraft in Europe, which is divided into three major segments: First, there’s the large legacy airlines, secondly the major low-cost airlines and finally the third group consisting of small and medium-sized airlines. Overall, the market is growing by three to four percent a year, but the development in different segments varies significantly. The most prominent growth is generated by low-cost airlines – growth rates in the other two segments are relatively low. If you want to grow in this low-cost segment, you automatically expose yourself to cost pressure, which is particularly pronounced here. There are no niches where operators can flourish undisturbed. As a result, there is great pressure on suppliers, including MRO companies, to reduce costs and provide better services. In addition, OEMs are pushing into the MRO market, intensifying the competition even further. How does Lufthansa Technik operate in this environment? Lufthansa Technik can only prevail through a combination of factors: Price, service, product and location, which all have to be just right. Our advantage is that we’re well positioned: Europe is our home market and we have the biggest market share. Lufthansa Technik takes care of 960 aircraft in Europe alone, plus the aircraft of Lufthansa German Airlines. We have an excellent network of facilities in our home region, for instance in Budapest, Sofia, Malta and London, to name just a few. This size as well as our global network and good relations to many customers

Corporate Sales Europe | 7

gives us the opportunity to defend or even increase our market share. To ensure continuous growth, we need first-class service and high customer satisfaction. At the same time, we are establishing partnerships with our customers, since that creates a true win-win situation. What characterizes us is that Lufthansa Technik takes a long-term view of the MRO business to minimize the total cost of ownership for its customers and create value in the long run.

subsidiary of Lufthansa, we at Lufthansa Technik know how airlines think and what the challenges are for an airline’s daily operation. We know how important reliability is. That’s what sets us apart from other MROs without an airline background, MRO providers simply can’t have the same understanding of the customer’s situation. Our primary consideration is always to understand the customer’s requirements. Listening and understanding are important so that we can then create a tailor-made solution. As a full-service provider, we are able to optimally adapt our products to these customer requirements. One example is our IT integration: We have readymade interfaces available that we can offer and activate quickly so that the customer experiences fully integrated service.

What are the highlights of the current fiscal year in this context? At the beginning of 2015, Lufthansa Technik won a major support contract for the Thomas Cook fleet and phased in a variety of aircraft types at different locations in a very short time. We were able to implement this seamlessly, providing excellent customer satisfaction – this proved a great What role does the company’s success and demonstrated that what ­innovative power play here? Lufthansa Technik promises will be delivered. The A350 contract with Finnair shows We are the most innovative company in the MRO industry. Through our innovathat we’re also excellently positioned to tions, we convince many potential customeffectively and efficiently support this new aircraft type. That we were able to sign the ers that we’re the best partner to work with – a partner who helps reduce costs, for first A350 supply contract worldwide example through repair procedures that speaks for itself. We were awarded the have been develcontract because oped in-house. we know what it Every year, we means to phase in We prove on a daily basis invest millions of a new aircraft type that we serve the low-cost euros in innovations – after all, we’ve ­segment very well. and generate prodbeen doing this  Georgios Ouzounidis ucts that meet the successfully again requirements of and again with customers. And our customers know that other new aircraft over the past years. The first TCS® (Total Component Support) con- they’re working together with the best and most innovative MRO provider. That is a tract for the 22 aircraft of Air Europa’s strong argument because customers ben787 fleet (see article on page 3) also highefit from having a share in that. And in lights our convincing performance. Our terms of the specified targets, our airline success can be attributed to the fact that experience comes into play once again. we understand and solve the problems of We know what airlines are concerned with: our customers. This kind of thinking is not problems such as fuel consumption, relimerely a claim; it’s firmly fixed in the ability and other vital issues. That’s why we heads of our employees – they’re able to develop products to support customers think and understand the problems from with these points in particular. the perspective of an airline.

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What characterizes Lufthansa Technik in particular? One outstanding factor is our airline experience. There are many customers in Europe who want to work together with a partner who thinks like they do. And as a

Which role does the global Lufthansa Technik Group play for European customers? Since our customers fly throughout the world, they benefit from our network everywhere. Our strength here is once again

Photo: Airbus S.A.S. 2014

Lufthansa Technik Connection 5.2015

that we’re able to help them quickly all over the world. Whether it’s a component pool in Miami, a component workshop in Shenzhen or the base maintenance location in Manila – our customers benefit directly from our great number of sites. Many customers from Europe, for example, fly their aircraft all the way to Manila for base maintenance layovers. What development are you aiming for over the coming years? Our success is based on greatest possible customer satisfaction and this leads to our customers staying loyal to us year after year. That’s the foundation of our customer retention philosophy. But of course we also want to generate more business in the growth segment of low-cost airlines. After all, we prove on a daily basis that we’re capable of serving this market segment very well. As a full-service provider for Wizzair, for instance, we’re supplying the biggest ultra low-cost carrier in Eastern Europe. For me, that's a perfect example to show we’re also able to provide excellent services at reasonable prices in this segment. Low-cost airlines are not always looking for the lowest unit price for single maintenance activities, but often they seek the lowest total cost of ownership – and we can deliver that. Which pillars will support Lufthansa Technik in future? What makes us strong is a combination of the following elements: customer satisfaction, efficient products, best value for money and beneficial innovations. These four pillars are a basis upon which we can build the future.

8 | Aircraft Services

Lufthansa Technik Connection 5.2015

“Thumbs up” for United Airlines When the line maintenance technician in Frankfurt signals “thumbs up” for UA 945 to Chicago at 8 AM he knows the day has been set for a good start. It is the first of eight daily flights that United Airlines operates out of Frankfurt, with Lufthansa Technik ­Maintenance International (LTMI) ­performing the transit checks.

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nited’s major destinations in Europe are London, Paris and Frankfurt. Since June, transit checks in Frankfurt are performed by ­Lufthansa Technik’s Frankfurt-headquartered line maintenance organization Lufthansa Technik Maintenance International. Currently Boeing 747, 767 and 777 ­aircraft are serviced and, starting in September, the new 787 Dreamliner will join the fleet. “That is quite a challenge”, says Matthias Thon, who is coordinating the team of mechanics that take care of ­United Airlines. “Departure times are stretched over the day, so we had to adjust our shift pattern accordingly.” Matthias Thon is upbeat when he describes how the team put their act together. “Six mechanics are dedicated to United’s operation in Frankfurt every day. Planning is a challenge, not only because we saw a 15 percent increase in the number of

United Airlines ICAO-Code: Founded: Headquartes: Fleet: Employees: Passengers: Alliance:

UAL 1926 Chicago, IL, USA 712 84.000 138 million Star Alliance

departures that we handle.” Thon’s department is supporting about 50 different airlines in Frankfurt. Lufthansa’s own operation is handled by a separate unit. “We found the dedication to customers more effective, so we do not mingle with the more than 400 daily departures of Lufthansa in Frankfurt.” The dedication pays off when the requirements are clearly different, best illustrated by the types of aircraft that are handled. Matthias Thon explains: “Equipment is sometimes substituted, say a 767 is scheduled to operate a flight that is normally performed by a 777. In such a case I’m glad that I can count on the flexibility of our staff.” A lot of flexibility was also needed to start the transit checks in the first place. “After being awarded the contract we had about four weeks to prepare. Thanks to a lot of support from United themselves we were able to set up a training scheme in no time. Some of our guys had to postpone plans for summer holidays, but that’s ok.” A lot of flexibility From a mechanics point of view today’s 767 may not be quite the same as yesterday’s 767 on the same flight, because the fleet of United reflects the 2010 merger with Continental airlines. The aircraft are

released to service electronically in United’s IT system and in case of trouble there is always the Technical Operations Maintenance Control Center of United Airlines that can be contacted 24/7. At 5 PM the last flight of the daily shift is released to San Francisco. While the passengers relax in their seats, Matthias Thon gets the message that the transit check went all right, the aircraft has been released and his mechanics are packing up for the day. He has meanwhile done the preparations for the coming days.

Aircraft Services | 9

Lufthansa Technik Connection 5.2015

Responsible for the transit checks in Frankfurt: ­Matthias Thon is coordinating the team of mechanics and seen here checking various items.

Line Maintenance in Frankfurt // Lufthansa Technik Maintenance International (LTMI) offers maintenance services and technical support to Lufthansa Technik’s inter­national maintenance customers. ­Lufthansa Technik’s ­maintenance subsidiary has all the required aviation authority approvals and has developed within a short time into an important hub of expertise for aircraft maintenance within the globally operating Lufthansa Technik Group. In addition to carrying out aircraft maintenance for all of the current Airbus and Boeing aircraft

types, the company’s portfolio of services also includes heavy checks (IL- and D-checks) of the Boeing 757 and 767 series aircraft. A dedicated Customer Support Center (CSC) is functioning as L­ ufthansa Technik’s central point of contact for all technical enquiries of its maintenance customers. //

For more information: www.lufthansa-technik.com/ linemaintenance

10 | Aircraft Services

Lufthansa Technik Connection 5.2015

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Innovation & Technology | 11

Lufthansa Technik Connection 5.2015

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With larger fleets being replaced by newer aircraft generations, Lufthansa Technik’s ongoing “Fleet Exit Services” project is establishing the base for a significantly improved service portfolio dedicated to supporting customers even better in phasing out their f­lying assets.

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everal hundred passenger aircraft are taken out of service every year around the world, with an increasing tendency. Some 450 aircraft will be decommissioned each year in the next five years alone, and more than 350 others will be returned to lessors. These are primarily aircraft in the Airbus A320 family, A330/ A340 as well as Boeing 737 Classic/NG, 747, 767 and Bombardier CRJs – aircraft types that Lufthansa Technik has in its portfolio. Airlines frequently do not have the required expertise when it comes to these phase-outs, especially in relation to optimizing residual lifetimes and parts management. Because of their complexity and rare occurrence, phase-out programs constitute an exceptional additional burden on top of daily business for many customers. Often, the parallel introduction of new aircraft further adds to the intricacies operators are facing during this phase. The resulting operative and financial risk is difficult to quantify, especially considering the required handover conditions for the phased-out aircraft. Lufthansa Technik is therefore developing an integrated service portfolio together with selected clients that will ease the burden on airlines in the future. Optimized supply Based on the results of the ongoing project “Fleet Exit Services”, Lufthansa Technik is developing a plan to offer a significantly improved service portfolio in 2016, dedicated to customers who want to phase out their aircraft fleets. Operators would then

have the option of transferring the tasks associated with a fleet exit fully or partially to Lufthansa Technik, which would support customers with their phase-out planning. Customers will benefit from Lufthansa Technik’s know-how in the thorough preparation of phase-out programs as well as through a financially and technologically optimized maintenance and material supply tailored to the individual customer’s exit scenario, without reductions in reliability or safety. Customers also enjoy the scale effects of a large MRO provider with a broad customer base. These economies of scale are not achievable when supplying a small fleet in-house. The existing in-house capabilities of customers can also be incorporated in the supply concept. The goal of the Fleet Exit Services project is to optimize maintenance services in the final years of the fleet’s operation and at the same time enable seamless aircraft availability. The affected aircraft therefore receive – in close coordination with the customers – integrated, individual and cost-effective technical support. A simple

transition to an attractive overall product will be ensured by bringing together a number of tried and true individual measures and products that are currently offered by Lufthansa Technik, and making effective use of the global Lufthansa Technik Group network and strategic partners. This applies, for example, to the intensified use of surplus material in the area of components and landing gear parts, and to the targeted optimization of repair scopes and the residual lifetimes of engines in relation to the individual exit scenario. The latter is already available today through Lufthansa Technik’s comprehensive smart.life product. Risk reduction Owing to some degree to its very close and successful long-standing cooperations with authorities and original equipment manufacturers (OEMs), Lufthansa Technik would also be able to handle regulated lifetime extensions. The employment of Lufthansa Technik’s flexible Airline Support

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12 | Innovation & Technology

Teams performing smaller on-site works further help to avoid bigger shop events shortly before phase-out. This gives airlines greater flexibility cost- and time-wise with their phase-out planning, while fulfilling their requirements for meeting the specific handover conditions. The range of services envisioned by an improved services package also include support for the demanding field of aircraft documentation. Thanks to a long-term and close consultation with the customers and recipients of the phase-out fleets (usually lessors or traders), the financial risks of phase-out programs are reduced significantly and planning certainty is increased. Even long after the phase-out, Lufthansa Technik can answer questions on aircraft documentation.

Lufthansa Technik Connection 5.2015

Individual financial solutions Customers’ financial maneuverability and ultimately their competitiveness are strengthened through asset acquisitions, purchase-and-lease-back options and individually coordinated billing and financing solutions (e. g. in regards to maintenance reserves). Moreover, the recycling potential of non-reusable material of decommissioned aircraft is currently being assessed with the aim of feeding highquality materials back into the industry’s recycling material chain in cooperation with specialized partners. Not only will this allow additional cost savings potential to be exploited, but resources can be saved and the burden on the environment reduced.

Support with the introduction of new fleets and with potential organizational adaptations (e. g. training, provision of tooling, etc.) round off the service portfolio. The “Fleet Exit Services” project will therefore not only lead to a modular, flexible and customizable product that provides airlines with cost-effective maintenance services and improved material management, but will also support airlines in concentrating on their core business and the introduction of new aircraft types.

Ulrich Hoffmann Phone +49-40-5070-67709 [email protected]

Major retrofit for A380 Lufthansa Technik Philippines (LTP) successfully carried out a passenger door retrofit and flap track #6 modification on an Airbus A380. The modification is the first such event performed within the Lufthansa Technik Group, underlining LTP’s status as the Group’s center of excellence for Airbus A380 overhaul services in Asia.

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odification programs for the LH/ RH flap track #6 assembly and all 16 doors of the A380 are the latest from the service bulletins implemented by Airbus to address and improve the aircraft’s performance as it enters maturity. Despite the extensive program, the A380 is safe to fly and operators can opt to carry out the passenger door retrofit program at planned intervals alongside scheduled C-checks. For this particular event, the aircraft underwent a C4-check at the Manilabased facility, combined with retrofit tasks for wing-rib, flap tracks, and passenger doors. Major modifications entail MRO providers to work closely with OEMs. To prepare for this competency, structural and

aircraft mechanics of Lufthansa Technik Philippines were trained by Airbus experts on site. The onsite Airbus retrofit team also assisted Lufthansa Technik Philippines in setting up dedicated equipment and the right environment to support the aircraft’s large components.

During the retrofit programs, the doors and flap tracks are carefully detached from the aircraft for structural modifications and reinforcements. With the necessary modifications complete, the doors and flap tracks are prepped, re-installed and skillfully rigged back to the aircraft. Lufthansa Technik Philippines will perform more passenger door and flap track retrofit works for the A380 in the coming months. “We are committed to helping A380 operators optimize their aircraft’s ground time by offering our customers a comprehensive service suite for their requirements,” says Marek Wernicke, Senior Vice President for Base Maintenance at Lufthansa Technik Philippines.

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Lufthansa Technik Connection 5.2015

easyJet increases work volume easyJet, the leading low-cost airline in Europe, has enlarged its contract with Lufthansa Technik Milan, raising the volume of work by some 50 percent. The Lufthansa Technik ­subsidiary is thus growing with the increasing demand of the customer.

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asyJet, the European low-cost airline based in London Luton Airport, has been a customer of Lufthansa Technik Milan at the Malpensa airport (MXP) since late 2010, when a light base maintenance line was established at the North Italian hub, easyJet’s largest on the European mainland. The contracted scope of work has grown continuously ever since, ranging from equalized maintenance checks to comprehensive defect rectifications to structural repairs and modifications for the airline’s A319/320 aircraft fleet. The current volume increase involves the installation of a second light base maintenance line for several days per week.

The planned rise in work volume is caused by the remarkable expansion of easyJet’s fleet. “We were looking for additional maintenance capacity within our existing network, and based on our experience with Lufthansa Technik in Milan, increasing capacity here was a logical decision,” states Brendan McConnellogue, Head of Line and Base Maintenance at easyJet. “The Lufthansa Technik team in Milan has adapted very well to our requirements of on-time performance, flexible problem-solving and transparent communications. We are happy to extend our partnership in MXP.” Jürgen Hupe, Managing Director of Lufthansa Technik Milan, highly appreciates the additional work:

“We are proud to have been entrusted with this program expansion, while we are also aware that we have to confirm the trust every day. It is a privilege for us to work with a benchmark partner like easyJet.” easyJet has contracted Lufthansa Technik line and light base maintenance services also in Berlin-Schönefeld as well as line maintenance services in Hamburg. In addition, Lufthansa Technik performs engine washes (Cyclean®) for the entire easyJet aircraft fleet at various stations across Europe on an annual basis. Cesare Ghermandi Phone +39-02-585714-24 [email protected]

14 | Technology & Innovation

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Lufthansa Technik Connection 5.2015

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The modern emergency floor path marking system GuideU 1000 offers unrivaled features with respect to installation effort, reliability, and flexibility. It represents the enhanced development of the first system based on the principle of photoluminescence, which Lufthansa Technik introduced some 20 years ago. A true success story.

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he impetus for development came directly from Lufthansa German ­Airlines. Continuous defects were occurring in the electrical systems at ­Lufthansa powering the emergency exit routes, with more than 200 delays by more than 10 minutes being recorded annually. Because the emergency floor path marking system is part of the Minimum Equipment List (MEL), a repair was then necessary each time prior to start-up. In their efforts to

ensure maximum reliability, the developers came upon the principle of photoluminescence. A suitable plastic is “charged” so to speak by illuminating it in a relatively short time and then releases the stored energy again slowly. Lamps, wires, and a current source as well as all associated potential errors are quite simply eliminated. To allow use as a replacement for the electrical systems used to date, its width was used as a guide for the strip width of

the new system. However, while the electrical systems were only installed on one side of the exit path, the new system was installed on both sides, therefore offering a clearly visible view of the aisle. The system, which was developed in cooperation with an external manufacturer, was initially installed in the Lufthansa fleet. The experience of the airline with the new system was so good that a contract was concluded with Airbus in 1999, which saw the

Original Equipment Innovation | 15

Lufthansa Technik Connection 5.2015

20 years of progress: Hans-Christian Lierow (left) headed the GuideU product since 1999. As of April 2015 Torben Biehl has taken on this task.

equipping of all new aircraft for Lufthansa with the system, referred to by the name Guideline® Classic. The first external customer for the innovative product was Southwest Airlines in 2000. The airline had its large Boeing 737 fleet equipped with Guideline®. In this case also, the customer was unhappy with the unreliability of the electrical system installed ex works and therefore decided to replace it at the first maintenance layover with the Lufthansa Technik product. Colored, curved, light-weight A dedicated product team was formed in 2004 in Lufthansa Technik, whose primary tasks included developing an improved system. Aircraft manufacturer Airbus was looking for a lower-weight system, which could also offer a variety of colors. The result was presented at the Aircraft Interiors Expo in 2005. Guideline® Colorfit fulfilled the requirements precisely and was available initially in eight colors.

This system was not only installed in the Airbus A380, but also as standard then in an entire series of popular aircraft types. A contract was subsequently signed with Bombardier in 2007 for equipping the CRJ regional jets. Lufthansa’s 747-8 was also ordered with this system. The next stage in development followed on from a call for tender from Airbus. ­Lufthansa Technik developed the current system under the name GuideU 1000. It offers more colors and with only one part number won the tender for the standard equipping of the A350. Boeing also took on the ultra-modern system later as an option for the 787. The last development stage followed one year later. GuideU ColorCurve is the first emergency exit route marking system that can be installed in almost any radii. It therefore not only offers the design team a greater degree of freedom, it is also lighter than all previous systems. The weight savings in the case of a twin-aisle aircraft amount to almost 8 kg. With a thickness of 2.5 mm, it is also compatible with the very

For more information: www.guideu.com

thin carpets that are being used increasingly. Extremely light underlays are available for thicker floor coverings. And ­another advantage: The material can be installed in the aircraft using a simple tool. Thanks to its excellent properties, ­GuideU 1000 represents the pinnacle of a development that began 20 years ago with a simple, illuminated plastic green strip. Torben Biehl Phone +49-40-5070-66623 [email protected] Customer advantages • No life limit • No maintenance • No power required • FAA/EASA approved • Light weight • Curved shapes • Cuttable on board • 19 different colors • One-piece system

16 | Aircraft Services

Lufthansa Technik Connection 5.2015

Start of operations in Puerto Rico On July 21, Lufthansa Technik’s new overhaul facility in Aguadilla, Puerto Rico has started operations with its first overhaul line. On time and just eleven months after ground-breaking in August 2014 the first Airbus A320 from US-carrier Spirit Airlines arrived for a C-check.

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pproved according to FAA Part 145 and EASA Part 145, Lufthansa Technik Puerto Rico (LTPR), the new member of the Lufthansa Technik’s base maintenance network, has commenced operations. Initial customers are Airbus A320 family aircraft operators, Spirit Airlines and JetBlue Airways, from the Americas. A second overhaul line is planned to be operational in November, followed by three more lines until early 2017 to include Boeing 737 by then. “Lufthansa Technik Puerto Rico has been founded to strengthen significantly our service portfolio in the Americas, one of the most important MRO markets worldwide. I would like to thank Governor Alejandro García-Padilla and his team for their comprehensive support and the excellent partnership which we could establish over the past two years,” said Dr. Johannes Bussmann, Chairman of the Executive Board of Lufthansa Technik. “And of course, I also would like to thank our launching customers, Spirit Airlines and JetBlue Airways, for the trust they have set in us in the forefront of this day. With the arrival of the first A320 Lufthansa Technik Puerto Rico becomes operational. Management and staff can be really proud of what they have achieved so far.”

“Today we begin to see the results of one of the most important projects of the economic agenda of this administration. Even in the midst of the fiscal situation our country is facing, we continue working to carry out those strategies which result in economic benefits for our island. Today, this MRO is finally a reality. The agreement between the government of the Commonwealth of Puerto Rico and Lufthansa Technik begins to translate into work and the facility begins to offer its services. Nonetheless, this is only the beginning. We will continue to see these facilities become the economic motor of this region both because of the jobs they create and their national and international alliances. Results such as these are the ones that guarantee that Puerto Rico has the capacity to overcome our present and inherited economic situation and achieve sustainable growth, as we unite outside of political party lines and commit to radically transform the way in which our government and our economy operates,” said Governor Alejandro García-Padilla. State-of-the-art technologies “We are thrilled to be Lufthansa Technik’s first customer in Puerto Rico,” said Spirit CEO Ben Baldanza. “We’ve had a long history with them as they have provided excellent support on our Airbus fleet through inventory, parts repairs and Reliability Engineering support. We’re excited about the next chapter as they provide heavy maintenance airframe support in Puerto Rico.”

“This is a fantastic moment for us,” said Elmar Lutter, CEO of Lufthansa Technik Puerto Rico. “I would like to thank my team which has carefully planned and worked hard for this moment since the beginning of this project two years ago. Now we can focus on the next milestones which are the ramp-up of the operations, the further development of our capabilities and the constant training of our highly motivated employees. I’m sure that Lufthansa Technik Puerto Rico will become an internationally acknowledged center of excellence for base maintenance services soon.” Currently, about 140 highly qualified employees have been trained and are working for Lufthansa Technik Puerto Rico. It is planned to grow up to a workforce of 400 in the next two years. The facility extends over a total area of 215,000 square feet. In its final configuration it will offer five lines for base and heavy maintenance checks (C-, IL- and D-checks), along with other maintenance work on narrow body aircraft. By using state-of-the-art technologies it is even possible to paint ­aircraft in the hangar while overhaul work is being conducted in parallel. Thanks to the geographic location of Lufthansa Technik Puerto Rico in Aguadilla, on the west edge of Puerto Rico, the maintennace facility is within flying distance of all Airbus A320 family aircraft in the Americas.

Lufthansa Technik Puerto Rico Phone +1-787-230-7700 [email protected]

Lufthansa Technik Connection 5.2015

Aircraft Services | 17

Precisely according to schedule: Employees of Lufthansa Technik Puerto Rico have gathered to salute the first customer aircraft, a Spirit Airlines Airbus A320.

18 | Component Services

Lufthansa Technik Connection 5.2015

Extending operational limits of CFRP parts Engineers in the Airframe Related Components (ARC®) unit of Lufthansa Technik have succeeded in extending the lifetime of the CFRP cascades of the CF6-80C2 thrust reverser. This highly innovative approach even eliminates the need for repairing such cascades within newly established limits.

Reverse engineering of the cascade involved cutting it up at critical sections.

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he cascades of a thrust reverser redirect the airflow forward and hence ensure the desired deceleration of the aircraft after landing. The CF6-80C2 thrust reverser uses carbon fiber reinforced composite (CFRP) cascades in order to reduce weight. During overhaul a certain percentage of these components exhibit defects. During the inspection phase cracks could be found at certain edges with a high probability. If the crack length exceeds predefined limits, the manufacturer prescribes the scrapping of such part. While exploring potential savings – one cascade segment costs approximately 5,000 US dollars and max eight each are installed in one CF6-80C2 reverser half – the ARC® experts at Lufthansa Technik started to carefully examine the component. In order to gain a better understand-

ing of the cascade’s stress characteristics and the resulting strain, an engineer specialized in such tasks established a finite element model (FEM) of the component and performed a simulation. The first issue which needed to be solved was that the properties of CFRP structures are dependent on the direction of the embedded fibers. As this inner structure cannot be

Finite element analysis was used to simulate operational loads of the cascade.

identified from the outside, a defective cascade was cut at the critical areas in order to determine the fiber orientation as well as the number and thickness of the individual layers. Reverse engineering then enabled the compilation of a precise, accurate and comprehensive computer model. Damage simulation Operating loads were applied to this model during the next step. For this calculation the ARC® experts benefited from the fact that they were able to draw on values measured while testing the engines after overhaul on the Lufthansa Technik test bench. The load range for the cascade was simulated with the measured data. The results showed that an asymmetrical load is created in the cascade when the

Component Services | 19

Lufthansa Technik Connection 5.2015

New wheels and brakes shop Lufthansa Technik has begun the construction of a new wheel and brake workshop at Frankfurt’s East Harbor. The ultra-modern facility will create sufficient capacity for the foreseeable future.

thrust reverser is operated, which causes the cracks to appear. The ARC® specialists went ahead with another decisive step. They asked the question: What impact might such cracks induce to the future operating behavior of the component? To find that out, a simulation of the operation of a cascade that was already damaged was introduced. The result was to some extent perplexing: the damage that occurred namely has no influence on to the reliability of the component. Based on this result, the engineers acknowledge the possibility to extend the lifetime limit of a defective cascade following individual inspections – with immediate knock-on cost savings for the operator. The corresponding approval was issued and approved at the end of August 2015. Furthermore, additional applications to other reverser types with similar structures are being planned. The analysis of a vast number of units at Lufthansa Technik was needed to achieve such result. In addition to the encompassing know-how of the innovation engineers at the ARC® business unit in the areas of composite materials and the ability to perform and correctly interpret FEM models, the engine shop also made an important contribution while providing real time data from the engine from the test bench. The result underscores the extensive problem solving expertise of Lufthansa Technik, which led once more to a highly cost efficient solution. Sebastian Krause Phone +49-40-5070-63454 [email protected]

Turning the first sod: Bernhard Massberg, from the Hessian Ministry of Economics, Energy, Transport and Regional Development, Karl Ulrich Garnadt, Member of the Board of ­Lufthansa Group and CEO of Lufthansa German Airlines, Dr. Johannes Bussmann, Chairman of the Executive Board of Lufthansa Technik, project manager Frank Zimmermann, Markus Frank, Frankfurt’s Economic Affairs Officer, Dr. Thomas Stueger, Lufthansa Technik Executive Board and Tino ­Fritsche, Chief Executive of C&E ­Consulting and Engineering (from left).

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n investment of just under 60 million euros for the new shop will yield a production facility which meets all requirements concerning lean production, ergonomic working environment and sustainability. The ultra-modern workshop will comprise a gross floor area of 14,500 sqm built on a 35,000 sqm plot. The building technology will enable the requirements of the Energy Saving Ordinance to be exceeded by 30 percent. For this purpose a separate combined heat and power plant will be constructed. Even the waste heat from the machines will be used for air conditioning the building. Thanks to optimized processes, tailored logistics and state-of-the-art plant equipment, the new site enables the cost-effective provision of wheels and brakes to ­Lufthansa and numerous other European customers. And while business with lowcost carriers is already strong, the new shop opens up opportunities for even further growth in this area. The new facility will be put into service at the beginning of 2017. It will enable Lufthansa Technik to continue to grow in the segment of wheel and brake overhaul.

The leading MRO provider is thus not only securing the 130 qualified jobs that already exist in Frankfurt, but is also creating opportunities for further growth. The most recent figures showed growth rates at more than three percent per annum based on the volume of serviced wheels and brakes. Dr. Johannes Bussmann, Chairman of the Executive Board of Lufthansa Technik, said: “Today we operate one of the largest maintenance shops for ­aircraft wheels and brakes in the world. We expect even more efficient processes under excellent working conditions with the new facility.” Considerable effort is invested in the maintenance of aircraft wheels and brakes owing to their importance for the safety of aircraft operations. Lufthansa Technik takes care of all the necessary work – from wheel or brake changes to small repairs or complete overhauls of a wheel or brake. Dirk Heil Phone +49-69-696-64936 [email protected]

20 | New Aircraft

Lufthansa Technik Connection 5.2015

“Prepared for the impossible” Sabrina Hornig loves the variety – and the challenges. The perfect conditions for her current responsibilities with Lufthansa Technik in Sofia. This is where the engineer has been completing the first part of her training as TOM Fleet Manager since October.

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abrina Hornig originally wanted a career in the cockpit. “But then I was drawn to a more down-to-earth role,” she explains smilingly. She quickly decided to go the route of a dual study program in cooperation with Lufthansa Technik. Having graduated in 2012, the mechanical engineer started working in

the company in the area of component services. Since October 2014 she has been working with Lufthansa Technik based in Sofia, where she is completing the first stage of her training as a TOM Fleet Manager (see info box right). The Fleet Manager trainees work through a number of deployment phases in several product divisions.

Line maintenance is a central aspect here as this is where they get to know their future area of activity intensively together with all the related processes. Sabrina Hornig was deployed on a d ­ aily basis for Bulgaria Air during the initial months of the demanding program – a ­program that requires extensive technical

Lufthansa Technik Connection 5.2015

Employee Portrait | 21

Sabrina Hornig checking an aircraft.

Technical Operations Management – TOM

knowledge and is expanding continuously. Taking on responsibility Like a trained TOM Fleet Manager she was closely integrated in the customer’s workSabrina Hornig now has to prepare for the flows, from technical consulting to the new responsibility in a number of ways: ­clarification of technical processes, the establish good connections between both improvement of material availability, hand­ companies that will improve the exchange ling of AOG events and follow-up, for of information. And naturally ensure inteexample in the logistics of time-critical gration of all associated services for the components. The program consists of winter layover times, from material mannumerous further training courses, such as agement to engineering services through in certified project management, negotiato takeover of related contracts between tion management as well as corporate the airline and Lufthansa Technik. “The strategic planning project should be simulation and also concluded within includes a sevenfour months,” she Except for certain invariables, week EASA part-66 reports. “This is a one never really knows what aircraft type training rather tight schedthe day will bring. course. As a techniule.” As she talks Sabrina Hornig cal consultant for her about it, her customers’ entire respect for the task fleet, she will therefore have accumulated is clear as well as her real sense of pleavery comprehensive knowledge of the major sure about the challenge. civil aircraft types on the market by the end Sabrina Hornig has already learned a of her training. little Bulgarian including the Cyrillic alphaFor Sabrina Hornig, Sofia is an ideal bet during the first few months of her stay. training location for getting to know fleet “Sometimes the language changes management on a smaller scale where much from English to the local language during is accomplished locally. She loves the meetings. But once I show that I can unpredictable moments of the working day. understand some of the content, everyone “Except for certain invariables, such as the quickly starts speaking English again,” morning information briefing on special events she grins. in the respective fleet and regular meetings with the customer, one never really knows Prepared for the unexpected what the day will bring,” she reports. The new task that Sabrina Hornig has What impressed her most during the past been working on recently is ideal for her: months? “Out of the box thinking is an she has solely taken on the role of Impleeveryday occurrence in Sofia, probably mentation Project Manager for integrating also because Lufthansa Technik’s Product the new Base Maintenance contract for the Divisions are not simply sitting in the office entire Germanwings fleet. Sofia will therenext door,” says Sabrina Hornig as she fore be the Base Maintenance hub for all comes back again to why she likes her job 61 aircraft in the current Germanwings fleet so much. “I have learned to be prepared for the next ten years. Many tasks for which for the impossible. After all, no matter how the airline itself was responsible ­formerly many steps are planned in advance – the will be transferred to Lufthansa Technik unexpected can still happen.” Sofia as of the 2015/2016 season. This is an impressive feat, not least because Thoroughly enjoying her work: Sabrina Hornig is looking f­orward to challenges. Sabrina Hornig is just 28 years of age.

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// In conjunction with a Total Technical Support (TTS®) contract, TOM enables operators to enjoy far-reaching efficiency advantages resulting from synergies in service integration and reduced complexity in their organizations. Operators can focus their resources on business development while maintaining full control over technical issues. Fleet manager on site Lufthansa Technik is working closely with the operator to optimize the integration of maintenance and engineering services into the airline’s flight operations and ensure the smooth functioning of all other MRO services. The permanent presence of the fleet manager at the customer’s home base ensures a close working relationship and the optimal adaptation of Lufthansa Technik’s services to the airline’s requirements. The fleet manager solves all technical problems, having direct access to the entire range of solutions offered by the global Lufthansa Technik network. Thanks to service guarantees and transparent performance measurements, the operator retains control and the ability to monitor operations at all times. Full control with manage/m® IT integration via Lufthansa Technik’s websuite manage/m® is a key element of TOM. 24/7 access to relevant data via a simple Internet connection and unlimited data ownership ensure that ­aircraft operators retain full control of maintenance activities. m ­ anage/m® is secured with the latest encryption technology and maintained by ­Lufthansa Technik. //

22 | Component Services

Lufthansa Technik Connection 5.2015

Epoxy repair of metal parts When aircraft components such as pumps are worn or corroded, the “Advanced Epoxy Coating Process” by Lufthansa Technik Intercoat often provides a suitable repair solution. Using the proprietary INTERFILL® material, components can be salvaged when other repair methods fail and parts normally need to be scrapped.

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amage to components caused by wear and tear, corrosion or cavitation does not automatically mean these parts have to be scrapped. Thanks to their “Advanced Epoxy Coating Process”, the specialists from Lufthansa Technik Intercoat in Kaltenkirchen, Germany, can repair such components. INTERFILL® is applied as a paste and then hardened by curing to develop its special characteristics. The surfaces are then machined in a second step to create the final contour. INTERFILL® consists of epoxy resin, which is mixed with filler materials. A wide range of variants have been established over the years, which can be differentiated in terms of their abrasion resistance, media resistance and acceptable operating temperature. The result is that the characteristics of coated components are often better today than those of the original ones. And as the base material properties remain unaffected, the repair can be repeated several times. Customer benefits • Highly cost-efficient • Component scrapping avoided • Excellent surface finish • Performance enhancement • Repair of highly complex components • Component life extension • Almost unlimited repair repeatability

Choosing the matching fillers, taking account of the base material of the repaired part and the given conditions, is one of the most difficult steps within the work process. The main criterion of the “Advanced Epoxy Coating Process” is a good wear characteristic, smooth surface quality and good protection against foreign object damage. “If we get, for example, a hydraulic pump in for repair we evaluate which INTERFILL® type is most suitable depending on the damage and component. And if there is no solution as yet for the case to hand, we mix the base material to order with the respective particle and fiber fillers,” says Martin Cholewa, Head of Engineering and Deputy CEO of Lufthansa Technik Intercoat. Lufthansa Technik Intercoat has meanwhile extended its product portfolio beyond repair technology. Thanks to the extensive machinery – a new 5-axis milling center was only commissioned in 2013 – the company can now also produce components in small batch series. For example, a door handle is currently being produced in cooperation with Lufthansa Technik. As far as Sales Manager Stefan Beinroth is concerned, this is just the beginning: “We are currently setting out to tackle the highgrowth Chinese market more intensively with an extended sales strategy.”

Lufthansa Technik Intercoat is certified by the authorities in Europe, the U.S., Canada and China and also directly by engine manufacturer Rolls-Royce. In addition to customers in the aviation industry, repairs are also taken in in Kaltenkirchen from customers in shipping, gas turbine produc-

Component Services | 23

Lufthansa Technik Connection 5.2015

Three questions to Andreas Sauer, CEO of Lufthansa Technik Intercoat.

You are the new CEO of Lufthansa Technik Intercoat (LTI) since February 1, 2015. What are your goals for the future? Andreas Sauer: We want to involve our customers more intensively in our developments so that we can tailor our products and services more individually to their needs and wishes. Our highly qualified employees have excellent know-how that we want to bundle in a new center of excellence. Moreover, we want to expand our portfolio and also extend the production for parts in small series, for example, in addition to component repair. Which target group is Lufthansa Technik Intercoat addressing? Our customers from the aviation sector and industry are located all around the globe. As highly professional providers, we are of course available to the entire Lufthansa Group. At the moment, for example, we are supporting the GuideU team at Lufthansa Technik in Hamburg in the manufacture of components. We also have close contact with the workshops in Hamburg as well as the Lufthansa Technik subsidiaries in Tulsa and Shenzhen. What innovations are you planning? In the future we want to develop and manufacture the epoxy resin ourselves, that’s the base material for INTERFILL®. This will create an additional unique selling proposition for us. This is because our competitors only offer ready mixed standard pastes. We are also considering introducing innovative ­procedures for restoring surfaces. We are searching for new procedures at present that will help us to develop additional application areas. // For preparation and final machining substantial equipment is required, whereas the application of the Interfill® material is a manual process.

tion and general engineering – all of whom receive a repair solution that is technically and economically state-of-the-art. Andreas Sauer Phone +49-4191-809-152 [email protected]

For more information: www.lht-intercoat.com

24 | Engine Services

Lufthansa Technik Connection 5.2015

Threefold power for on-site support

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The Airline Support Teams (AST® Engines) are the efficient answer to engine problems thanks to their on-wing and on-site support. New bases in Canada and China mean that Lufthansa Technik is now even closer to its customers, tripling its capacity and reducing deployment - 4 0 - 5 070 49 times to ensure an even more efficient service. T® n o n 2: E

Engine Services | 25

Lufthansa Technik Connection 5.2015

Montreal

Frankfurt

Shenzhen

Three independently operating bases are ­effectively tripling the capability of Lufthansa Technik’s AST® Support. Each location features a separate AOG desk with 24/7 availability.

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hen Lufthansa Technik set up the Airline Support Teams (AST®) more than twenty years ago, they came about from the necessity to resolve an AOG incident caused by engine failure locally at the aircraft location. This rapid intervention soon became known by the name “Flying Doctors”. However, the development showed that the AST® principle offers even greater potential. By strategically developing its own procedures that allow engines to be maintained directly on wing or on site, Lufthansa Technik also succeeded in allowing modification packages to be implemented by the AST® teams, such as for example processing of service bulletins (SB) and AD notes. As Director of Engine Services at Mainbase Frankfurt, Bernhard Husenbeth is responsible for development of the product. He explains the basic concept: “The idea is not to dismantle the entire engine, rather to always only work at the location of a finding.” A shop visit causes considerable additional expenditure, regardless of any other problems actually found. Apart from transport costs, there is the cost of the full disassembly, diagnosis, documentation and the – likely – additional repairs needed to many components. By avoiding the shop visit, an AST® deployment is therefore an extremely efficient maintenance element for the customer.

AST® deployment typically takes between one and six days. With the demand for AST® services increasing and the realization that serving an increasing number of customers from all over the world from Frankfurt does not make sense, a re-alignment of the service was planned. Efficient on-site solution The new AST® service brings Lufthansa Technik closer to the customer, therefore directly into the regions. For the Americas the relevant facility is being extended in the Canadian city of Montreal and at Lufthansa Technik in Shenzhen in China for the AsiaPacific region. Currently the capacity expansion is in full swing, the tooling has been acquired for Montreal, while the tooling for Shenzhen is being procured. Apart from the technical requirements, a separate AOG desk with 24/7 availability is being set up both in Canada and in Shenzhen. Expert technicians and engineers will be on site permanently at the same time in order to define the workscopes, which essentially means three independently operating AST® bases for the future.

Thus Lufthansa Technik is set to triple its capacity with the AST® expansion, with the faster response time to customer requests being the most important reason for the development. The installation of three independent AST® bases firstly means faster on-site availability with the customer but also lower costs because of the con-siderable reduction in transport costs for the tooling – often a significant factor when tonweight containers with tools have to be flown from Frankfurt to the respective deployment location. The expansion of the AST® network indicates that as founder of the AST® principle, Lufthansa Technik is not resting on its laurels, rather is investing increasingly in future development and changing customer demands in a dynamic market. The discussions the MRO provider is holding with various OEMs on the inclusion of new engines in the portfolio will also serve to underpin this future proofing. This ensures that the term AST® will remain synonymous in the future with optimal efficiency through on-wing or on-site maintenance at the customer’s location. Olaf Hamm Phone +49-40-5070-1763 [email protected]

Closer to the customer AST® deployments focus at present on performing planned modifications. The affected aircraft frequently are in a layover during which time the AST® teams then look for a suitable slot to perform the modification. Depending on the problem, the engine type and its suitability for rapid intervention, an

For more information: www.lufthansa-technik.com/ast

26 | Original Equipment Innovation

Lufthansa Technik Connection 5.2015

Intensive care unit on all long-haul routes New Supplemental Type Certificates (STC) have been granted for the installation of the Patient Transport Compartment PTC in Boeing 747-8 and Airbus A380 aircraft. Developed by Lufthansa Technik, the f­lying intensive care unit can therefore now be used for ­transporting patients on all Lufthansa long-haul flights.

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ufthansa can now offer its Patient Transport Compartment (PTC) in its entire network of long-haul flights from its hubs in the German cities of Frankfurt and Munich. Since 1999, the company has already been using the PTC on its Boeing 747-400 and Airbus A330/ A340 aircraft. A total of up to 100 intensive care patients are transported in the PTC by Lufthansa every year. Developed by Lufthansa Technik in cooperation with Lufthansa’s Medical Service, the new Patient Transport Compartment features a multitude of advantages compared to a conventional air ambulance, for example a time saving of up to 50 percent due to the fact that it is installed in an airliner, which can fly nonstop from South-America or Southeast Asia to Europe. The spacious interior of the compartment offers enough space for a patient bed, two seats for the doctor treating the patient and a Lufthansa

Perfect integration of the Patient Transport Compartment in the cabin. The new version is a lot roomier than its predecessor.

Medical Crew Member as well as intensive care equipment together with the required consumables and medication. The Patient Transport Unit Next Generation (PTU NG) forms the core of the compartment. The comfortable and flexibly adjustable bed is suitable for extreme long-haul flights. The 13,000-liter oxygen supply and electrical power supply of 1.6 kW enable the use for repatriation missions with flight times in excess of 15 hours. The PTU NG has a low system weight for rapid conversion. The robust and modular design allows adaptation to the specific needs of each individual customer including VIP, military and special mission

operations. In addition to a wide variety of options for accommodating medical consumables, medical equipment can be attached to the PTU NG itself or to a separate rack – depending on the requirement defined by the medical teams of customers flying the PTU NG without the compartment. Improved medical supply Extensive effort was required to obtain approval for the new, improved PTU NG owing to the rigorous tightening of airworthiness requirements in recent years. However, this was finally achieved thanks to the extensive and unique experience of

Events & Exhibitions | 27

Lufthansa Technik Connection 5.2015

Meet us at... 6 – 8 October 2015 | Munich

inter airport Europe Focusing on airport equipment, inter airport Europe is a worldwide recognized airport industry international meeting hub of vendors, decision makers, system integrators and buyers.

13 – 15 October 2015 | London

MRO Europe For maintenance, repair and overhaul, as well as manufacturing, at MRO Europe the latest standards for productivity and aerospace technology are presented.

21 – 23 October 2015 | Hunter Valley

RAAA Convention Lufthansa Technik’s design and certification engineering. The oxygen system integrated in the PTU NG was also approved in accordance with new stricter EASA requirements. As a product of the new Lufthansa Technik “Original Equipment Innovation” product division, the PTU NG is more than just a customized instrument for long-haul medical transport. It is also proof of the innovative strength of a company that continues to work on further projects to improve medical supply. In the area of Patient Transport & Medical Solutions Lufthansa Technik is developing further innovative products and services and

offers medical turnkey solutions for VIP and business jets as well as Medevac Special Mission operators. The expertise of the Lufthansa Technik medical care specialists is also available in the form of consultancy services concerning the integration of medical equipment in the PTU NG or the development of medical products. For example development is currently under way on a dedicated child restraint system as well as a special children’s oxygen mask.

The Regional Aviation Association of Australia (RAAA) Convention is highly regarded as a premier annual aviation event of the region.

3 – 5 November 2015 | Singapore

MRO Asia-Pacific MRO Asia-Pacific is the largest ­conference and exhibition in the region dedicated to the aircraft ­maintenance, repair and overhaul (MRO) market.

Eckhard Freimuth Phone +49-40-5070-3147 [email protected]

Preview Highlights of the next issue: • Aircraft Base Maintenance • Side-by-side engine teardown • Lufthansa Technik Shannon For more information: www.lufthansa-technik.com/ patient-transport-unit

For more information: www.lufthansa-technik.com/events

28 | Products & Services

Lufthansa Technik Connection 5.2015

Airbus

World of services No matter if you are a regional start-up, a small or mid-sized carrier, a private or governmental operation, or a legacy airline: Our range of products and services can be tailored for commercial and private fleets of every mix, kind and age.

A300/A310

Total Support Services Total Support Services are the first choice for any customer wanting to enjoy cost-efficient and reliable flight operations and focus on his core business at the same time. • Total Operational Support (TOS®) • Total Technical Support (TTS®) • Total Base Maintenance Support (TBS™) • Total Material Operations (TMO®) • Total Component Support (TCS®) • Total Engine Support (TES®) • Total Landing Gear Support (TLS™) • Aircraft Leasing & Trading Support (ALTS®)

A318

Line Maintenance Base Maintenance Component Services Engine Services: JT9D, PW4000-94, GE CF6-80C2

A300

A319

A318

Single Services Single services and shop load events such as letter checks, engine overhauls or repairs of single components are at the core of a unique assembly of products and services. • Aircraft Services • Component Services • Engine Services • Landing Gear Services • VIP & Executive Jet Solutions

A320

A319

A321

A320neo

H otl i ne

For more information: www.lufthansa-technik.com/services

A321

H

308

eServices Lufthansa Technik’s Technical Operations Websuite manage/m® allows operators to manage their technical operations via a web-based system.

A330

-4

+

Special Services The world’s leading manufacturer-indepenent MRO provider offers a product portfolio reaching beyond traditional MRO services from the manual. • Composite Repairs (ARC®) • Engine Parts & Accessories Repair (EPAR) • Maintenance Management Services (MMS) • Logistics & Training - 4 0 - 5 0 70 49 • AOG Services • Surface treatment otline Original Equipment Innovation – OEI Lufthansa Technik has successfully established a line of cabin products. • Cabin Management & IFE Systems • Aircraft & Cabin Equipment • Connectivity • Patient Transport Solutions

Airbus A300/A310

24/7 k AOG des

A340 A330

Airbus A318 Line Maintenance Base Maintenance Component Services Engine Services: CFM56 Completion

Airbus A319 Line Maintenance Base Maintenance Component Services Engine Services: CFM56-5, V2500-A5 Completion

Airbus A320 Line Maintenance Base Maintenance Component Services Engine Services: CFM56-5, V2500-A5 Completion

Airbus A321 Line Maintenance Base Maintenance Component Services Engine Services: CFM56-5, V2500-A5 Completion

Airbus A330 Line Maintenance Base Maintenance Component Services Engine Services: CF6-80, PW4000-100, Trent 700 Completion

Airbus A340 Line Maintenance Base Maintenance Component Services Engine Services: CFM56-5, Trent 500 Completion

A350 A340-300

Airbus A350 Line Maintenance, Component Services, Engine Services: Trent XWB

A380

Airbus A380 Line Maintenance Base Maintenance Component Services Engine Services: Trent 900 Completion

Products & Services | 29

Lufthansa Technik Connection 5.2015

Boeing 737

Regionals Boeing 737 Line Maintenance Base Maintenance Component Services Engine Services: CFM56-3 Completion

737 NG 737

Boeing 737NG Line Maintenance Base Maintenance Component Services Engine Services: CFM56-7B Completion

747 737NG/MAX

Boeing 747

Q-Series

Line Maintenance Base Maintenance Component Services Engine Services: PW100, PW150 Q-Series

CRJ

Boeing 757 Line Maintenance Base Maintenance Component Services Engine Services: RB211-535 Completion

757 767

CRJ 700

CSeries

Boeing 777-9X

vorläufige Zeichnung

777 777X

Bombardier CSeries in preparation

E-Jets

ERJ 190

Embraer E-Jets 170/175, 190/195, Line Maintenance Base Maintenance Component Services Engine Services: GE CF34

Boeing 767 Line Maintenance Base Maintenance Component Services Engine Services: PW4000-94, CF6-80C2 Completion

767 777

Bombardier CRJ Line Maintenance Base Maintenance Component Services Engine Services: GE CF34

Line Maintenance Base Maintenance Component Services Engine Services: JT9D, PW4000, CF6-80C2 Completion 757 747-8

Bombardier Q400

Boeing 777

Business Jets Airbus Corporate Jets

Line Maintenance Base Maintenance Component Services Completion

ACJ Line Maintenance Base Maintenance Component Services Engine Services: CFM56, V2500-A5 Completion

Boeing 777X

Boeing Business Jet

in preparation

Airbus Corporate Jetliner Line Maintenance

BBJ Base Maintenance Component Services Engine Services: CFM56-7B Completion

787

Boeing 787 Line Maintenance Component Services Engine Services* Completion

Bombardier

Challenger, Learjet, Global Express. Line Maintenance Base Maintenance Component Services Engine Services: CF34

*schedule to be defined

787

MD-11

MD-11 Line Maintenance Base Maintenance Component Services Engine Services: CF6-80C2, PW4000-94

Bombardier

Boeing Business Jet (BBJ)

Challenger Family

Embraer

Embrear Executive Jets

Embraer Legacy, Lineage. Line Maintenance Base Maintenance Component Services Engine Services: CF34

30 | Contacts

Lufthansa Technik Connection 5.2015

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

Lufthansa Technik Connection 5.2015

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] www.lufthansa-technik.com/ 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] www.lufthansa-technik.com/ india Lufthansa Technik Shannon Phone +353-61-370-000 Fax +353-61-361-100 [email protected] www.lufthansa-technik.com/ 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] www.lufthansa-technik.com/ vostok Lufthansa Technical Training Phone +49-69-696-2751 Fax +49-69-696-6384 [email protected] www.ltt.aero

Lufthansa Bombardier Aviation Services Phone +49-30-8875-4600 Fax +49-30-8875-4511 [email protected] | www.lbas.de Lufthansa LEOS Phone +49-69-696-8222 Fax +49-69-696-93888 [email protected] www.lufthansa-leos.com Airfoil Services Phone +603-6145-3612 Fax +603-6141-6810 [email protected] www.airfoilservices.com Ameco Beijing Phone +86-10-6456-1122 ext 4100/4101 Fax +86-10-6456-1823 [email protected] www.ameco.com.cn BizJet International Phone +1-918-832-7733 Fax +1-918-832-8627 [email protected] www.bizjet.com Hawker Pacific Aerospace Phone +1-818-765-6201 Fax +1-818-765-5759 [email protected] www.hawker.com Heico Aerospace Phone +1-954-961-9800 Fax +1-954-987-7585 [email protected] www.heico.com IDAIR Phone +49-40-5070-69416 Fax +49-40-5070-64144 [email protected] www.idair.aero lumics Phone +49-40-5070-61361 [email protected] www.lumics-consulting.de N3 Engine Overhaul Services Phone +49-3628-5811-0 Fax +49-3628-5811-8240 [email protected] www.n3eos.com Spairliners Phone +49-40-5070-66499 Fax +49-40-5070-66742 [email protected] www.spairliners.com

A never-ending story.

N O

O N I

I N

V

A T

Lufthansa Technik is synonymous with innovation. Thanks to creative engineering work and cuttingedge research facilities, we constantly set new standards. Alongside the continuous further development of maintenance, repair, and overhaul procedures, we develop new technologies, cabin products, and servicing processes for aviation. Always striving for the highest quality and safety standards, we are able to guarantee technological excellence. Lufthansa Technik AG, [email protected] Call us: +49-40-5070-5553

www.lufthansa-technik.com/innovation

More mobility for the world