The Lufthansa Technik Group Magazine

5.2016 September/October

First Ka-band high-speed internet

Seamlessly connected

Corporate Sales

“Compete and collaborate”

Lufthansa Technical Training

“The one” maintenance training organization

Aircraft Production Inspection

Values more than skin deep

2 | Content

Lufthansa Technik Connection 5.2016

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News • VIP & Special Mission Aircraft: Laser-supported assembly Aircraft Modification • Ka-band high-speed internet: Seamlessly connected • Electronic Flight Bag: The connected cockpit

Seamlessly connected

Lufthansa Technik Group • Lufthansa Technical Training: “We want to be the OneMTO”

Lufthansa Technik has received type certificates for the installation of high-speed internet via the Ka-band.

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Aircraft Services • Aircraft Production Inspection  14 Program: Values more than skin deep • Interview with Daniel Schiffer: 17 “Through the eyes of an airline”

“We want to be the OneMTO” Rubin Siddique, CEO of Lufthansa Technical Training, explains how his company is preparing for the future.

11 14 Values more than skin deep The Aircraft Production Inspection Program (APIP) is a market-leading service.

“Compete and collaborate” Robert Gaag, Senior Vice President ­Corporate Sales EUMEA, talks about today’s market perspective.

Innovation and technology • Research and development: 18 Understanding engine aging • Finding cabin leaks: 26 Pressure test made easy • »chair« receives ETSO certification: 27 Ready for production Events and exhibitions • Aircraft Leasing & Trading Support: 19 Lessors’ get-together in Dublin Employee portrait • Matthias Schulz: The equipment master

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Corporate Sales • Interview with Robert Gaag: “Compete and collaborate”

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VIP & Special Mission Aircraft Services • Cooperation with DC Aviation: 25 Local VIP services in Dubai Categories • News 4– 5 • Events 27 • Products and services 28 • Contacts 30 Lufthansa Technik Connection is a complimentary information service for Lufthansa Technik’s family and friends. Published every two months. This and earlier issues can be downloaded from our website www.lufthansa-technik.com/connection

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Publisher Lufthansa Technik AG Kai Raudzus · Corporate Marketing · HAM TS1/M Weg beim Jaeger 193 · 22335 Hamburg, Germany Infoline +49-40-5070-5553 · Fax +49-40-5070-8860 [email protected] · www.lufthansa-technik.com Angela Huber-Saffer · Database management Editorial production Editorial office: Flightlines, Hamburg Design: Art Works!, Hamburg Photos: Lufthansa Technik AG, Deutsche Lufthansa AG Printing: Beisner Druck GmbH & Co. KG

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Augmented Reality at your fingertips

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Lufthansa Technik Connection 5.2016

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Augmented Reality (AR) is gaining increasing foothold in industrial work processes. ­Lufthansa Technik’s VIP & Special Mission Aircraft Services product division has introduced an AR system which supports structural assembly work in the cabin.

With support of the laser, correct positioning of the fitting becomes easy.

www.lufthansa-technik. com/en/pmu

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ugmented Reality offers users additional information in real time over and above what users actually perceive. AR systems provide the combination of the real world with the virtual world, enabling the real spatial world to be supplemented by virtual elements and data. Numerous companies are already using Augmented Reality as a core technology for enriching and complementing reality with computer-generated contents. Laser-based AR system Augmented Reality, i.e. fusing the 3D reality with data, allows innovative procedures and methods to be implemented. Lufthansa Technik is already using the opportunities afforded by Augmented Reality with the goal of optimizing production, maintenance and inspection processes. Structural work in VIP completion projects is one example. In the past, mechanical measurement and alignment tools requiring manual work were exclusively used for installing primary structural connections in the frame of

initial completion of VIP aircraft. This required a significant effort for calibrating installation positions as well as long set-up times. To reduce the level of effort required for these installations, Lufthansa Technik has introduced a laser-based AR system for supporting the installation work as part of the “projection-based installation support” project. A mobile laser projection system is used, which can be flexibly positioned and aligned in the aircraft fuselage corresponding to the respective installation situation. Based on the contents of the mechanics current job card, the installation template is projected onto the work environment for the responsible mechanic. The template corresponds to the component contours selected in the virtual 3D model, which are projected onto the structure in the correct position, acting as a positioning and alignment aid for the component to be installed. With no interruptions or other interactions, the employee can install the component with high precision, a process which is significantly more efficient than

using conventional alignment tools. In the first completed project phase the technical implementation of the laser projection system was demonstrated both on a mock-up in the training workshop and in practice on aircraft modification. Today, the system has been successfully proven in three layovers. The results are convincing: Not only was the precision significantly increased when installing primary structural connections (T-Rails), but the amount of work required was almost cut in half. Lufthansa Technik is currently testing additional applications of projection-based Augmented Reality, for example in the form of foiling and painting templates. The use of future digital assistance systems for other departments is also being examined at present for use in a larger-scale innovation project. The preparations for the project are already underway.

Moritz Gaack Phone +49-40-5070-67961 [email protected]

4 | News

Lufthansa Technik Connection 5. 2016

Hamburg

Connecticut

Arnstadt

London

Trent XWB overhaul N3 Engine Overhaul Services // The joint enterprise of ­Lufthansa Technik and RollsRoyce plc., N3 Engine Overhaul Services (N3), will begin overhauling the latest RollsRoyce engine, the Trent XWB, which powers the Airbus A350, from October 2016. Parent companies Lufthansa Technik and Rolls-Royce reached an agreement to this effect based on Deutsche ­Lufthansa’s autumn 2013 ­decision to order 25 Airbus A350-900 aircraft. Lufthansa is expected to take its first A350 into service in the second half of 2016 and will allow ­Lufthansa Technik to take care of its entire A350 fleet in all aspects of aircraft maintenance and spare part supply. The Trent XWB is the fourth Trent engine type in the product portfolio of N3. Now employing a staff of over 600, the company currently overhauls around 100 civil large aero engines per year from the Rolls-Royce Trent 500, 700 and 900 series. //

GE9X and GEnx-2B services

Strategic agreement with Pratt & Whitney

Engine Services // Lufthansa Technik and GE Aviation have signed new long-term agreements for maintenance services for the GE9X and GEnx-2B engines. The GE Branded Services Agreements (GBSA) for the GE9X and GEnx-2B include comprehensive TrueChoice™ Materials agreements and provisions for technical support and assistance on overhaul work­ scoping, component repair licenses, joint repair development and training. The agreements facilitate establishment of a planned GE Aviation and ­Lufthansa Technik joint venture overhaul facility due to open in 2018. “We are building on our long-standing relationship with Lufthansa Technik to provide customers industry-leading MRO offerings to optimize their cost of ownership,” said GE ­Aviation Services President and CEO, Kevin McAllister. “We have done two further important steps in our common efforts to offer the best possible services for these two state-ofthe-art engine types. I am really looking forward to continuing this successful cooperation,” added Dr. Johannes Bussmann, chairman of the Executive Board at Lufthansa Technik. //

Geared Turbofan™ services // Engine manufacturer Pratt & Whitney and Lufthansa Technik have signed a strategic agreement, making the MRO provider a key member of the Pratt & Whitney Geared Turbofan (GTF) engine MRO network for services on PW1100G-JM and PW1500G engines. The GTF engine network currently includes Pratt & Whitney and its GTF engine collaborators, MTU Aero Engines and Japanese Aero Engines Corporation. Together with Lufthansa Technik, these companies will deliver the highest level of maintenance support and value to customers with facilities strategically located worldwide. “Lufthansa Technik will serve the full scope of MRO services and will bring long-lasting and leading expertise in engine overhaul, engine parts repair and engineering support to this co-operation,” said Dr. Johannes Bussmann, chairman of the Executive Board of Lufthansa Technik. “The GTF engine maintenance network consists of the best MRO providers in the industry,” said Matthew Bromberg, president of Pratt & Whitney Aftermarket. “We are proud to enter into this relationship with ­Lufthansa Technik to tap into its valuable maintenance expertise and expand our customer services to meet aircraft operators’ ever-changing needs.” //

Warehouse at Heathrow Component Services // Lufthansa Technik is opening a new warehouse for component supply at London Heathrow Airport. With this local presence in the United Kingdom, Lufthansa Technik is further consolidating its supply network for customers within Europe and significantly shortening the supply times for British customers. In opening this new warehouse location, Lufthansa Technik is underlining the importance of its British customers and the British aviation market. The state-of-the-art facility, in operation 24/7/365, and the seamlessly integrated transport ­concept allow the company to even better fulfill the high quality exectations of its customers. The regional proximity means that equipment can be delivered airside to any airport in the UK in just a few hours. Located directly at London Heathrow Airport, the new site also facilitates the quickest possible transport connections to international destinations. //

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Lufthansa Technik Connection 5.2016

Hamburg

Taipeh Aguadilla

First A350 APU in Hamburg shop

Hamburg

TCS® for China ­Airlines A350 fleet

Opening of third bay

Total Component Support // Lufthansa Technik and China Airlines have entered into a long-term agreement for component services (Total Component Support, TCS®) for China Airlines Airbus A350 fleet. The services covered include maintenance, reliability monitoring, reliability enhancement programs as well as logistic services. Lufthansa Technik will also provide worldwide AOG support for China Airlines modern widebody. C. J. Huang, Senior Vice President at China Airlines said: “After a long selection process we came to the conclusion that Lufthansa Technik could offer us the high level of performance and reliability that we need for the component support of our new A350 fleet. We believe partnering with Lufthansa Technik is a win-win strategic move and will further strengthen the collaboration between China Airlines and Lufthansa Technik.” Lufthansa Technik has been responsible for supplying material for China Airlines’ A330 and A340 long-haul fleets under a TCS® contract since 2010. //

Lufthansa Technik Puerto Rico // The third bay has started operating at Lufthansa Technik Puerto Rico. The new bay is a heavy maintenance line performing C-checks and cabin modifications similar to the existing two operating bays in the hangar. It will be the ­second line for Spirit Airlines. “We are proud to have redelivered 33 aircraft to our two launching customers in the first year so far. This accomplishment has only been possible because of the dedicated work of our whole team and the trustful relationship with our customers,” said Elmar Lutter, CEO of Lufthansa Technik Puerto Rico. There are already 15 checks scheduled in 2016 for the new bay and 17 for 2017. A third standalone cabin modification line for Spirit ­Airlines is planned to open in September 2016. Lufthansa Technik Puerto Rico started its operation in July 2015, and 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 narrowbody aircraft. //

On-site engine services Cooperation // Pratt & Whitney and Lufthansa Technik have announced that Lufthansa Technik will become Pratt & Whitney’s principal provider of mobile engine maintenance services for V2500, PW1100GJM, PW1500G and PW1900G engines. This new cooperation will provide Pratt & Whitney customers with more efficient and cost-effective engine maintenance. “This agreement significantly strengthens our leading role as a global technical services provider for engine overhaul and mobile support. The increasing trend towards light engine maintenance is crucial to avoid unscheduled engine removals as well as cost-intensive, timeconsuming maintenance,” said Dr. Johannes Bussmann, chairman of the Executive Board of Lufthansa Technik. “This expanded capability offers Pratt & Whitney customers the most tailored maintenance possible with the least impact to their operations,” said ­Matthew Bromberg, president of Pratt & Whitney Aftermarket. “Lufthansa Technik’s on- or near-wing services, performed when and where they are needed, help us provide faster service to our customers.” //

APU Services // ­At the end of July, Lufthansa Technik has received the first HGT1700, the Auxiliary Power Unit (APU) of the Airbus A350, in its shop in ­Hamburg. Before reaching the expected time to a routine check, the engine operated by a ­Lufthansa Technik customer was damaged during operations and brought to Hamburg for an initial test run and repair. Lufthansa Technik’s APU shop commenced preparation for maintenance, repair and overhaul of the ultramodern HGT1700 APU starting in 2014, receiving the approval of the aviation authorities in August 2015. This first HGT1700 shop event ushers in a new era in APU overhaul in Hamburg. Up to three further APUs of this type are expected to make a shop visit in 2016. As of 2017, about 20 APU of this type are expected to arrive every year. //

Stay up to date! Customer Newsletter // Lufthansa Technik’s online customer newsletter Connection Flash supplements our popular ­bi-­monthly Lufthansa Technik Group ­Magazine Connection with first-hand news on innovative technologies and developments, new services and offers, and future events. //

www.lufthansa-­ technik.com/­ customer-newsletter

6 | Aircraft Modification

Lufthansa Technik Connection 5.2016

Seamlessly connected around the globe With two Supplemental Type Certificates (STC), Lufthansa ­Technik has shown that high-speed internet via the Ka-band can be ­implemented quickly and cost-effectively. Preparations are now underway for modification of other aircraft types in airline and VIP use.

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earning from experience: Lufthansa system was needed. A system that also Technik started the process back in allows internet connectivity on short-haul 2002 when Lufthansa’s long-haul fleet fleets. The decision was made last year in was connectivity-readied. The Connexion favor of a consortium involving Inmarsat as by Boeing broadband system operated a satellite operator in the Ka-band, Honeysuccessfully up until 2006, when the satelwell as a hardware supplier, and Lufthansa lites were discontinued. The program was Systems for software, and portals and then resumed in BoardConnect as a 2009 with the new distribution system. partner Panasonic Lufthansa Technik under the banner is responsible for Our ability lies in integrating such FlyNet® 2, running development, systems in the aircraft so that very successfully to approval and instalthey can operate reliably. Because date and providing lation. The compawe partner a number of manuthe airline with an ny has gained vast facturers we are really neutral. Nina Schulz important means of experience from product differentiainstalling such systion. With internet on board increasingly tems in various aircraft and has learned, being assumed as a given and the requiretogether with the system manufacturers, ments in terms of bandwidth and coverage how to overcome teething troubles relating escalating significantly, a forward-looking to engineering, production and material issues. With the Supplemental Type Certificates (STC) that are now available for the Airbus A320 family and the A340, the company can offer an all-inclusive package that includes development and approval of the entire system for an aircraft type or a fleet. Lufthansa Technik is not only predestined by the experience of integrating the systems, especially the large antennae, but also the capacity of the group’s network. Simultaneous conversion of up to ten aircraft is possible and allows a fleet to be retrofitted in record time. Nina Schulz,

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Head of Product Sales & Partnerships Aircraft Modification at Lufthansa Technik, clarifies: “We are now at the starting point and can cover the topic fully – from design to integration through to subsequent operational support.” Worldwide coverage Stefan Barck, the responsible Project Manager for Aircraft Modification, is in no doubt: “The Ka-band is the future.” He has an entire series of arguments to back up

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Lufthansa Technik Connection 5.2016

INMARSAT > Coverage map > Global Xpress

Global Xpress coverage Global Xpress coverage 90° 80° 70° 60° 50° 40° 30° 20° 10° 0° 10° 20° 30° 40° 50° 60° 70° 80° 90° 180°

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I-5 Indian Ocean Region

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Global Xpress network available over at least 99% of this area

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Extendable Global Xpress coverage via steerable beams

This map depicts Inmarsat’s expectations of coverage, but does not represent a guarantee of service. The availability of service at the edge of coverage areas fluctuates depending on various conditions. Global Xpress coverage June 2015.

inmarsat.com/globalxpress

his view. The Inmarsat Global Express (GX) network offers worldwide coverage using three satellites. The Ka-band is still relatively underused but at the same time provides users with the latest technology. Apart from a large main antenna, the satellite has six other small antennae, which can be controlled individually. This spot-beam technology allows areas with increased demands to be supplied more efficiently. Barck goes on to say: “The latency during a change from one satellite to another is also shorter because the  P

Using three geostationary satellites, the Ka-band solution provides global coverage.

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Lufthansa Technik Connection 5.2016

Connectivity choices • System Ka-band/Ku-band • Operation Short-range/long-range • Utilization Commercial/VIP • Installation Lufthansa Technik network (customer site) • Service Global network

The wireless access points require careful planning and installation of the wiring.

connection handoff – the so-called handshake – is more effective. It is therefore possible to fly practically seamlessly around the world.” This feature means that the system is also suitable for long-haul use. STCs for new types Additional aircraft types are consequently in preparation, for example the Airbus A330 and Boeing 777. Development of an STC takes around one year, with every location in the network being conceivable in principle for this purpose. Stefan Barck does not even want to exclude the possibility of an STC in the customer’s shop: “While it is easier to work in a local facility with its tailored processes, we will go where the customer wants us. For example, we once performed a system upgrade in New Caledonia following on from a retrofit in Singapore.” Incidentally so-called T-Pad Compliance is also part of the STC, in other words proof of avionics immunity

through the wireless network. When developing the conversion, emphasis was placed on remaining neutral in terms of VIP or commercial configurations, so there are no specific differences here. The Cabin Distribution System (usually BoardConnect) was approved separately – the customer therefore also has a choice in this regard. Considerable efforts were made to achieve a short layover. The aim is a conversion time of four days. Nina Schulz is in no doubt: “This is not something another company can achieve lightly – and especially not from a single source.” Freedom of choice Even if a customer prefers the Panasonic system, this is not a problem for Lufthansa Technik. Nina Schulz comments: “Our ability lies in integrating such systems in the aircraft so that they can operate reliably. Because we partner a number of manufacturers, we are really neutral.” And

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Lufthansa Technik Connection 5.2016

ZAL TechCenter

www.lufthansa-technik. com/connectivity

Stefan Barck goes on to say: “The same know-how is required to install the antennae for the two systems. We place great emphasis in this respect on low maintenance and the ease of installation. We try to get by with minimum changes.” This is an important aspect especially for leasing aircraft, because the re-conversion is then also simpler. Whether the alternatives are commercial or VIP aircraft, Ka-band or Ku-band, short-haul or long-haul – Lufthansa Technik can develop and implement a solution at short notice to meet every requirement for high-speed connectivity – and thus supply an essential component in guaranteeing passenger satisfaction in the aircraft cabin of tomorrow.

support. This so-called European Aviation Network (EAN) is in principle an LTE (Long Term Evolution, a mobile phone standard) network for the aviation sector, which will again offer higher speed and greater capacity at a lower cost. Since it is based on ground stations, it is especially interesting for airlines operating on a continentwide basis, in other words regionals. And because a small antenna on the fuselage belly requires much less effort to install, this will without doubt be the preferred solution in this segment. Lufthansa Technik has commenced development and is planning to install the first system in 2017.

Direct air-to-ground

Nina Schulz Phone +49-40-5070-67351 [email protected]

Lufthansa Technik is also getting ready for the next step in on-board connectivity, a direct air-to-ground system without satellite

Stefan Barck Phone +49-40-5070-65032 [email protected]

Video presentation // Setting out to enhance the networking of the civil aviation industry in Hamburg and simplify cooperation between the participating companies, the “ZAL – Center of Applied Aeronautical Research” has commenced operations. ­Lufthansa Technik is one of the main shareholders in the forward-looking research facility. To learn more about the ZAL, please use the link below:

www.lufthansatechnik.com/en/zal

10 | Aircraft Modification

Lufthansa Technik Connection 5.2016

The connected cockpit Pilot cases packed with manuals are already obsolete in many cockpits thanks to the introduction of the Electronic Flight Bag (EFB) – with the added benefit that the electronic data is easily kept up to date. Lufthansa Technik has now connected the EFB ­electronically with ground stations, thus opening up revolutionary new opportunities.

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ufthansa Technik offers an entire series of options for upgrading aircraft with Electronic Flight Bag, with different configurations and devices available from laptops to tablets. For example ­Lufthansa has opted for Microsoft tablets as devices for its aircraft. Due to a fixed mounting solution as well as power and data connection to the aircraft, pilots are able to use their tablets for planning and performing their flights by using relevant aircraft data. The system offers outstanding reliability and security and is now clearly the preferred choice of pilots. In a further development, Lufthansa Technik is now introducing a connectivity solution for the EFB. Two Airbus aircraft (A340 and A320) were modified in the first stage for test purposes. Communication between ground stations and aircraft is carried out initially via ACARS (Aircraft Communications Addressing and Reporting System). Despite the relatively low bandwidth available, completely new operational advantages can be gained as a result.

Up-to-date weather The latest weather information can be sent to the cockpit during the flight. The availability of up-to-date weather maps may result in changing the flight path. Such decisions have no longer to be taken solely on the basis of the pre-flight briefing and radio communication with pilots of other aircraft. The flight deck crew can therefore make a more informed and thus better decision – for example on the best path to take around a weather front. Not only does this lead to enhanced security, rather the efficiency of the flight operations can also be improved. Another option that can likewise improve efficiency considerably is the introduction of 4-dimensional flight planning. The EFB has a special software module installed for this purpose from the aerospace software provider PACE in Berlin. This solution combines the flight data with the latest weather information and calculates the most efficient flight path to the destination airport including the optimum speed and presents this information to the pilots. This option allows the prevailing wind conditions to be exploited optimally. Such a wind-optimized route results in shorter flight times, lower fuel consumption, and therefore a more efficient flight. Location services EFB connectivity essentially allows the communication channels to be used for additional information. For example, the aircraft position can be transmitted to the ground. Higher bandwidth transmission between ground stations and aircraft is

also possible by switching to the newly available Ka-Band communication channel. A team of Lufthansa Technik developers is currently working on the live streaming of aircraft parameters, for example, which are normally stored in the Flight Data Recorder (FDR) or which can be used for predictive maintenance. The EFB therefore offers entirely new possibilities for flight deck crews and supporting ground stations. Customers can benefit from this in many aspects, for example through the extensive range of options available for the EFB equipment. Heike Handke, Product Manager Aircraft Modification, sums up the Lufthansa Technik philosophy: “We integrate the best systems available on the market. We do not have to sell specific systems, rather we adopt a neutral consultancy stance. This means we can put together the best possible solution for the customer.” The flexibility of the connectivity solution from Lufthansa Technik for the EFB system also means that personal EFB devices of every pilot can be upgraded without any difficulty. When upgrading – for example when a new tablet generation is introduced on the market – the aircraft installation remains the same. Lufthansa Technik is therefore the partner of choice for the role of integrator – from consultancy to the philosophy of the EFB system through to installation and commissioning. Moreover, good contacts with the aviation authorities also ensure that approval, which is often seen as a hurdle, is handled reliably. Holger Driesner Phone +49-40-5070-8739 [email protected]

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Lufthansa Technik Connection 5.2016

www.ltt.aero

“It’s our goal to be the OneMTO” With its expert employees, new teaching and learning methods and continuously adapted processes, Lufthansa Technical Training (LTT) is preparing to meet its goal of becoming “the one” maintenance training organization – or OneMTO. Connection talked to Rubin Siddique, Chief Executive Officer of Lufthansa Technical Training.

You took over as CEO of Lufthansa Technical Training at the beginning of April 2016. How new was this task for you? Rubin Siddique: I was Chief Commercial Officer before I took on the management of the company. Even so, now my role is different – and significantly more farreaching: In addition to the business administration, I bear responsibility for production and thus overall responsibility for all the Lufthansa Technical Training locations worldwide. How do you see the company from the perspective of your new position? I took over a company that was once again fundamentally restructured over the past two years, so that we can now lead it into

the future. This transformation process is not concluded yet, but since April we have identified the most important fields of action for the future. Our company has many committed, expert employees who are strongly anchored at Lufthansa Technical Training as a company and in the topic of maintenance training, and at the moment they are buffering the things that aren’t working quite as smoothly in our current processes as we hope they will in the future. You mentioned fields of action and other changes. What role do you envision for Lufthansa Technical Training in the market in the future? It’s our goal to be the OneMTO – that is, “the one” maintenance training organization. This means first of all that we need to

be the competence center for the entire Lufthansa Group on the topic of maintenance training – above and beyond our role for our parent company, Lufthansa Technik. But it is also very important that we become the main provider for our customers outside the Lufthansa Group. When our current and future customers think about maintenance training, they  should immediately think of Lufthansa Technical Training. In that connection, we want to work more strongly with the OEMs in the future, because we can create genuine added value for them on the training side. A good example of that is the Bombardier C Series: Here we are the worldwide exclusive Authorized Training Provider and have already received very good feedback from the first participants.  P

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Lufthansa Technik Connection 5.2016

How will Lufthansa Technical Training develop with regard to teaching and learning methods? The keyword here is “new learning”, and it has been defined as a field of action. This involves, for one thing, the topic behind terms such as Industry 4.0 and digitalization: that is, the question of which digital media, communication paths and learning paths are right for us. We’re very active here and are investing heavily in a corresponding program. However, new learning doesn’t just mean technological change; it also refers to the modernization of didactic concepts – the question of how learning can actually be structured differently. That includes such things as how to create a higher degree of interaction in simple classroom training.

every training course we offer. We need to improve in that regard, and we will.

The offer and teaching methods are one side of the coin. What other topics does Lufthansa Technical Training need to master to be visible on the market? First, there’s the topic of operational stability: Owing to all the changes we have already made, we’re not quite as stable as we want to be. And where we want to go is very clear to us: We want to ensure the smooth flow of

How do you plan to achieve this? We plan to establish a continual improvement process that shall become part of the company’s DNA. Every employee needs to know when he or she should raise a hand and say that a process needs to be changed because certain parameters have changed. Ultimately, these continually improved processes will contribute massively to the topic of stability, and that, in turn, is an important platform for achieving our vision of OneMTO and the sustainable implementation of new learning.

How are the processes doing? That’s another topic that I see as a cornerstone of our work. In our six fields of action, I call this “adaptive processes”. The other improvements we’ve already achieved and still want to achieve – starting with production and manpower and all the way to the right relationship between quality and price – won’t unfold their full and sustainable value for our customers unless we continually monitor and adapt the processes. In the face of ever faster changes in the aviation industry as a whole, we need to adjust our processes continually to current conditions, and that is a very clear goal for the near future.

Where do you still see a need for action? The core of our work as I’ve described it here is framed by two essential topic areas. One is our competitiveness: Our customers should experience a product that corresponds qualitatively to the expected price, so that they see no reason to change training providers. The challenge here is that training quality is more difficult to compare than the quality, for example, of an object such as an aircraft component. At the end of training, what matters is not just the certificate. Far more important is what the individual participants take home in terms of learning and competence and whether they can apply that learning correctly in their future work. In the process, what’s decisive is what the customer wants. That becomes the focus of our action insofar as we can reconcile it with our standards of quality and safety. The central question is: How can we fulfill the needs of our customers optimally, and what does our offer look like in this regard? You mentioned another cornerstone... Yes, another important field in a service company like ours is an open culture. As a training provider, we are very dependent on the performance readiness and motivation of our employees. Each of them contributes to the success of Lufthansa Technical Training. We want our employees to do what they do with passion and dedication, and that’s what our customers should sense, ultimately: that they are dealing with a highly competent

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Lufthansa Technik Connection 5.2016

About Lufthansa Technical Training

company, a reliable partner, and in particular with committed people who teach them facts they didn’t know before. What sets Lufthansa Technical Training apart from the competition? What the customer already receives – and this will be even stronger in the future – is a comprehensive product portfolio. A professional customer, whether an airline, an MRO provider or an OEM, can get an endto-end portfolio of maintenance training at Lufthansa Technical Training. The second thing, and this factor distinguishes us hugely from the competition, is that we are part of the world’s leading MRO provider, Lufthansa Technik. For customers, that means training that reflects the operator’s view of an aircraft. At Lufthansa Technical Training, trainees receive more than just knowledge of, for instance, new aircraft types; they also get in-depth insights into the way those types actually behave in daily operations and the benefit of our experience of what is and isn’t important above and beyond the handbook. How does this special competence manifest itself with new products? We are able to create brand-new products and pursue new approaches especially because of our experience, whether that calls for establishing a new training facility in Asia or actively fulfilling our role in maintenance training for a new aircraft type such as the Bombardier C Series. At the moment we also bear the primary responsibility for training for three aircraft now undergoing their entry into service at the Lufthansa Group: the A320neo, the A350 and the C Series.

Translating the new aircraft types and especially their new technology into sensible, operator-oriented training concepts is a challenge, but one that we have mastered very well to date and in close cooperation with the manufacturers. Where do you see Lufthansa Technical Training over the long term? Lufthansa Technical Training will bundle its competences more strongly and use digital media much more intensively in its training. Over the long term, I see us as a force to drive forward the topic of maintenance training fundamentally and develop concepts that can be offered to our customers’ trainees increasingly in cooperation with partner companies. We will be an integral partner within the Lufthansa Group, and all our other customers will benefit from this expanded knowledge and portfolio. Our participants should have fun taking part in our training courses and our customers should enjoy having us meet their training needs.

// Founded in 1995 as a 100 percent subsidiary of Lufthansa Technik, Lufthansa Technical Training is a global training provider for staff involved in the Maintenance, Repair and Overhaul (MRO) industry for aircraft, engines and aircraft components of civil aviation. Lufthansa Technical Training covers all aspects of training important for safety-, reliability- and cost-sensitive qualifications, ranging from vocational training, basic technical training and type-related further training to competence training. The company’s extensive experience and knowhow make it possible to conduct professional training for manufacturers and suppliers of aircraft for civil and military aviation, aviation-related companies as well as for other industrial sectors in which the aspects safety, reliability and economic efficiency have the highest priority. // Features • Aviation technology training (EASA Part-147 and Part-66) • Approvals: EASA, Singapore, Canada, U.A.E., Russia etc. • Aviation technology vocational training • Toolmaker vocational training • Basic training • Type training (Airbus, Boeing, Bombardier, Embraer, Fokker) • Competence training (engineering, management and language competencies) • E-learning capabilities • Consulting services • State-of-the-art classrooms

Training finder: www.ltt.aero/en/training-finder

The Lufthansa Technical Training app is dedicated to aviation ­enthusiasts, technically interested people and aviation professionals. It is optimized for iPad and can be downloaded via iTunes.

14 | Aircraft Services

A350 production inspection // Highly experienced Lufthansa Technik Aircraft Production Inspection Program (APIP) staff is directly embedded in the Airbus production facilities. Lufthansa Technik’s experience and know-how from looking after customer fleets worldwide on a day-to-day basis means it receives continuous feedback in the areas of technical quality and operational flexibility. Customers can thus benefit from reduced maintenance costs and downtimes in flight operations – and achieve the maximum safety and reliability for their new A350 from the beginning. Shown here is Lufthansa’s first Airbus A350-900 (MSN074) nearing structural completion at the Toulouse final assembly line. //

Lufthansa Technik Connection 5.2016

Aircraft Services | 15

Lufthansa Technik Connection 5.2016

Values more than skin deep Now available for the A350, an independent production i­nspection through Lufthansa Technik’s Aircraft Production Inspection ­Program (APIP) is an ideal product for both established and new aircraft types. The early detection of production defects during ­aircraft production are the basis for optimized costs and reliability in flight operation as well as securing a long-term asset value.

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hile the Aircraft Production the first “Section Inspection” module is Inspection Program (APIP) at only relevant for the European aircraft first glance involves quality conmanufacturer. “This is the only chance for trol of the production of new aircraft, customers to perform acceptance of specific “advantages such as improved reliability sections,” explains Daniel Schiffer. “Once and also sustainable benefits are more the sections have been assembled, cerobvious at second glance,” explains Daniel tain critical areas are no longer accessible Schiffer, Head of Aircraft Production in the final assembly stage in Toulouse or Inspection Program at Lufthansa Technik. Hamburg. This especially affects the wing Even though such structure.” The proan independent induction inspection of spection is not relethe first segments of Our service maximizes vant from the perthe Lufthansa Airbus ­the reliability and longevity spective of aviation A350 is currently of an aircraft. law, it is precisely underway. Seven airDaniel Schiffer these advantages craft of this type will that come to light at undergo the APIP for second glance that underscore the susthe Lufthansa Technik parent company tainable value of this product (see interalone in the next two years. view). Thanks to its experience with daily flight operations, Lufthansa Technik is a Final assembly and delivery global market leader when it comes to this complex service. There is a fixed schedule of work for the second “Final Assembly” module for all Modular product structure areas of the aircraft, for example fuselage, wing structure, sections, cabin, systems, APIP is modular by design, which means paint, etc. This work will be carried out in that customers can choose individual the framework of a different number of services to suit their respective needs. inspections over the production period Because Airbus, unlike Boeing, also offers depending on the aircraft type. While this selective inspections throughout Europe, involves around 30 inspections for the  P

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16 | Aircraft Services

Lufthansa Technik Connection 5.2016

Aircraft Production Inspection Program – APIP Marketed under the name of Aircraft Production Inspection Program (APIP), Lufthansa Technik offers independent production inspection to both airlines and leasing companies. APIP is a modular product under which, if the customer so requests, the entire production process is scrutinized. APIP modules • Section Inspection (Airbus) • Final Assembly Inspection • Delivery/Final acceptance 

Supplementary services • Concession Assessment • Acceptance Flight Crews • Aircraft delivery, ferry and positioning flights Capabilities • Airbus (all a/c types) • Boeing (all a/c types) • Bombardier • Embraer ERJ/E-Jets • ATR

A320 family, there could be up to 250 inspections in the case of the Boeing 777 and even more than 400 inspections in the case of the 747-8. The inspectors must be on site and at the aircraft within a short response time of 30 minutes in order not to hold up the assembly unnecessarily or even miss important inspections. Lufthansa Technik therefore has employees permanently stationed at the main production locations of the two major aircraft manufacturers. Customers ultimately have two options for the “Delivery”: Lufthansa Technik can

deploy a consultant who is on hand for the customer during the entire final acceptance, but if the customer needs more support an entire Lufthansa Technik team can perform the final acceptance in full, with the result that “the customer virtually just has to provide someone to sign the documents and the pilots for the ferry flight home,” explains Daniel Schiffer. Standardization and reporting While the modular structure of the APIP product has been the foundation for the

Aircraft Services | 17

Lufthansa Technik Connection 5.2016

“Through the eyes of an airline” Daniel Schiffer, Head of Aircraft Production Inspection Program, explains the added value of an independent production inspection thanks to expertise from daily operation of fleets worldwide. Are findings actually dangerous with a new aircraft? Daniel Schiffer: Our findings are in most cases not safety relevant. Airbus and Boeing both have quality systems in place that ensure all aircraft adhere to the industry’s high safety standards. Why are aircraft owners nevertheless turning to this service increasingly? While the aircraft are safe to operate with our without additional inspections by the customer, our service maximizes the reliability and longevity of an aircraft. Our findings and their rectification prevent AOGs, shortened maintenance intervals and surprises during line and base maintenance events that cost the airlines ­material, time and subsequently a lot of money.

www.lufthansatechnik.com/apip

product since it was launched some ten years ago, market demand has reached a critical level, which has necessitated standardizing the process consistently at all production locations across Europe (Toulouse, Hamburg) and the US (Renton, Everett, Charleston, Airbus in Mobile, Alabama). “This was necessary also because some of our major customers have their new aircraft in production in parallel at different locations and they expect to get the same product across the board,” says Schiffer. Specialists at Lufthansa Technik are currently supervising the final

What part does the experience of the inspectors play here? Our employees look at the aircraft through the eyes of the airline. They have many years’ experience from the line and base maintenance of all popular aircraft types and are well aware of the weaknesses of

assembly of around 20 aircraft at the same time at the different production locations. Innovative and transparent reporting allows customers to maintain an overview of the findings at all times. Every deviation and the corresponding correction by the manufacturer are recorded. If the corrections are not completed to the customer’s satisfaction, they are rejected and reported later if appropriate in the Commitment Letter. “We ultimately demonstrate the value of our service through our reporting,” says Daniel Schiffer with conviction. Overall the head of APIP expects that his department

the aircraft, especially from an operational perspective. Many employees are qualified right across all relevant trades, be it in terms of structure or electronics. What does Aircraft Production Inspection offer the customer? We offer a modular product structure with standardized processes at all locations. Added to this is innovative reporting. And all at a fixed price and a service level that is tailored fully to the needs of the individual customer. What is the relationship with the manufacturers, whose quality is scrutinized to a certain extent by the product? Certainly we could be perceived as a nuisance under some circumstances. Our work, however, is very reliable. We are always on hand when we are needed thanks to our permanent presence, thus ensuring that production is not held up any longer than is necessary. The value of our broad expertise is also recognized by the aircraft manufacturers. We are a kind of “free engineering” for them.

will look after some 140 Airbus aircraft in 2016, 30 for Lufthansa and the majority of 90 for customers from all around the globe. Added to this are private aircraft, which are subsequently supplied as “green aircraft” to their designated Completion Center, including to Lufthansa Technik. Another 75 aircraft are expected in the current year for Boeing in the USA.

Daniel Schiffer Phone +49-40-5070-64819 [email protected]

18 | Innovation and technology

Lufthansa Technik Connection 5.2016

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Two research projects launched to advance the entire aircraft engine overhaul process have reached their final phase: APOSEM (Advanced Prediction Of Severity effects on Engine Maintenance) and EVE (Engine for Validation Experiments). A deeper understanding of the aging process is the key to further efficiency gains in maintenance.

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ith the use of computer information systems, aircraft engines can be monitored continuously. Using Engine Conditioning Monitoring (ECM), Lufthansa Technik has been monitoring its customers’ engines during flight since the 1970s. All data relevant for analysis and trend diagnosis are continuously sent to a data center in Frankfurt. This allows immediate action to be taken in case of irregularities before more serious damage occurs. Moreover, the optimum

time for overhauling an engine can be determined in this way – independently of the recommended maintenance intervals. A critical aspect in this regard is to also be able to predict future changes in condition on the basis of trends in the ECM and on the actual operating conditions. More accurate predictions Of particular importance is the ability to predict aging in engines of customers

whose entire fleet is looked after by Lufthansa Technik over a longer period of time. Precise removal planning and careful fleet management can contribute significantly to optimizing the costs per flight hour and reduce the risks for all parties involved. Despite decades and thousandfold experience with various engine types, predictions of the operation-dependent aging of engines have not been very exact to date. To change this, Lufthansa Technik is working together with the company ANSYS, the German Aerospace Center (DLR), the University of Stuttgart and the TU Braunschweig to develop a new methodology in the framework of the research project APOSEM (Advanced Prediction Of Severity effects on Engine Maintenance). The objective is to assess engines over their entire lifetime using physics-based models and to make advanced predictions concerning the impact of operation on maintenance.

Events and exhibitions | 19

Lufthansa Technik Connection 5.2016

Lessor’s get-together in Dublin Integration of flight data In the past, data from inspections carried out in the shop and – if available – specific data from flight operations have been used for risk assessment and flat-rate contracts in engine overhaul, in addition to empirical knowledge. But that is not enough. Solid underlying data is important and necessary. Integration of Big Data analytics with ­physics-based modelling is what is needed to make the breakthrough. Over the course of the three-year project phase, from January 2014 to December 2016, such physics-based models are developed in very detailed form for individual components that are critical for the engine and validated with existing data. At the same time, a methodology for simulating flight operations and for ­predicting aging is developed for the engine as an overall system. Methods such as numeric flow simulation and thermomechanical lifetime consumption analysis are being used for developing these models.

Lufthansa Technik had invited representatives of lessors and banks to a dedicated get-together in Dublin in the Republic of Ireland.

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ircraft and engine lessors are a very special customer group with needs and wishes that differ from other aircraft operators. With Aircraft Leasing and Trading Support (ALTS®) Lufthansa Technik has a special product and a dedicated team to care for this group. Andreas Kehl, Lufthansa Technik’s Vice President Sales for Lessors and Banks, greeted the participants in the conference center of the Irish Aviation Authority (IAA). As special guest, Eamonn Brennan, CEO of the IAA, gave a presentation on his organization and on the Irish aircraft leasing community.

Representatives of more than 20 companies joined the event.

Understanding aging To validate the aging behavior of engines predicted by the models experimentally under real conditions, a decommissioned engine of the type CFM56-5C was modified to create a test model as part of a separate project (EVE, Engine for Validation Experiments) by Lufthansa Technik. Extensive additional instrumentation was fitted. Using an independent data acquisition system, more than 300 additional measurement parameters are established. The engine can now be examined in detail under different operating conditions, i.e. temperature and weather, or with flown high-pressure compressor blades as well as with simulated power-up, taxiing and start-up after different cooling periods. One of the objectives is to understand the response of the secondary air system and to record its impact on the air flow and aging of the turbine. Long-term prediction With the support of the APOSEM research project funded by the Federal Ministry of Economics and Technology (BMWI) and the EVE project, it will be possible to make long-term predictions regarding the operation-related aging of engines. This will allow reliable prediction of the respective service life and the required depth of intervention, such as for example scrap rates and workscopes. Moreover, the underlying basis will also be created for improved costing in the framework of flat-rate contracts. And the findings derived will help to acquire an increasingly deeper and more comprehensive understanding of the engines. Dr. Christian Werner-Spatz Phone +49-40-5070-2428 [email protected]

Challenges and solutions related to the Airbus A350 were the predominant topic of the conference. Joe Venuto, Chief Technical Officer of AirCap, presented an overview on the A350 market and commented in particular on the challenges and chances of this aircraft from a lessor’s point of view. Carsten Wortmann, Lufthansa Technik’s C ­ orporate Product Manager for the Airbus A350, followed, giving an overview on the company’s product and service offerings for this latest generation aircraft type. Marc Wilken, Director Engine Services at Lufthansa Technik, gave an outlook on Lufthansa Technik’s engine product strategy. Alexander Stern, Chief Executive Officer of N3 Engine Overhaul Services, pointed out the challenges in maintenance and overhaul of the A350’s engines. Lufthansa Technik’s key account for Lessors and Banks takes particular care of the lessor’s wishes to maintain the value of their assets. How this can be achieved, especially when there are aircraft repossessions or early terminations of lease contracts, is the subject of many talks between the leasing community and Lufthansa Technik’s experts. That is why after the success of the talks on 16 June, the event series will be continued, and the next lessor’s get-together is already in preparation. Andreas Kehl Phone +49-40-070-4780 [email protected]

www.lufthansa-technik.com/alts

20 | Employee portrait

Lufthansa Technik Connection 5.2016

Matthias Schulz and his ­colleagues have 1,500 ­moving equipment parts for the VIP maintenance hangars in their care.

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Lufthansa Technik Connection 5.2016

The equipment master As Ground Support Equipment (GSE) Resource Manager for VIP Jet ­Maintenance, Matthias Schulz is responsible for all of the equipment required for aircraft maintenance – and has many ideas for improvements.

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e look after everything to do with the aircraft that has four wheels or an ignition key, is not an aircraft part and cannot be obtained via the tools crib,” explains Matthias Schulz, GSE Resource Manager in the VIP & Special Mission Aircraft Services division. This includes, for example, ladders, tow bars, dock components or also smaller vehicles such as fork lift trucks or electric tow tractors. Overall, he and his colleagues have 1,500 moving equipment parts in their care. “We are the in-between port of call,” he says as he describes his job. “The hangar managers come to us and we coordinate the supply of equipment so that the production can operate smoothly.” ‘A la carte’ rather than buffet service A program has been underway since January that has turned his task area completely upside down. The equipment is now supplied, rather than simply being made available. He explains the difference as follows: “We formerly had a kind of ‘buffet system’ in place that everyone could access but had to look after themselves. Now we supply the equipment ‘a la carte’. Since the program started and has been accepted by the production, the daily supplies with equipment were intensely increased.” The advantages are obvious: Since they no longer have to look after the equipment, the mechanics can concentrate more effectively on working directly on the aircraft. The 1,000th equipment part was supplied according to the new principle in summer. From a purely organizational perspective, the change means that the equipment,

which was formerly owned by the production departments, is now allocated to their own specialized department. Matthias Schulz does his production rounds every morning in Heavy Maintenance and Line Maintenance in the VIP hangars where he records the requirements. The tasks are then divided up in the supply round. “I explain what production wants and everyone says what he or she can do,” he says as he describes the procedure. He then makes sure that the required equipment is supplied for production. In the afternoons he frequently takes part in meetings where the procurement of new equipment is discussed. The workload is particularly high when an entire dock has to be moved for example. “Everyone then heads out, even the colleagues in the office and ‘push iron’. This is very unifying,” he says. Mechanic and process specialist in one Matthias Schulz is celebrating his 20th anniversary with Lufthansa Technik this year – eleven years of which have been spent as a mechanic and five years in layover logistics. “I have grown up here,” he says as he surveys the maintenance hangar. Having trained as an aircraft mechanic, Matthias Schulz worked for six years on the fuselage and in the aircraft cabin, for three years on the tanker conversion of the Multi-Role Transport Tanker (MRTT) for the Special Air Mission Wing of the German Air Force and then spent two years as a system technician. A stint of lean training program brought him to project work. Having collaborated on several projects, he was finally appoint-

ed as manager of GSE resources in VIP Jet Maintenance. For him this is the ideal combination of the two worlds. “I have one foot in production and one in administration,” he says. “Thanks to my experience with aircraft, I feel that I can do a lot more to help my colleagues. I can express what they need. And therefore ensure on a daily basis that the colleagues can work more efficiently in the hangar.” Not only that but he knows practically everyone working in the hangars and offices. Vision for the future: “self-managing” equipment Matthias Schulz is presently working in a project on creating “self-managing” equipment. This would involve location services for the equipment and a planning platform. “The potential here is enormous,” he says. “The customer ultimately does not pay us to perform searches, which is why we also should not waste any time doing so.” The difficulties locating equipment are not hard to imagine, considering for example 84 mobile ladders on an apron of some 1.4 kilometers in length. A knowledge database is to be developed in order to gather and pass on experiences – for example that an extension cable is also usually required for a specific equipment part and should be provided as well. “We have developed into a service unit as a result of the reorganization – and we will continue to develop,” says Matthias Schulz with satisfaction. And that’s not the end to the possibilities for him. “We also see enormous potential in our model for other areas within Lufthansa Technik.” ­Initial inquiries are already underway.

22 | Corporate Sales

Lufthansa Technik Connection 5.2016

“Compete and collaborate” In the run-up to MRO Europe, the region’s leading conference for the maintenance, repair and overhaul industry, Connection talked to Robert Gaag, Senior Vice President Corporate Sales EUMEA (Europe, Middle East, Africa), about how Lufthansa Technik is meeting the challenges facing the industry in Europe today.

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Lufthansa Technik is a powerhouse in Europe, supporting fleets of every size (photo top: Wizz Air) and new aircraft types such as the Airbus A350 (photo below).

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What’s your view of the current situation in the MRO industry in Europe? Robert Gaag: At the moment I see stronger consolidation than ever before; the major airline groups in Europe are focusing very much on flying. We observe a readiness to outsource tasks such as maintenance and focus on few in-house maintenance activities for the airline’s own fleet. At the same time, the low-cost carriers are becoming even stronger in the European airline market. Lufthansa Technik plays a substantial role as one of the prime MRO providers in that segment, Wizz Air is a longstanding partner of Lufthansa Technik with all kind of maintenance services. Another example is easyJet, for whom we just started a maintenance hangar operation at London Gatwick. We want to grow our services with these successful airlines and improve our footprint in the MRO market. What’s also been clear over the last six to twelve months, in my view, is a more agressive approach to the MRO market in Europe by the OEMs. That’s not new in some areas, such as engines, but the airframe manufacturers in particular are very present nowadays as well, to a degree we didn’t observe before.

Lufthansa has put its first A320neo into operation. How is Lufthansa Technik positioned for the introduction of this aircraft and other new types? From what I see, the introduction of the A320neo was a bit bumpy in the beginning, but is now going quite smoothly. We still have a dedicated team working on this aircraft. The aircraft is flying on selected routes only to babysit the fleet introduction. We have received our third aircraft midAugust with some engine software modifications implemented that will help to bring the aircraft back on track as far as operability is concerned. For many of our component support customers, who already operate A320s, it’s pretty much “just another A320”, and the introduction as far as our component support is seamless. Preparations for the entry into service of the A350 at Lufthansa are very smooth. Just as with the “neo”, we already have customers for the A350 for whom we provide extensive component support, APU and line maintenance services, for instance. We’re well prepared for the A350 operations; after all, we have been active partner to Airbus in the A350 flight test program and we’ve demonstrated our competence to introduce new aircraft types repeatedly in recent years, most recently with types such as the A380 and the 747-8.

What particular focus does Lufthansa Technik have right now with regard to its customers? Well, we are of course permanently seeking ways to reduce cost in what we do for our customers. In a dedicated program we are trying to reduce for example overhead cost significantly. All product divisions are working on their own efficiency programs and thus cost position in general. In this context, our strategic network agreement with Pratt & Whitney is very important: Lufthansa Technik is becoming a key member of the Pratt & Whitney Geared Turbofan (GTF) engine MRO network and will offer the MRO services on PW1100GJM and PW1500G engines. What are the other focal points? Another spotlight is always on performance, especially with regards to turnaround times. In the engine shop, for instance, that wasn’t always as good as we wanted it to be. We are dependent on certain suppliers – as is often the case with the OEMs themselves – so we’re working on solutions that safeguard sourcing and the supply chain for our customers and thus reduce turnaround time.  P

24 | Corporate Sales

What role in that process is played by innovation? Innovation is the third issue alongside cost-cutting and performance. As Lufthansa Technik, we’re making a particular effort to be right out in front of the crowd in exploiting the potential of the major topics digitalization, MRO 4.0 and Big Data management. There are many ideas, but some of them are so revolutionary that they’ll take some time to be approved in an industry as strongly regulated as aviation. One example with that kind of potential is Augmented Reality in maintenance. I also think we could make big efficiency gains with digital documentation. A third innovation topic is predictive maintenance: The new aircraft types generate a lot of data. The intensive use of these data has the potential to improve performance and ­service levels. Many people talk about all this for a while. Now it is time to deliver. We have a couple of ideas that we identified and will present at the MRO Europe. What customer demands loom large at the moment? Right now, we’re seeing a strong demand for cabin upgrades and modifications, both for short-range and long-range fleets. Generally, these requests are driven by the need for more seats to improve the earning capacity of the asset or better passenger comfort with improved cabin layouts. Connectivity, which is already nearly mandatory on long-haul flights, is penetrating the short-haul market in Europe as well. Here, Lufthansa Technik is already out in front with the corresponding type certificates for Ka-band installations, some key partnerships and is well prepared for installations. Are there changes in customer orientation at Lufthansa Technik at the moment? Fundamentally – and this applies not just to Europe – we want to get to a point with our customers where we integrate their flight operations more strongly with our maintenance activities. We want to find out

Lufthansa Technik Connection 5.2016

where we can create the best value for our customers by docking on with our processes to their processes, whether it is line maintenance, warehousing, logistics or anything else. What are their pain points? How can we use the data lake of our ­customers’ operations to help them, both in their flight operations and in their ­maintenance operations? We can use our engineering know-how to try to generate ­added value, longer on-wing times, better dispatch reliability and lower costs for our customers.

our know-how, our market position and the innovative, creative mix of competences. These drive us to find repair solutions that help prevent material consumptions for aircraft, engines or components. I’m convinced that manufacturers also want a partner with a sound financial stability. We have a good reputation here, too, along with our know-how. We have a very stable structure firmly embedded in the Lufthansa Group and because of that, we may even be attractive as a risk-sharing partner.

How is your cooperation with manufacturers and competitors? I call this “compete and collaborate”. What’s behind this is the fact that we at Lufthansa Technik have changed our strategy over the last few years. We work in selected partnerships with the OEMs now much more than we used to do in the past. We choose them as partners very consciously and in isolation for specific topics. One example is Honeywell, which is now a cooperation partner for component and APU services on the A350, but remains a competitor in other product segments. Similar partnerships in different setups from loose cooperations to 50/50 joint ventures are in place with the engine OEMs. Beyond the OEMs, we also cooperate in a targeted fashion with MRO competitors when it makes sense. One example is our work with Air France Industries in our joint venture Spairliners. This cooperation is focused on component support for the A380 and the E-Jet aircraft. These markets are just too small to address it by ourselves. So we cooperate. In other respects, we compete with each other strongly. This focused teamwork with specific partners creates the efficiency gains we need in this industry.

Do you have a current example of that? Yes, our Engine Services again. It’s always been our goal to avoid shop visits for engines and to keep them in operation longer by our mobile repair teams on wing or on site at the customer’s facility. That saves operators a great deal of money over the life cycle of the engine. This insight is increasingly spreading throughout the community of engine manufacturers as well to reduce their cost for Powerby-the-Hour (PBH) contracts. This is why we have been selected globally as the principal provider of mobile engine maintenance services for the V2500, PW1100G-JM, PW1500G and PW1900G engines for Pratt & Whitney.

And how do the OEMs regard Lufthansa Technik? Sometimes we are surprised by what a good reputation we seem to have among the OEMs. I think it shows that they see Lufthansa Technik’s strengths in terms of

About 40 percent of the world’s fleets consist of leased aircraft. What trends and opportunities do you see for this customer group? According to some estimates, the share could even grow up to 50 percent in the medium term. Today, aircraft lessors function as asset managers; they buy, sell and lease aircraft. But beyond that, I can imagine them joining forces with an MRO like Lufthansa Technik to use the Big Data management in aircraft maintenance to optimize life cycle costs. Together, we could create complete solutions, including MRO, that reduce costs across leasing periods over the aircraft’s entire life cycle, ease transitions, and create genuine added value in the industry. And I firmly believe the advent of digitalization offers us better opportunities to do that than ever before.

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Lufthansa Technik Connection 5.2016

Local VIP services at a global hub DC Aviation Group and Lufthansa Technik jointly offer VIP aircraft maintenance and FBO (fixed-base operator) services at Al Maktoum International Airport in Dubai.

Michael Kuhn, CEO of DC Aviation, and Walter Heerdt, Senior Vice President VIP & Special Mission Aircraft Services of Lufthansa Technik, sealed the cooperation of the two companies with a handshake.

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C Aviation Group, one of the leading business jet operators in Europe, and Lufthansa Technik are offering their VIP customers a first-class modular package of services at Al Maktoum International Airport (Dubai World Central Airport). Since last September, customers benefit from the combined expertise of two leading companies which represent the “Made in Germany” pledge to quality.

Customer benefits Efficient – Local maintenance services provided in Dubai or by a mobile team at the customer’s location – no ferry flights needed Convenient – Integrated services, including passenger and aircraft handling, parking and maintenance Comprehensive – Coverage of entire fleets from small business jets to large widebody aircraft Modular – Additional services available from a single source and closely coordinated with the local team Flexible – In case of unforeseen findings, access to a wealth of experience through the extensive network

The local and integrated maintenance services for Dubai and the Middle East region will be provided in the hangar and VIP facilities of DC Aviation Al-Futtaim LLC, a joint venture of DC Aviation and the Al-Futtaim Group. The central location at the Dubai hub gives customers access to an array of services close to their doorstep and avoids costly and time-consuming ­ferry flights. The comprehensive service portfolio is designed to meet the needs of VIP customers at all times in an expeditious, professional and cost-efficient manner. This includes regular checks and maintenance services as well as unplanned repairs, for example in the case of an AOG (Aircraft on Ground) situation. The two companies also offer services for aircraft cabins, including small modifications. Moreover, they plan a mobile aircraft and cabin service to serve the region.

square meters have already been finalized, with completion scheduled for summer 2017. An experienced and highly qualified team of engineers and mechanics ensures cost efficiency and high quality. The portfolio is rounded off by extensive FBO services for ground operations at the airport, such as fueling, catering for passengers and pilots, and transport services. A luxuriously equipped terminal with 1,300 square meters of space is available for this purpose. Together with around-the-clock facilities for entry procedures and customs clearance, the FBO services guarantee seamless support of VIP customers and a comfortable and enjoyable travel experience at all times.

A second hangar is planned

For Airbus A320 and Boeing 737 aircraft and larger: Lufthansa Technik Phone +971-4-405-7550 More info about [email protected]

The maintenance and parking hangar extends over 5,700 square meters of floor space and accommodates business jets up to the size of an Airbus A320 or Boeing 737. Plans for a second hangar of 6,900

For business jets: DC Aviation Group Phone +971-4-870-1800 [email protected]

DC Aviation and the cooperation

26 | Innovation and technology

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Lufthansa Technik Connection 5.2016

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Finding leaks in the pressure vessel of an aircraft fuselage can be a tedious task, as this usually requires the activation of the aircraft’s pressurization system. Now Lufthansa Technik has developed a system that reduces the complexities of the job. Other work inside and outside of the cabin can be continued.

W

hen there’s whistling in the aircraft cabin, it does not necessarily mean that there is a goodhumored individual sitting next to you. Even the smallest air leaks at windows and doors can create unusual noises in the pressurized cabin of a commercial aircraft. Such leaks are difficult to find on the ground, however, without the pressure difference that exists in flight. Currently the seals at windows and doors are checked for leaks by means of visual inspection and a simulated cabin pressure test, with the seals being replaced afterwards if necessary. This is a very time-consuming and personnel-intensive process that allows no other work to be carried out in the cabin. This situation is now set to change, however, with the Vacuum Leak Check developed by Lufthansa Technik. Mobile vacuum system

After the suction system creating the necessary pressure differential has been installed, leak detectors are used to locate the noise.

The Vacuum Leak Check is a mobile vacuum system which simulates maximum ­in-flight pressure differences of an aircraft on the ground. Windows and doors can be checked and any leaks pinpointed precisely. The main advantage of the system: The procedure will replace the existing time-consuming process of activating the cabin pressurization system. The fuselage structure is not exposed to additional loads and other work on the aircraft can be carried out at the same time. The technology used for the test procedure bears a lot of resemblance to the vacuum bagging process used in manufacturing composite parts. First, the windows and doors including the seals being examined are cleaned thoroughly and closed.

A special textile fiber (suction fleece) is then overlaid from the outside followed by an airtight latex film with hose fittings. Finally the structure is fixed in place with adhesive tape. After the entire area to be examined is sealed airtight, vacuum hoses are fitted and connected to a pneumatic driven ­vacuum pump. The vacuum can now be generated and leaks localized precisely in the interior of the cabin by means of a standard leak detector. Less work, shorter ground times In addition to the features mentioned above, the vacuum procedure offers further benefits. Error sources are excluded and process times reduced significantly, leading to drastically shortened ground times of the affected aircraft. Moreover, less working time is needed and therefore costs reduced as only two instead of four employees are required to carry out the work on site. The test equipment is stowed in a practical box so that the quick and simple vacuum procedure can be used flexibly anywhere for selective identification and resolution of errors in the framework of troubleshooting. Stefan Mehler Phone +49-69-696-90680 [email protected]

www.lufthansa-technik. com/en/vacuumtool

Events and exhibitions | 27

Lufthansa Technik Connection 5.2016

Meet us at...

Ready for production

27 – 29 September 2016 | Singapore

MRO Asia-Pacific

The innovative VIP seating solution »chair« developed by Lufthansa Technik has received its ETSO (European Technical Standard Order) certification. INAIRVATION, Lufthansa Technik’s joint ­venture with F/LIST, will soon commence the production of »chair«.

www.lufthansatechnik.com/chair

MRO Asia-Pacific is the largest conference and exhibition in the region dedicated to the aircraft Maintenance, Repair and Overhaul (MRO) market. 28 Sept. – 1 October 2016 | Monaco

Monaco Yacht Show The Monaco Yacht Show (MYS) is the place to visit and purchase extraordinary one-off super­yachts built by the world’s most respectful shipyards. 40 new launches are unveiled in world premiere at every edition. Luft­hansa Technik will be present with its own booth, demonstrating its competence in VIP aircraft completion and VIP cabin upgrades. 18 – 20 October 2016 | Amsterdam

MRO Europe

T

he European Aviation Safety Agency (EASA) has granted two European Technical Standard Orders (ETSO) for the »chair« family, the new VIP seating solution of Lufthansa Technik. The certification process allows Lufthansa Technik to validate changes to »chair« without intensive re-testing. As the EASA testing was passed with maximum dynamic load cases, changes can be classified as minor deviations under the umbrella of the granted ETSO. With this approval, the »chair« VIP aircraft seat is now ready for production. Production and sales partner The product family »chair« can be ordered now. Lufthansa Technik has selected ­INAIRVATION, its joint venture with F/LIST, to coordinate production and sales. This approach combines the outstanding core competencies of the two shareholders. Lufthansa Technik’s Original Equipment Innovation (OEI) Division in Hamburg, ­Germany is responsible for all airworthiness requirements and the final certification, whereas F/LIST takes care of the production of the skeleton and all rigid surfaces at its site in Thomasberg, Austria.

Oliver Thomaschewski, Head of Seating and Structures at OEI, said: “In order to find an optimum of craftsmanship, manufacturing experience and cost-efficiency we established the Lufthansa Technik and F/LIST partnership as the perfect solution. That is why »chair« is offered by INAIRVATION.” Unlimited design possibilities The VIP seating solution »chair« is based on an innovative pedestal design with a mounted baseline core structure. The overall look and feel can be ­configured, shape, upholstery and padding can be selected to allow for an uncompromised interior design under one certification. The customizable »chair« skeleton is a perfect backbone for any advanced aesthetic design. For upholstery, the customer may choose its own favorite supplier or rely on the experienced INAIRVATION partner Boxmark. With several bids submitted INAIRVATION is expecting first orders within the next weeks. Dr. Philip von Schroeter Phone +49-40-5070-61685 [email protected]

At MRO Europe the latest standards for productivity and aerospace technology are presented. In addition to networking, MRO Europe presents opportunities with other service providers and aerospace companies. Lufthansa Technik will participate with its own booth and two speakers at the conference running in parallel. 19 – 21 October 2016 | Hunter Valley

RAAA Convention The Regional Aviation Association of Australia (RAAA) Convention is highly regarded as a premier annual aviation event. CASA, the government and other regulatory bodies are well represented and contribute significantly to the program, which is open to members and non-members. Lufthansa Technik AERO Alzey will be present at this event.

Follow this link to find out more about Lufthansa Technik’s participation and presentations at upcoming fairs and conferences. lufthansa-technik.com/events

28 | Products and services

Lufthansa Technik Connection 5.2016

Airbus

World of services Our range of products and services can be tailored for commercial and private fleets of every mix, kind and age.

A300/A310

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

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

A318

A300

A319

A318

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

A320/neo

A319

A321

A320neo

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Please follow this link for the complete MRO service portfolio and more details about Lufthansa Technik’s solutions for fleets of any size. www.lufthansa-technik.com/services

A330

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

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Special Services Lufthansa Technik offers a product portfolio reaching beyond traditional MRO services from the manual. • Composite Repairs (ARC®) • Engine Parts & Accessories Repair (EPAR) • Maintenance Management Services (MMS) • Logistics and training • AOG services • Surface treatment Original Equipment Innovation (OEI) Lufthansa Technik has successfully established a line of cabin products. • Cabin management & IFE systems • Aircraft and cabin equipment • Connectivity • Patient transport solutions

Airbus A300/A310

A340 A330

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

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

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

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

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

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

A350 A340-300

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

A380

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

Products and services | 29

Lufthansa Technik Connection 5.2016

Boeing 737 CL/NG

Regionals Boeing 737 CL/NG Line Maintenance Base Maintenance Component Services Engine Services: CFM56-3, CFM56-7B Completion

737 MAX 737NG/MAX

Boeing 737 MAX

Q-Series

Bombardier Q400 Line Maintenance Base Maintenance Component Services Engine Services: PW100, PW150

Q-Series

CRJ

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

Component Services Further services in preparation

CRJ 700

747

737MAX

757 747-8

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

ERJ/E-Jets

ERJ 190

Embraer 135/145, 170/175, 190/195 Line Maintenance Base Maintenance Component Services Engine Services: GE CF34

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

757 767

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

767 777

Boeing 777-9X

vorläufige Zeichnung

777 777X

Boeing 777

Business Jets Airbus Corporate Jets

Line Maintenance Base Maintenance Component Services Completion

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

Boeing 777X

Boeing Business Jet

in preparation

Airbus Corporate Jetliner Line Maintenance

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

787

Boeing 787 Line Maintenance Component Services Engine Services* Completion

Bombardier

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

*schedule to be defined

787

MD-11

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

Bombardier

Boeing Business Jet (BBJ)

Challenger Family

Embraer

Embrear Executive Jets

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

30 | Contacts

Lufthansa Technik Connection 5.2016

Senior Vice President Corporate Sales EUMEA

Senior Vice President Corporate Sales Americas

Robert Gaag p +49-40-5070-68406 [email protected]

Frank Berweger p +1-305-379-1222 [email protected]

Let’s talk about solutions

Vice President Corporate Sales Eastern Europe and CIS Dmitri Zaitsev p +49-40-5070-5404 [email protected]

Vice President Corporate Sales USA and Canada

Vice President Corporate Sales Europe

Sahib Ajjam p +1-305-677-5199 [email protected]

Georgios Ouzounidis p +49-40-5070-5295 [email protected]

Vice President Corporate Sales Middle East and Africa

Vice President Corporate Sales Latin America and Caribbean www.lufthansatechnik.com/sales

Richard Haas p +49-40-5070-3053 [email protected]

Jörg Femerling p +1-305-379-2604 [email protected]

Americas

Europe, Middle East and Africa

Canada Dan Hepworth p +1-514-245-0143 daniel.hepworth@ lht.dlh.de

BeNeLux Rudi Preud’homme p +32-2-752-8690 rudi.preudhomme­@ lht.dlh.de

Dubai

Chile

Italy Emanuela Marabese p +39-02-58571483 emanuela.marabese@ lht.dlh.de

Turkey

Carlos Sotomayor p +56-2-2573-7770 carlos.sotomayor@ lht.dlh.de

Ziad Al Hazmi p +971-4-4057-557 ziad.al-hazmi@lht. dlh.de

Fulya Türköz p +90-212-465 55 57 fulya.tuerkoez@ lht.dlh.de

Contacts | 31

Lufthansa Technik Connection 5.2016

Senior Vice President Corporate Sales Asia Pacific Gerald Steinhoff p +65-6733-5539 [email protected]

Vice President Corporate Sales VIP & Special Mission

Vice President Corporate Sales Lessors & Banks

Line Maintenance Worldwide

Wieland Timm p +49-40-5070-2548 [email protected]

Andreas Kehl p +49-40-5070-4780 [email protected]

Michael Struck p +49-69-696-69660 [email protected]

Affiliates & Corporations Lufthansa Technik AERO Alzey Phone +49-6731-497-0 Fax +49-6731-497-197 [email protected] www.lhaero.com Lufthansa Technik Brussels Phone +32-2-752-8660 Fax +32-2-752-8673 [email protected] www.lufthansa-technik.com/ brussels

Vice President Corporate Sales North East Asia Benjamin Scheidel p +852-2846-6370 [email protected]

Lufthansa Technik Budapest Phone +36-1-296-3000 Fax +36-1-296-3001 [email protected] www.lht-budapest.com Lufthansa Technik Component Services Phone +1-954-440-7014 Fax +1-954-302-3925 [email protected] www.lht-componentservices.com Lufthansa Technik Intercoat Phone +49-4191-809-100 Fax +49-4191-2826 [email protected] www.lht-intercoat.de

Vice President Corporate Sales South East Asia and Australia Zang Thio p +65-6733-9081 [email protected]

Lufthansa Technik Landing Gear Services UK Phone +44-20-8589-1941 Fax +44-20-8589-1901 [email protected] www.lht-landinggear-uk.com Lufthansa Technik Logistik Services Phone +49-40-5070-5331 Fax +49-40-5070-8667 [email protected] www.ltls.aero

Asia and Australia Australia & Pacific

China

Joseph Giarrusso p +61-3-9551-9064 joseph.giarrusso@ lht.dlh.de

Steven Wang p +86-10-6465-1593 steven.wang@ lht.dlh.de

India

Japan

Reshma Singh p +91-11-2568-7713 reshma.singh@ lht-services-india.com

Hidenori Sato p +81-45-309-2777 hidenori.sato@ lht.dlh.de

Lufthansa Technik Maintenance International Phone +49-69-696-141910 Fax +49-69-696-90942 [email protected] www.lufthansa-technik. com/ltmi Lufthansa Technik Malta Phone +356-2560-4000 Fax +356-2560-4190 [email protected] www.lht-malta.com

Lufthansa Technik Middle East Phone +971-4-299-4443 Fax +971-4-25176-55 [email protected] www.lufthansa-technik.com/ lht-middle-east Lufthansa Technik Milan Phone +39-02-585714-24 Fax +39-02-748-64924 [email protected] www.lht-milan.com Lufthansa Technik Philippines Phone +63-2-855-9311 Fax +63-2-855-9309 [email protected] www.lht-philippines.com Lufthansa Technik Puerto Rico Phone +1-787-230-7700 [email protected] www.lht-puertorico.com Lufthansa Technik Services India Phone +91-22-935-37409 Fax +91-99-5800-5695 [email protected] 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 INAIRVATION Phone +43-2644-21111 [email protected] www.inairvation.aero lumics Phone +49-40-5070-61361 [email protected] www.lumics-consulting.de N3 Engine Overhaul Services Phone +49-3628-5811-0 Fax +49-3628-5811-8240 [email protected] www.n3eos.com Spairliners Phone +49-40-5070-66499 Fax +49-40-5070-66742 [email protected] www.spairliners.com

Every innovation starts with a new direction.

Lufthansa Technik has a tradition of forging new paths. Innovation is our daily motivation. Thanks to creative engineering work and cutting-edge research facilities, we constantly set new standards. We develop new aviation technologies, cabin products, and servicing processes in addition to the ongoing further development of our maintenance, repair, and overhaul procedures, and can guarantee technological excellence through our pursuit of the highest quality and safety standards. Lufthansa Technik AG, [email protected] Call us: +49-40-5070-5553

www.lufthansa-technik.com/research-innovation