Availability around the clock

Transcription

1 The Lufthansa Technik Group Magazine January/February Component loan, exchange and sale Availability around the clock New aircraft services Spot landing for 787 services Lufthansa Technical Training Hands-on MRO experience Regional markets Reliable partner in the Middle East

2 2 Content Lufthansa Technik Connection Hands-on MRO experience Practical experience in an approved EASA Part-145 training environment is now on offer at the Erfurt training center of Lufthansa Technical Training. Technical Training Erfurt training center: 4 Hands-on MRO experience Interview with Andreas Kaden: 6 A fantastic training environment eservices manage/m : Plug & Play 7 4 Availability around the clock Single Component Availability (SCA) is Lufthansa Technik redesigned portfolio for the loan, exchange and sale of components. Spot landing for 787 services Lufthansa Technik s expanded portfolio of Boeing 787 services is valued by more and more customers The meaning of SMART SRU Manufacturing and Repair Technology is dedicated to developing andperforming new repairs. 21 Single Component Availability: 8 Fast, flexible and available worldwide! Interview with Isabell Aßmann: 10 Quality and reliability Repair Technology: 21 The meaning of SMART Aircraft Services StarFlyer: 11 Lease return and more Maintenance & Engineering: years of cooperation with MIAT Aircraft Engineering Services: 25 Strong focus on SCAMT Employee Portrait Jana Ludwig: 12 Taking off into the world of MRO New Aircraft Boeing 787: 16 Spot landing for the Dreamliner Technology & Innovation Landing gear components: 14 Precision coupled with reliability Integrated bushing production 18 Engine Services Acoustic panels: 24 Quiet, please! Laboratory Services: 25 Oil filter analysis for CFM56 Events & Exhibitions Dubai Airshow: Reliable partner in the Middle East 26 Categories News 3, 4 Events & Exhibitions 26 Products & Services 28 Contacts 30 Lufthansa Technik Connection is a complimentary information service for Lufthansa Technik s family and friends. Published every two months. This and earlier issues can be downloaded from our website Publisher Lufthansa Technik AG Tilman Tesseraux Marketing & Sales HAM TS/M Weg beim Jäger Hamburg, Germany Infoline Fax [email protected] Editorial Production Editorial office: Flightlines, Hamburg Design: Art Works! Werbeagentur, Hamburg Photos: Lufthansa Technik AG, Lufthansa AG Printing: Beisner Druck GmbH & Co. KG

3 Lufthansa Technik Connection News 3 Contract signing (from left): CEO Dr. Michael Arumemi- Ikhide and Chairman Sir Joseph Arumemi-Johnson of Arik Air, Senior Vice President Marketing & Sales of Lufthansa Technik Walter Heerdt and Altfried Nessel, CCO of Lufthansa Technik Maintenance International. Support and training for Arik Air Partnership // Lufthansa Technik and Nigeria s Arik Air, the largest airline in western Africa, are expanding their partnership in the technical care of the airline s fleet. The cooperation between the two companies, which has existed since the airline began operations in 2006, has now been expanded as part of a Total Operational Management (TOM) contract and extended by six years. By this extended and expanded contract, we signal to both our travelling customers and the aviation community at large our resolute determination to continue underpinning our operations with world-leading serviceability protocols available only through a select cadre of maintenance providers. Lufthansa Technik enjoys a place of prominence within this distinguished group and, as such, Arik Air is proud to continue building upon our successful partnership, said Dr. Michael Arumemi-Ikhide, Group CEO and President at Arik Air. // Norwegian Air Shuttle extends contract Boeing 737 // Norwegian Air Shuttle and Lufthansa Technik have extended the current wheels & brakes services contract for the airline s Boeing 737 fleet. The new contract also covers pooling and homebase lease services for the carrier s growing Boeing fleet currently comprising 69 aircraft. In the past we have made good experience with Lufthansa Technik s support and they facilitate Norwegian s sustained growth. That s the reason why we have decided to continue and even expand the contract for wheels & brakes services with Lufthansa Technik, said Asgeir Nyseth, Chief Operating Officer of Norwegian Air Shuttle. Wolfgang Weynell, Vice President Marketing & Sales at Lufthansa Technik, commented: Over the past years our two companies have established a very close relationship. This latest contract is a great proof that our success story will continue. We will do our best to remain Norwegian Air Shuttle s preferred technical partner. // Boeing 767 fleet overhaul Ameco Beijing // Ameco Beijing and Business Air have signed a three-year contract for the airline s entire Boeing 767 fleet overhaul. The first layover starts in January The cooperation between Ameco and Business Air started in September Ameco has provided Business Air with Boeing 767 airframe overhaul and PW4000 engine leasing and overhaul services. // Boeing 777F phase-in Lufthansa Technik Maintenance International // At the end of 2013, Lufthansa Technik Maintenance International (LTMI) together with its customer, Lufthansa Cargo (LCAG), officially welcomed the first member of the new Boeing 777F fleet, which has been named Good Day, USA, in Frankfurt. To ensure that the phase-in proceeds smoothly, the LTMI colleagues have been working on the entry into service of the new fleet, which will number five aircraft, since October 2012 on a joint project involving several different departments. Thus, for example, the dock has been remodelled, employees trained and over a million euros has been invested in tooling and operating resources. // Paul Snyder, Vice President of Customer Service for UTC Aerospace Systems Aircraft Systems segment (center), with Heike Hartmann and Dr. Gunther Kruse from Lufthansa Technik. Support for 787 nacelles Contract with UTC Aerospace Systems // Lufthansa Technik and UTC Aerospace Systems have signed a long-term contract to provide rotable provisioning and MRO services for Boeing 787 nacelle components designed and manufactured by UTC Aerospace Systems Aerostructures business. Heike Hartmann, Director of Lufthansa Technik s Airframe Related Component (ARC ) business unit (photo left), said: This agreement is a further milestone for our roadmap to establish Lufthansa Technik as one of the leading MRO providers for the new Boeing 787 program. Lufthansa Technik now offers its customers the full spectrum of life cycle support services for Boeing 787 nacelles on both General Electric and Rolls- Royce engine nacelles. Such services include sophisticated high-tech repairs and modifications, lease and exchange of nacelle components and on-site repairs around the world to quickly resolve aircraft on ground situations. //

4 4 News Lufthansa Technik Connection Engine support for Pakistan International PW4000, PW127 // Lufthansa Technik and Pakistan International Airlines (PIA) signed a comprehensive engine support contract. The German company will look after the Pratt & Whitney PW4000 engines of the six Airbus A310s in PIA s fleet. Signed at the Dubai Airshow by Samin Uddin Naqvi, PIA s Director Engineering and Maintenance (left), and Walter Heerdt, Senior Vice President Marketing & Sales Lufthansa Technik, the contract covers spare engine support, engineering services, logistics and repair and overhaul. The new partnership follows the recent signing of a three-year contract covering technical services for the Pratt & Whitney Canada PW127 engines in PIA s fleet of six ATR42 turboprop aircraft, to be provided by Lufthansa Technik s subsidiary Lufthansa Technik AERO Alzey. The first engine is currently undergoing overhaul. // SAA continues cooperation TES for CFM56-7B engines // South African Airways (SAA) and Lufthansa Technik are continuing their cooperation in the area of engine overhaul. A contract to provide support services for the 23 CFM56-7B engines in SAA s Boeing fleet that has been in place since 2001 has been extended and will now continue until the aircraft are taken out of service. Under the terms of the Total Engine Support (TES ) contract Lufthansa Technik not only overhauls the engines. The company also guarantees the continuous availability of the highly flexible Airline Support Teams AST. // Cooperation with Spirit AeroSystems Thrust reverser services // Lufthansa Technik and Spirit AeroSystems, Inc. have entered into a cooperation agreement related to the joint provision of repair, overhaul and supply services for the CFM56-7B and GE90-94/-115 thrust reversers and cowlings. Under this agreement, Lufthansa Technik and Spirit AeroSystems will utilize each other s repair facilities and capabilities in the Europe, Middle east and Africa (EMEA) region as well as other support elements for each company s respective repair and overhaul services. We are looking forward to working closely together with one of the world s largest designers and manufacturers of thrust reversers and cowlings, said Heike Hartmann, Director of Lufthansa Technik s Airframe Related Component (ARC ) business unit. // Lufthansa honors Father of the 747 Joe Sutter // Boeing engineer Joe Sutter (92) changed aviation history when he spearheaded the design and development of the world s first Jumbo Jet, the Boeing 747, more than 40 years ago. In honor of his dedication to aviation and long-standing partnership with Lufthansa, the airline presented him with the Lufthansa Lifetime Achievement in Excellence Award and an honorary certificate signed by the Executive Board of the Lufthansa Group. Sutter is the first person ever to receive this award. Joe Sutter is a true pioneer in our industry and his ingenuity has been integral to Lufthansa s successful 50-plus year partnership with Boeing, said Nico Buchholz, Lufthansa s Executive Vice President Fleet Management, who presented the award on behalf of the Lufthansa Executive Board. // EASA Part-145 environment in Erfurt. The only thing we can t do is fly, says Andreas Kaden, Managing Director of Lufthansa Technical Training (LTT), and sums up the unique offering of the company s training center in Erfurt, Germany. Here, a Boeing 737 is available to the course participants as a real-life learning object, with all the associated manuals, jobcards, tools and resources. Customers work in professionally equipped workshops with specialist tools and materials for the aerospace industry. Maintenance and repair tasks specially designed for the trainees and individual supervision ensure the acquisition of practical skills. Experts with appropriate EASA Part-66 CAT B licenses supervise the course participants during their practical assignments.

5 Lufthansa Technik Connection New Aircraft 5 Scan the QR code for more information. Hands-on MRO experience Practical experience in a German Federal Aviation Office (LBA) approved EASA Part-145 environment is now on offer at the Erfurt training center of the Lufthansa Technik Group s training specialist for the MRO industry. Just recently, the German Federal Aviation Office (LBA) approved the Erfurt training center as a learning environment in accordance with EASA Part-145. As a result, Lufthansa Technical Training can now offer customers a practical program lasting up to three months (minimum participation period is one month and the courses start at the beginning of each month), which is subsequently certified as counting towards the practical experience requirements of the European Aviation Safety Agency. In Erfurt Lufthansa Technical Training provides students with high-quality training for their future activities as approved aircraft mechanics in a fault-tolerant working environment: from simple maintenance tasks such as a brake or wheel change to more complex jobs such as working on control mechanisms or fault rectification. The practical experience gained is certified on LBA form 19.2, which has to be submitted to the LBA by the aircraft mechanic or avionics technician when applying for a Category A or Category B Aircraft Maintenance License (AML). As Andreas Kaden points out: Lufthansa Technical Training is the only training provider in Germany that offers participants their own EASA Part-145 training environment and is now also able to certify practical experience of up to three months according to statutory requirements. In the near future we would like to gradually expand our capabilities to allow the entire practical experience section to be carried out at our own training center. International customers in particular can benefit greatly from this because often they don t have an employment agreement with maintenance organizations. Jens Lange, Product Manager of Basic Training at Lufthansa Technical Training, says: We very often have customers requesting that their staff gain maintenance experience according to EASA regulations, so we have set the relevant training in motion in Erfurt. This training now allows us to offer them extraordinary flexibility as to how they gain the practical experience necessary for obtaining an AML. Lufthansa Technical Training Phone [email protected]

6 6 Technical Training Lufthansa Technik Connection A fantastic training environment Training in a realistic Part-145 environment, managed training solutions and the development of customized training: Andreas Kaden, Managing Director of Lufthansa Technical Training, explains how the company positions itself for the future. The market for technical training is fairly dynamic at the moment. What is Lufthansa Technical Training s current situation? Andreas Kaden: Lufthansa Technical Training has already undergone a transformation over the last few years. We positioned ourselves to be even more up-todate, including our training media and content. Our portfolio of web-based training courses, our media concept for aircraft types such as the A330, A320 or A380, and our training with 360 interactive spherical panoramas are proof of this. Beyond that, the latest example of our ongoing adaptation to current and future market requirements is our array of EASA EU1149/2011-compliant training courses. Lufthansa Technical Training provides its customers a total of 400 practical and theoretical EASA-approved type training courses for 17 aircraft types as well as 50 basic courses in compliance with the new regulations that have been in effect since August As a matter of fact, all the relevant type training courses offered by Lufthansa Technical Training were approved well in advance of the statutory deadline, allowing us to offer customers a timely change to training concepts and content in accordance with the new regulations. How have your customers benefited from this? One positive secondary effect of our approach is that some courses have been shortened and that means our customers employees spend less time away from work. That alone offers a significant economic advantage: from the overall cost perspective of the customer, the absence of a productive employee is much more expensive than the mere costs of a training course. Beyond that, we have also invested more strongly in distance learning products to enable blended learning, which is the optimum mix of classroom instruction, distance learning and the use of new media. We re also looking at virtual classrooms again with the goal of minimizing the necessity of travel for our customers. What highlights do you see in Lufthansa Technical Training s portfolio, today and in the future? One important highlight is our training center at Erfurt Airport in Germany, where we ve been offering hands-on training since We ve got a fantastic training environment there that you ll find nowhere else. In addition to classrooms with the usual media, we have an instructional workshop and in particular an aircraft hangar with genuine, living aircraft and all of that at a single site. The aircraft in particular a Boeing 737 and the tools in the hangar and workshop are the same as you would find in a fully equipped Part 145 operation. In other words, the entire environment, the IT landscape and the procedures are organized exactly as they would be in a genuine maintenance organization. The only thing we can t do is fly. And there s more: the German Federal Aviation Office has approved the Erfurt training center as an EASA Part-145 environment. As a result, we are the only training provider in Germany that can offer customers an in-house EASA Part-145 environment and can now also certify practical experience of up to three months according to statutory requirements. We plan to gradually expand our capabilities in the near future to allow the entire practical experience section to be carried out at our own training center. International customers in particular benefit greatly from this, because often they don t have an employment agreement with maintenance organizations. What support can you offer customers beyond the actual training courses? In the future we want to offer our large customers in particular the option of having us administer their training. That is, we would take on all the organization, including participant registration, travel arrangements, lodging, all the way to documenting the results which is where there are legal requirements to consider. This would ideally be managed using a web-based tool. We already have the software environment we need to take over the complete administration of participants, including recordkeeping. I m firmly convinced that managed training solutions like these offer customers genuine added value, and we hope to be able to offer them as of mid But they apply primarily to regular training, the kind that appears in course catalogs. What about customized training for individual training needs? It s true that there is always a need for training whose content and structure is based on very individual, customer-specific requirements. This is why we want to immerse ourselves more strongly this year

7 Lufthansa Technik Connection eservices 7 in training development. We want to use our methodical and didactic know-how to advise customers on questions regarding the right mix of media of all kinds whether printed or web-based that they need in their training to reach a certain level of qualification. What about offers for basic vocational training? To date we have always provided basic vocational training exclusively to Lufthansa Technik and other Lufthansa Aviation Group companies, but in the future we also want to make this or a similar product available to the third-party market. The German dual-study system with its mix of vocational school and workplace is very well known beyond our national borders, and it enables better, more practice-oriented training. We have been approached increasingly by interested foreign training providers and even foreign governments about mapping this training model in other countries, too, and we are in a position to do that. An example is Lufthansa Technik Philippines in Manila, where we already do something similar. We offer basic vocational training there in a way that is closely tied to on-site production. Why does it make sense for a customer to commission the training of its own technical personnel from a specialist like Lufthansa Technical Training? As an independent subsidiary of Lufthansa Technik, we are well positioned to offer training in the third party market. But the reality in the rest of the industry is often very different. Many MRO operations train their aircraft mechanics in-house. And because it s usually the operation s own productive employees who serve as trainers, the costs associated with providing training are frequently not accurately assessed. If you pull a productive employee away from his work for a week or two, he can t earn any money for the company during that time, and the probability is high that these losses are greater than the costs of training procured outside the organization. Plug & Play The brand new portable data loader mini PDL-Pad enables any aircraft software to be transferred wirelessly from the manage/m module m/modification/software to the aircraft, eliminating any need for physical media. Using the mini PDL-Pad, jointly developed by Lufthansa Technik and mbs electronic systems, data loads can be performed unattended and up to 60 percent faster. In addition, thanks to the secure aircraft software storage inside the mini PDL-Pad, the reliability of data loads is increased. As ground times are reduced as well, this device is a great relief for line maintenance operations. The aircraft software in question includes the navigation database, which has to be updated in the aircraft every 28 days, i.e. at least 13 times a year. With the new mini PDL-Pad other aircraft software can be loaded, as well. Similar to a tablet PC in size and shape, the handy mini PDL-Pad is a lot smaller and lighter than the previously used carrying case-like portable data loaders, which weigh about twelve kilograms. Complementing features such as its handy size and integrated capability to communicate over Ethernet, WLAN or UMTS, a separate power cable is no longer required for operation, as the mini PDL-Pad uses the aircraft as its power source. All these advantages, together with the Secure USB feature, make the mini PDL-Pad a superior portable data loader, says Matthias Fliegner, Lufthansa Technik IT project manager, in charge of developing the new device. The above mentioned Secure USB feature patented by Lufthansa Technik makes the mini PDL-Pad particularly unique. This enables us to eliminate even USB media. As a result, we save a lot of valuable time and process costs while at the same time data security is significantly increased, underlines Fliegner who is optimistic about the product s future: Right now the interest in the new mini PDL Pad is constantly rising and we hope we will be adding many customers as users in the near future. Lufthansa Technik s manage/m module m/modification/software is a comprehensive application for tracking aircraft software configurations. The application can be used for planning aircraft software updates as well as for reporting the software configuration of any aircraft at any point of time. In addition to the traditional creation and distribution of software, m/modification provides a seamless integration of portable data loaders, making the use of any physical media unnecessary. Erik Abels Phone [email protected]

8 8 Lufthansa Technik Connection Fast, flexible and available worldwide! Lufthansa Technik has redesigned its portfolio for the loan, exchange and sale of aircraft components and consolidated these availability products into its new Single Component Availability (SCA) product. SCA features fast availability from one of the biggest component pools in the world. SCA customers can tailor Lufthansa Technik s service according to their needs. Some customers require logistics services along with the actual aircraft component, while others prefer to arrange their own transport.

9 Lufthansa Technik Connection SCA Hotline 24/7 Hotline As one of the world s leading MRO providers, Lufthansa Technik is ideally placed to offer component loans, exchanges and sales. Lufthansa Technik s material pool and warehouse locations in Europe, USA and Asia give customers access to one of the biggest inventories of aircraft components in the world irrespective of whether they already have a contract with Lufthansa Technik. Lufthansa Technik is known for its high quality standards and in-depth understanding of the airline business, which is why our customers are always approaching us for component loans and sales, says Isabell Aßmann, who heads up the Lufthansa Technik team dedicated to the new product. But Single Component Availability is more than just a new brand name; it represents our commitment to the needs of our customers as well as to the market demand for ad-hoc component availability. We acknowledge that aircraft operators require fast, simple and transparent access to aircraft components around the clock to and from every destination around the globe. Dedicated Sales and Loan Team Single Component Availability (SCA) is the logical extension of Lufthansa Technik s established portfolio of services and customer solutions. However, a large number of SCA inquiries are triggered by unplanned events such as AOG situations. Hence, SCA inquiries often arrive at Lufthansa Technik s AOG Desk, where a dedicated Sales and Loan Team manages component loans, exchanges and sales around the clock. Please continue on page 10 Single Component Availability SCA For more information about SCA please scan the QR code // With Single Component Availability (SCA), Lufthansa Technik makes loans, exchanges and sales of aircraft components available on a case-by-case and non-contractual basis to every customer. The component portfolio includes line replaceable units (LRUs) and enginerelated components for all Airbus and Boeing commercial aircraft as well as selected regional platforms such as the Bombardier Q400 and CRJ. //

10 10 Lufthansa Technik Connection Quality and reliability Isabell Aßmann, Team Manager Loan & Exchange, talks about the customer benefits of Lufthansa Technik s Single Component Availability (SCA). SCA Hotline 24/7 Hotline Why is Lufthansa Technik so well qualified for the loan, exchange and sale of aircraft components? Isabell Aßmann: To start with, we have a material inventory worth more than a billion euros, which enables us to provide non-routine components rapidly. We re located at the heart of the operations of over 230 airlines with more than 2,500 aircraft. This means we re familiar with the problems operators face, especially in AOG situations, and we re not restricted to a single aircraft type. What warranties does Lufthansa Technik offer for components? We re renowned for our high level of repair and component logistics expertise. We can offer the quality and reliability that customers expect of components purchased or borrowed from us. That s one reason why we offer SCA components with a six months or 1,000 flight hours warranty. Which sales channels offer operators access to SCA? In our experience, most inquiries arrive via or phone. We established a dedicated Sales and Loan Team number and address, which is manned around the clock. The Sales and Loan Team is located on the same floor as Lufthansa Technik's AOG Desk. This ensures that inquiries are handled right away. How is SCA represented on the online marketplace? We are already very active on the ILS platform and we also sell components through AeroXchange. Our inventory of components is listed on both ILS and AeroXchange. Currently we are also testing five additional online platforms to expand our customer channels. And if a part doesn t appear online, it s always worth calling or ing the Sales and Loan Team. Isabell Aßmann Phone [email protected] SCA customers can tailor Lufthansa Technik s service according to their needs. Some customers require logistics services along with the actual aircraft component, while others prefer to arrange their own transport. Lufthansa Technik has an extended logistics network and the necessary capabilities at its disposal to provide global component support for every fleet size. Lufthansa Technik is ideally positioned to add further value to Single Component Availability through the logistics supply chain. The same applies to the repair of unserviceable components, which customers can send to Lufthansa Technik for repair under a Single Component Maintenance (SCM) agreement. Strong customer orientation Single Component Availability benefits from more than just a dedicated team, with the possibility of additional logistics or component repair services. When Lufthansa Technik established the SCA product, the internal loan, exchange and sales processes were restructured to reflect a stronger customer orientation. This enables Single Component Availability to deliver the quality and responsiveness that Lufthansa Technik is known for, says Isabell Aßmann. Customer advantages Worldwide access to vast global component inventory Fast 24/7 availability 6 months/1,000 FH warranty occurs first High Lufthansa Technik quality standards Expert staffing Material listed on various online platforms Logistic services if requested SCA Hotline [email protected] SITA: HAMAOLH

11 Lufthansa Technik Connection Aircraft Services 11 For the lease return work, the aircraft was ferried to Lufthansa Technik Philippines. For more information about ALTS please scan the QR code Lease return and more Japanese airline StarFlyer has expanded and extended its support agreement with Lufthansa Technik. The contract comprises the complete execution of the customer s lease returns, among others. Lufthansa Technik has been providing technical support to StarFlyer since the airline began operating in Now StarFlyer, which is currently operating a fleet of eleven Airbus A320 aircraft, has extended the Total Technical Support (TTS ) agreement. The integrated technical support we receive from Lufthansa Technik allows us to focus optimally on flight operations, emphasized Tatsuji Fukuro, a member of the board of StarFlyer. We are very pleased to continue to support the growth of this successful airline so extensively, said Dr. Johannes Bussmann, Chief Executive Human Resources, Engine & VIP Services of Lufthansa Technik. Total Technical Support TTS Within the frame of the TTS contract Lufthansa Technik provides a wide range of technical services to Starflyer. Covered are for example services for the engines and landing gears, an AMOS MRO software package support as well as Lufthansa Technik s Aircraft Production Inspection Program (APIP). As part of the contract, for the first time Lufthansa Technik also takes over the complete execution and integrated support of a customer s lease returns. Early November the first aircraft had already been ferried to Lufthansa Technik Philippines in Manila. The Airbus A320 with the call-sign D-AAAL the aircraft has a temporary German registration was put through a careful lease return check. Already at the first day of the return work, a specialist composites repair (ARC ) team from Lufthansa Technik Shenzhen was in Manila to check the thrust reversers and inlet cowls in order to avoid possible surprises prior to the return. Ralf Schulze, Senior Sales Executive, points to a current trend in lease contracts: Today, at lessor s choice, most of the leasing contracts do oblige the lessee to return an aircraft in accordance with either EASA or FAA requirements. This means, that an operator not flying under EASA regulations definitely requires the support of a CAMO organization for a lease return. Luft hansa Technik is perfectly prepared to take on such responsibilities. The on-site presence of StarFlyer during the lease return could be limited as the entire work is managed and performed by Lufthansa Technik. As this issue of Connection goes to print, the aircraft will be in the hands of its owner. Two more aircraft are scheduled for lease returns during the coming months and one more aircraft in early Founded seven years ago with initially three Airbus A320s, StarFlyer offers domestic service to destinations in Japan. Ralf Schulze Phone [email protected] Performing a careful check, the Airbus twin jet is prepared for return to its owner.

12 12 Employee Portrait Lufthansa Technik Connection Taking off into the world of MRO Working in different departments and learning at the same time: as a trainee at Lufthansa Technik, Jana Ludwig is acquainting herself with different areas and projects in the company and is working on making the services even more attractive for customers. Right from the start of my studies I wanted to join Lufthansa Technik, as I am fascinated by aviation, aircraft technology and travel. Here I work close to the aircraft and the product, says Jana Ludwig, explaining her decision to apply for a place as a StartTechnik trainee. Her dream came true: she has been working at Lufthansa Technik as a trainee for over a year now, and in this time she has gained many impressions and contributed to the suc- cess of projects. On graduating from high school Jana Ludwig studied Transport Engineering at Dresden University of Technology. After the intermediate diploma she decided to specialize in Air Transport Technology and Logistics. Her first direct contact with Lufthansa came during an internship in Revenue Management for the Lufthansa long-haul fleet. During a second internship she worked in process optimization for the A380 production at aircraft manufacturer Airbus. I realized during my studies and the internships that working merely in systems engineering would not be my goal for a later employment, says Jana Ludwig. I m more interested in projects and interfaces. And I wanted to obtain a deeper understanding of other departments. company and, as they say, I m becoming a Lufthansa Technik specialist, she says. During their program trainees choose four assignments in different parts of Lufthansa Technik, which do not necessarily all have to be connected to their former studies. I didn t know exactly what I wanted to do career-wise. So for me it s a great opportunity to get to know many people, see how things are interconnected within the company and work in different areas. I got to know a lot of fantastic colleagues who are very enthusiastic and totally committed to their products. Jana Ludwig After a long selection process Jana Ludwig received her acceptance, and finally started at the company in October The first three weeks were spent on an introduction course involving lectures, tours and workshop visits that was attended by all trainees starting their program in 2012, with activities in Frankfurt and Hamburg. The trainees themselves choose where their four assignments over the next two years will take place, receiving support from Human Resources. From logistics to strategy After a theoretical thesis Jana Ludwig wanted to do something tangible, so her first assignment was with Operations Engineering at Lufthansa Technik Logistik Services, where she worked on a project in the Aircraft Components Services department. Lufthansa Technik s component pool warehouse was relocated to Frankfurt. This involved a complete change to the component admission and issue processes, with the aim of serving customers more quickly and more effectively in the future, Jana Ludwig explains. In a series of pilot phases the processes were reviewed and optimized. I was involved in the planning, preparation and implementation and as a result I was also able to witness the results. Together with the colleagues from the production and the project team we were able to find the best solutions, she says enthusiastically. It wasn t plain sailing, but we found our way to overcome the obstacles. On her second assignment she came to see a quite different side of Lufthansa Technik, working in Strategy and Product Off to a good start with StartTechnik On completing her diploma thesis she therefore applied for the StartTechnik trainee program at Lufthansa Technik. I was attracted by the flexibility of this program, and as a result I am seeing a lot of the A lot of self-initiative, mobility and flexibility is expected of the Lufthansa Technik trainees.

13 Lufthansa Technik Connection Employee Portrait 13 Management in Aircraft Engineering, at Line Maintenance in Frankfurt. I definitely wanted to take a look at strategic processes, as this was something I hadn t touched on at all during my university studies, she explains. One task was to reform the way the business unit s products are presented and to highlight the benefits for customers. During my research I got to know a lot of fantastic colleagues who are very enthusiastic and totally committed to their products, she says. She also carried out a preliminary study on the IT systems in Aircraft Maintenance and market expectations, with a view on how customers using different IT systems can be cared for at the same service level. Self-initiative and dedication As well as their assignments, trainees also get involved in other areas. They organize introduction weeks with lectures from the senior management for specialists and engineers at Lufthansa Technik, who by this means get better acquainted with parts of the company outside their immediate areas of responsibility. In this connection we meet a lot of interesting colleagues and find out more about other areas and products, says Jana Ludwig. The trainees also contribute with their own experiences to the program and thus develop it further. To date around 50 trainees have already completed the StartTechnik program and an active alumni network has developed. A lot of self-initiative is expected of the trainees, along with mobility and flexibility. The subjects in the assignments are very complex, but can be managed, says Jana Ludwig. And you get a lot in return. In this connection she has the support of a buddy, a former trainee, and a mentor from the management of Lufthansa Technik. I meet my mentor regularly. She assists me by giving advice and she helps me with decisions and her own experience. As far as the future is concerned, Jana Ludwig can well imagine working in the project environment, as she did during her first assignment. I like the exchange of information and ideas and working closely with other people, she says. But perhaps I will surprise myself. At the moment I have the luxury of being able to see so many different departments and projects. Jana Ludwig started her third assignment just recently. This time her work took her a long way away to Lufthansa Technik Philippines in Manila. Jana Ludwig On graduating from high school Jana Ludwig studied Transport Engineering at Dresden University of Technology. After the intermediate diploma she decided to specialize in Air Transport Technology and Logistics.

14 14 Technology & Innovation Lufthansa Technik Connection Precision coupled with reliability Enhanced process reliability in connection with the grinding of landing gear components such was the goal of the Grinding innovation project tackled by Lufthansa Technik with the support of the Federal Ministry of Education and Research (BMBF). Landing gears, the legs of commercial aircraft, are highly stressed during operation and are therefore built to be extremely robust. But even they have to go into the shop to be overhauled, normally after an operating period of around ten years. This is the point at which, amongst other things, the anti-friction coating of the sliding tubes is renewed. These surfaces, which are generally implemented as a hard chrome layer, are electroplated and then finished to the required size using special grinding machines. The accuracy required of these large components is to a tolerance of a few hundredths of a millimeter. Local overheating This grinding process poses major demands on man and machine. To start with, it is imperative that the accuracy and surface quality requirements are adhered to. As grinding is a very time-consuming process, the technicians try to increase productivity by stepping up the rate at which metal is removed. But this introduces the danger of local overheating, which can damage the component. To assure the quality of the grinding process, Lufthansa Technik has therefore set itself the goal of increasing the process reliability during the grinding of these landing gear components. The technological groundwork for this was laid by the development of a grinding process with integrated quality assurance that could be monitored online. Under the Grinding project,

15 Lufthansa Technik Connection Engine Services 15 CF34-10E MRO for Air Astana The fiber optic cable is embedded in the grinding wheel. which was supported by the Federal Ministry of Education and Research (BMBF), a number of new techniques were developed that will help to systematically eliminate damage to work pieces during the grinding process. Sensor technology To avoid overheating the component that is being ground, first of all a suitable temperature sensor was developed. This suspends the grinding process as soon as a critical threshold is reached, thus avoiding damage to the landing gear component. As the component is covered by the grinding wheel and the cooling lubricant throughout the grinding operation, a special fiber optic cable that measures the surface temperature of the component in real time is used here. This technology eliminates the possibility of the expensive landing gear parts sustaining grinding burn, which can result in uncontrolled loss of strength. Laser measurement system In a further step the parameters of the grinding process were optimized. The aim was to avoid damaging vibration during the grinding process, which could result in surface blemishes. This optimization made it possible to guarantee a stable and virtually vibration-free grinding process. A further outcome of the Grinding project is a laser-based measurement system that measures the component throughout machining. This system prevents the grinding disk from colliding with the component in case the machine operator has made an error in entering the machining parameters. Once again the effect of this will be to improve process reliability. Optimization of process reliability Under the Grinding research project, which ran from January 2011 through November 2013, not only was a large volume of special proprietary data gathered, but machining of the landing gear parts was improved through optimization of the grinding parameters and process reliability was raised. At the same time a lot of time was saved, yet the quality of the workmanship was higher. As the results obtained constitute unique characteristics, the rights to these have been protected through several patent filings. In this way in collaboration with the Institute of Production Management and Technology of the Technical University of Hamburg-Harburg Lufthansa Technik has succeeded in extending its expertise in the grinding of landing gear components and in widening its technological edge in the area of landing gears. Lufthansa Technik AERO Alzey // Kazakhstan national carrier Air Astana (KZR) has signed an exclusive-agreement with Lufthansa Technik AERO Alzey (LTAA) for the provision of MRO services for the carrier s fleet of CF34-10E powered Embraer 190 aircraft. Air Astana introduced the first of twelve planned Embraer 190 into the regional operation in May Under the new contract Lufthansa Technik AERO Alzey will provide maintenance, repair and overhaul services as well as spare engine support. Following the positive experience with our previous PW125B MRO support agreement, we decided earlier in 2013 to extend the relationship by entering into an exclusive engine service agreement for our new E-Jet fleet with Lufthansa Technik AERO Alzey. We have worked with the Alzey shop since the airline started operating PW125B powered Fokker 50 in 2002 and we have found that Lufthansa Technik AERO Alzey is delivering the service we require at very competitive prices, says John Wainwright, Senior Vice President Engineering Group, Air Astana. We are very pleased to continue our partnership with Air Astana and are looking forward to supporting the airlines future growth says Martin Hach, COO of Lufthansa Technik AERO Alzey. We believe the achievement of this agreement is a result of LTAA commitment to the regional aircraft engine market to provide the most flexible and comprehensive services to our customers. // Signing ceremony (from left): Peter Foster, President Air Astana, Martin Hach, COO, LTAA, Andreas Kehl, VP Sales & Marketing, LTAA, and John Wainwright, SVP Engineering Group, Air Astana.

16 16 New Aircraft Lufthansa Technik Connection Spot landing for the Dreamliner Lufthansa Technik s further expanded and deepened portfolio of Boeing 787 services is valued by more and more customers. New services have been added and cooperative agreements are in place to support the entire life cycle of the Dreamliner. While an increasing number of airlines are taking delivery of their first Boeing 787s, the long sought-after aircraft that will usher in an innovative new aircraft era, Lufthansa Technik is further expanding the range of services it offers for the composite airliner. As the fleet numbers rise and operation of the 787 ceases to have a niche status, the airlines are clearly going to need 787 MRO services that go beyond the successful Total Component Support (TCS ) that Lufthansa Technik already provides to Japan Airlines and Ethiopian Airlines. In addition to component support, one of the most important cornerstones of reliable flight operations, Lufthansa Technik has now added a new element to its broad spectrum of life cycle services for the 787 the Aircraft Production Inspection Program which supplements services such as start-up support, line maintenance, engine change teams, engineering support and VIP completions. Meanwhile Lufthansa Technik recently acquired two more 787 operator customers for its TCS offering: Air Canada and TUI Travel have both signed support contracts tailored to their individual needs. Whereas Lufthansa Technik is set to provide full component support for Air Canada s 787 fleet, the contract with TUI Travel focuses on the 787 engine-related components of the GEnX. These two new agreements are a good example of how Lufthansa Technik has the flexibility to adapt its comprehensive material support services to the varying needs of different airlines. Customized component support Air Canada has signed a Total Component Support contract that is due to take effect when Boeing delivers the first 787 to Air Canada in the first quarter of Under the agreement, Lufthansa Technik will provide Air Canada with a wide-ranging service portfolio, including the supply of serviceable parts from Lufthansa Technik s extensive 787 component pool, the maintenance, repair and overhaul of removed components, home base lease, transportation logistics, reliability reporting and seamless IT integration. The largest Canadian airline has placed firm orders for 37 Boeing 787s, with a further 23 options. Air Canada is the newest TCS customer.

17 Lufthansa Technik Connection New Aircraft 17 The selection of a component support provider for our 787 fleet is an extremely important decision, said Alan Butterfield, Vice President Engineering and Maintenance of Air Canada, on the occasion of the contract signing. Lufthansa Technik clearly demonstrated their commitment and ability to ensure the integrity of our 787 long-haul operation from day one. An onsite program manager at Air Canada s head office in Montreal and expansion of the component pool in Miami, Florida, will ensure that Air Canada receives the best possible level of service. For the four airlines Thomson Airways, Arkefly, TUIfly Nordic and Jetairfly, which all are part of TUI Travel and have taken delivery of their first 787s, Lufthansa Technik will provide full coverage for all enginerelated components of the 787 s GEnx-1B engines. In this case Total Component Support covers a subset of the 787 components but still incorporates all services, including MRO, pooling and provisioning of home bases tailored to each airline s particular requirements. Now that these two new customers have joined Lufthansa Technik s service network, the MRO provider handles a significant share of the material support requirements of current and future 787 fleets. Please continue on page 10 Photo: Bernie Leighton Japan Airlines, Ethiopian Airlines and several TUI Travel airlines are among the continuously increasing customer base for comprehensive material support.

18 18 New Aircraft Lufthansa Technik Connection From phase-in to line maintenance To ensure that the integration of the Boeing 787 into an airline s fleet proceeds without a hitch, Lufthansa Technik is the first MRO provider in the world to also now offer its acclaimed and extremely popular Aircraft Production Inspection Program (APIP) for this aircraft type. With experienced inspectors stationed directly at the assembly line, Lufthansa Technik performs individual inspections on-site to ensure the optimal production quality and a high degree of reliability in subsequent aircraft operation. 50 Boeing 787 production inspections have already been commissioned and the first 787 to have been quality checked by Lufthansa Technik has been delivered. Once the aircraft is in service, the technical support coverage that Lufthansa Technik provides to 787 operators goes further: the company is also fully prepared to offer Lufthansa Technik clearly demonstrated their commitment and ability to ensure the integrity of our 787 long-haul operation from day one. Alan Butterfield comprehensive engineering support for the latest Boeing aircraft, from start-up support to all engineering services during the aircraft life. In Munich and Frankfurt Lufthansa Technik is already performing line maintenance for the 787 aircraft of international customers. Together with UTC Aerospace Systems, a key supplier in the Boeing 787 Dreamliner program, Lufthansa Technik now also provides rotable provisioning and MRO services for Boeing 787 nacelle components, offering the full spectrum of life cycle support services on both General Electric and Rolls-Royce engine nacelles. Services on offer include the lease and exchange of nacelle components, on-site repairs around the world to quickly resolve aircraft on ground situations and high-tech shop repairs and modifications of these components, making full use of Lufthansa Technik s many years experience of composite materials in the aviation industry. Last but not least, the services offered in the premium segment VIP completions illustrate just how well-prepared Lufthansa Technik is for the Dreamliner with its modern composite structures. Even before the first Boeing 787 VIP for private or government customers is delivered at the end of the year, Lufthansa Technik has finished all its preparations for the completion and technical care of this state-of-the-art aircraft type. With the development of a new process for cabin installations in the new aircraft types with composite airframes, the company has also laid the foundation for customized cabin solutions for its VIP customers. In short, with services to cover every aspect of the expanding life cycle of the Boeing 787, the specialists of Lufthansa Technik are passing on unique expertise and experience to operators around the globe Lufthansa Technik is the partner of choice for industryleading independent and tailor-made services for the Dreamliner. Dirk Winkler Phone [email protected] Integrated bushing production A mobile system for the measurement of landing gear components is the heart of a Lufthansa Technik proprietary development aimed at increasing the efficiency of the landing gear overhaul process, eliminating potential faults and improving precision. Aircraft landing gears are not only subjected to enormous loads during a hard landing the forces can exceed the weight of the aircraft by a substantial factor the harsh operating conditions of landing gears often cause corrosion in the drilled holes and on the flange surfaces of the bushings. Regular maintenance of the landing gear is therefore a must to satisfy the safety requirements and ensure a long service life. Whereas the corrosion on the components can be removed by machining, the bushings can no longer be used. In the course of a typical landing gear overhaul bushing replacement is therefore mandatory. The manufacture of the replacement bushings made of bronze, aluminum or steel alloys however is a challenge. As each component repair requires a different cutting depth to remove the surface damage, the bushing holes on every component have different diameters. This means that a new bushing with individual dimensions has to be fabricated for each bore. After replacement, the component with the new bushings installed must precisely match the dimensions prescribed by the original equipment manufacturer (OEM). In the past both the measurement and the manual calculation of the bushing dimensions required a large amount of labor. After machining the landing gear components were first measured to an accuracy of a hundredth of a millimeter with hand-held instruments (caliper gauges, measurement guns, micrometer calipers and three point internal micrometers). The data was noted down by hand and entered into the SAP system. The new bushing dimensions (length, flange thickness and diameter) were then calculated based on the measured data. Then the new dimen-

19 Lufthansa Technik Connection Technology & Innovation 19 sions and the corresponding order information had to be entered into the bushing drawings again manually before being passed on to the workers in the machine group, who would then once more manually enter them into the CNC machine tool. Automatic data transfer Working with the Department of Informatics of Hamburg University and Lufthansa Systems, Lufthansa Technik has developed a software that puts an end to the tedious process. It enables the bushing dimensions to be calculated automatically and the automatic transfer to the relevant technical drawings. By using a semi-automatic measuring arm, a lot of time can be saved, component measurement can be significantly improved and the error rate reduced. The measuring arm automatically transfers the component dimensions to the SAP system. The SAP system calculates the necessary dimensions of the new bushings and controls the printing of all necessary order documents and drawings. As a result, the effort required to manually transfer the data and perform the associated administrative tasks is drastically reduced. Only the data for the new bushing dimensions must still be entered into the CNC machine manually, but in the future this too will be automated. Semi-automatic measuring arm in use. Bushing manufactured on lathe. Reduced process time Within this research project, which was funded by the Federal Ministry of Education and Research, the work steps component measurement, calculation of bushing dimensions and bushing production have been combined into a coherent, integrated system. As a result only a few, optimally interconnected interfaces are now required. Linking the measurement methods and automating the work processes has not only made it possible to reduce process times by up to 30 percent, but the quality level has been further improved. To ensure that the research results are put to best use, an intensive information exchange has taken place with all subsidiaries and affiliates of the Lufthansa Technik Group that are involved in landing gear overhauls. A patent application for a mobile measurement system that incorporates the results of the Software Development Bushings research project, has already been filed. Measuring a bushing diameter with an outside micrometer. The bushing is inserted into the landing gear component.

20 20 Aircraft Services Lufthansa Technik Connection years of cooperation with MIAT MIAT Mongolian Airlines and its Maintenance & Engineering Organization and Lufthansa Technik can proudly look back at 15 years of successful cooperation. Over this time the engineering arm of Mongolian Airlines has steadily developed into an independent and multi-faceted MRO company while Lufthansa Technik remained reliable partner and supplier of MRO services on the side of the airline from the Far East. All beginnings are difficult, so they say. In case of an airline, Total Technical Support (TTS ) from Lufthansa Technik will usually be the solution. When Mongolian Airlines acquired its first Airbus A310 back in 1998, the logical next step was therefore to put this support solution in place. This universal service program, ranging from component to engine support and from aircraft maintenance to on-the-job training for Mongolian technicians and engineers, which was carried out on-site by Lufthansa Technik personnel, was essential for the success of the technical operation and the formation of MIAT s own M&E Organization. Over the years MIAT developed with a sense of purpose, systematically acquiring and expanding its own maintenance competencies. The real breakthrough happened in March 2005 when the quality of preparations was recognized by the European Avi- ation Safety Agency and the airline received its first approval for line maintenance of Airbus A310 and Boeing 737NG aircraftin accordance with EASA Part-145 rules and regulations. Yet before the end of the same year the scope of approval was expanded to cover performance of C-checks. In 2006 MIAT successfully performed its first in-house C-checks on Boeing 737 and A310 aircraft. As MIAT s M&E Organization continued with line and base maintenance of the Boeing 737NG fleet, Lufthansa Technik won a contract for Total Component Support (TCS ) of the aircraft type. The same applied to the Boeing 767aircraft that was integrated into the fleet in For this type too Lufthansa Technik has taken on the provision of component support. In the same year the European Aviation Safety Agency expanded MIAT s scope of approval for performance of the ER line and base maintenance. Gaining independence Last year Lufthansa Technik and MIAT celebrated 15 years of successful cooperation. At an event held to mark the anniversary, Walter Heerdt, Senior Vice President of Lufthansa Technik for Marketing and Sales, handed over a voucher for an aircraft painting training course for partner s employees. All through the years of cooperation with Lufthansa Technik, MIAT Mongolian Airlines has thus benefited from the support of its partner: it has been always able to rely on the high quality technical services it required and has also enjoyed handson assistance, know-how transfer and training of the MRO provider as it moved towards self-sufficiency. Today MIAT s Maintenance & Engineering Organization performs all kinds of aircraft maintenance work independently, down to the D-check, while Lufthansa Technik provides Total Component Support and a variety of MRO services for the aircraft operated by the airline. As such, this partnership incarnates the success of the cooperative approach of Lufthansa Technik. Dmitri Zaitsev Phone [email protected] Photo: miat.com MIAT Vice President Mr. Khurelbaatar S. (right) takes the training voucher from the hands of Walter Heerdt, Senior Vice President Marketing and Sales of Lufthansa Technik.

21 Lufthansa Technik Connection Preparing a Main Fuel Pump Housing for machining. The meaning of SMART SRU Manufacturing and Repair Technology is a Lufthansa Technik specialty engineering, production and process team dedicated to developing new repairs and performing them series production of components included. Ten engineers work mainly on developing new processes to save parts that would otherwise have to be scrapped. Lufthansa Technik s SRU Manufacturing and Repair Technology (SMART) prides itself on its conviction that a better solution can always be found. SRUs or shop replaceable units are sub-components or piece parts that can be quickly replaced at a shop. Whereas today the term smart sometimes appears hackneyed in connection with products, at Lufthansa Technik the name is spot-on. The SMART team of is staffed by a group of experienced engineers focused on improving SRUs. They have already handled components from a wide range of aircraft subassemblies. These include engines, landing gears and structural parts and are not limited to components of all aircraft systems. The aim of their development work is always to improve the reliability and service life of a component and specifically to avoid the need to scrap parts. This service, a highly flexible combination of development and production, is possible thanks to Lufthansa Technik s status as a Design and Maintenance Organization. Today airlines, MRO companies and even OEMs benefit from the expertise of this team that is able to cover the full service spectrum from damage analysis to the development of an improvement or the certification and implementation of a largevolume repair. These days even the contract production of parts in large unit numbers is nothing unusual for the team. Please continue on page 22

22 22 Lufthansa Technik Connection The plating shop offers a comprehensive portfolio of processes. These pins are chrome-plated. A mechanic carefully performs a visual check before plating. Engineering Services The service portfolio of SMART is based on two pillars. The first of these is Engineering Services, which covers the development of the product, the production process and the necessary tools and equipment. The spectrum of work handled here extends from the analysis of operating principles and mechanisms of action to construction model analysis and definition of the actual requirements for every individual component and their systematic classification. The final outcome is a new design with improved durability, longer service life and often even lighter weight. Production Services and Repair Production Services then covers the production of individual parts in the facilities of Lufthansa Technik. The instruments used in this connection extend across all the strands of technology available in the SRU and Manufacturing Center, from machining to surface technology and beyond. In this way the customer receives a certified part from a one-stop shop ready for installation. The development of a special repair for an air-oil IDG cooler assembly is a good example of the wide-ranging capability of the SMART team. During operation, heavy wear occurs on the oil cooler cascade, which directs the outlet air of the cooler to the bypass flow of the engine. As typical repairs such as replacing individual vanes using TIG welding proved to be of limited value, Lufthansa Technik s engineers developed a new cascade using a casting technique. The new cascade is welded to the cooler assembly. This repair returns the air-oil cooler to its original operating condition, with form, fit, function and fatigue equivalent to an OEM part. The big difference is the dramatically lower cost, which easily justifies the investment in developing the cascade assembly as casting. A different approach was chosen by the engineers when a toilet bracket came under scrutiny. The original part was made of an aluminum alloy, which didn t hold up well under the highly corrosive conditions found in an aircraft toilet. The parts often simply wore out. The SMART engineers changed the material from aluminum to a plastic material saving weight and eliminating the possibility of future failures due to corrosion. The replacement parts manufactured by Lufthansa Technik are the equivalent of OEM parts in terms of form, fit, function and fatigue, and brought only half of the cost with them. The handling of a Service Bulletin concerning Boeing 777 aircraft is a typical case of a component repair performed by SMART. SB A0018 requires the replacement of existing horizontal stabilizer pivot pins The close connection to Lufthansa Group s airlines gives us highly detailed knowledge of the requirements of every single aircraft component. Sabrina Hornig with new or reworked pivot pins, as micro cracks have been found in the chrome plating, sometimes extending into the base metal. As the pins join the horizontal stabilizer to the stabilizer support bulkhead, a fractured pin could result in loss of control of the airplane. Lufthansa Technik decided to offer the rework of the pins. The chrome plating on the pins is removed, the base structure is checked for defects and a new chrome plating is applied. After grinding the pins to the final dimension, a careful check ensures that the pins are in operational condition again. This process cuts IDG oil cooler after repair. A new cascade the grey casting has been welded to its core.

23 Lufthansa Technik Connection Aircraft Services 23 LTMI Customer Forum Replacing the aluminum brackets with plastic eliminated failures due to corrosion. Representatives of twelve airlines attended Lufthansa Technik Maintenance International (LTMI) s recent Customer Forum in Frankfurt. As well as German airlines, delegates came from England, Ireland, Norway, Turkey and Abu Dhabi and their feedback on the event was extremely positive. the cost of a new pivot pin kit set in half. When it comes to the development of improvements to SRUs, customers benefit not just from the technical competence of the MRO market leader. As Sabrina Hornig of Product Engineering and Planning points out: The close connection to Lufthansa Group s airlines gives us highly detailed knowledge of the requirements of every single aircraft component. This gives us a distinct edge. On top of this, in addition to the repairs ready for production that have already been developed, working with the customer we can also develop and implement new repair solutions. The result of each individual repair speaks for itself. Depending on the individual part more than half of the cost can be saved. But at the same time these highly efficient repairs, once carried out, have the effect of significantly lengthening the service life of the components. In this way Lufthansa Technik s customers benefit twice over a solution that truly deserves the name SMART. Sabrina Hornig Phone [email protected] Customer advantages Proprietary developments Cost reduction Extended service life Reduced scrap rate Availability improved Increased reliability Participants at the Lufthansa Technik Maintenance International Customer Forum attended a concentrated program of informative presentations and discussions covering every aspect of the maintenance world. Topics ranged from the A320 extended service goal to various maintenance program models and innovation topics, to the 787 engineering. There was also a briefing on the latest developments in manage/m. The attendees were particularly interested in two contributions on the subject of quality, which stimulated animated discussion among the airline representatives. It was exactly the right choice of topics, said John Fields, Engineering Manager Aer Lingus, praising the agenda. Andy Beck, Manager EasyJet, concurred: The conference is very well structured and focused on problem solving. Opportunity for improvement requests One of the high points of the Forum every year is the Airline Caucus, at which all the representatives get the opportunity to put their improvement requests to the Lufthansa Technik Maintenance International management. The session was kicked off by Altfried Nessel, CCO of Lufthansa Technik Maintenance International, who recapped on the suggestions for improvement that had been voiced the previous year and outlined the progress made in those areas since then. After that the floor was opened up for discussion and the exchange of experiences. Participants were particularly complimentary about the speed with which Lufthansa Technik Maintenance International always comes up with solutions for different customer problems. One topic that has not yet been entirely resolved is the desire on the part of customers to deal with a single point of contact within Lufthansa Technik for all operational matters. Mario Hess, in charge of Maintenance at Eurowings and a veteran participant of LTMI Customer Forums, values highly the good exchange of information and pleasant atmosphere. Wolfgang Urich, Manager Stations TUIfly, who had come directly from the International Airlines Technical Pool (IATP) in Abu Dhabi, said that he had accepted the invitation because every year there is something new to make attending the Forum worthwhile. Alexander Heilmann, CEO of Lufthansa Technik Maintenance International, commented: We are very grateful for the open discussion and the direct, honest feedback of our customers. And it is a great delight to be able to welcome a number of delegates to the event year after year. // Altfried Nessel Phone [email protected]

24 24 Engine Services Lufthansa Technik Connection Quiet, please! In partnership with the German Aerospace Center, Lufthansa and Lufthansa Technik are looking for new possibilities for noise suppression. Under a project which is led by the Lufthansa Group acoustic panels have been modified. The noise produced by turbofans is one of the limiting factors in air transport. Engineers therefore fight for every decibel by which the noise emissions can be reduced. There are a number of angles from which the level of sound produced during operation can be tackled. For example, it is well known that acoustic panels located in the engine inlets play an important role in the overall acoustics of an aircraft engine. They consist of annularshaped sandwich segments covered with wire mesh that extend up to the fan. As previous findings reveal these panels to have some acoustic shortcomings, the acoustic engineers have been looking for alternatives to the classic configuration. During an extensive series of tests conducted in collaboration with the German Aerospace Center (DLR) and supported by the Federal Ministry of Economics and Technology (BMWi), two hard wall acoustic panel variants for CF6-80C2 have been developed and tested. The acoustic measurement took place at Lufthansa Technik s engine test cell in Hamburg using DLR s unique microphone array that has been developed especially for indoor measurements. The array consists of some 60 microphones placed in the bottom right corner of the test cell covering different sound emission angles. Three days of measurements have lead to an enormous amount of data that currently is analyzed by DLR. Thus the so-called MODAL project (German: Modelle und Daten zur Entwicklung aktiver Schallschutzmaßnahmen im Luftverkehr) is an excellent example of how Lufthansa Technik not only vigorously pursues cost-effective efficiencies, but also goes to great lengths to achieve the best solutions for the environment that are technically feasible today. Lufthansa works permanently with partners in industry, public administrations, academic institutions and research to develop perceptible noise-reduction measures. This manifests itself in concrete efforts, such as the continuous modernization of the aircraft fleet, the ongoing optimization of the existing fleet and the use of noise-reducing procedures in daily flight operations. Dr. Gerd Saueressig Phone [email protected]

25 Lufthansa Technik Connection Aircraft Services 25 Oil filter analysis for CFM56 Strong focus on SCAMT Lufthansa Technik s Laboratory Services unit has been licensed to examine oil filters of CFM56 engines. Adding this special competence means another big step towards becoming the one-stop-shop for all MRO-related laboratory demands. As well as lubricating and cooling the highly stressed bearings in turbine engines, the oil also serves the important additional function of washing out wear debris and small particles and trapping them in the filter. The analysis of these particles caught in the filter is an important way of evaluating the technical health of an engine, which is CFM56 oil filter analysis has been added to the capability spectrum of Lufthansa Technik s Laboratory Services. why the engine manufacturer requires that regular examinations are carried out. Lufthansa Technik s Laboratory Services is now licensed to conduct oil filter analysis for the CFM56 engine series. This kind of examination is required, among others, by the following Service Bulletins: CMF56-5B SB , SB , SB and SB Training and audit classified and described by size, material class, condition and total quantity, supported by the appropriate images. Because Laboratory Services already has the necessary equipment, including the scanning electron microscope required for the analysis, obtaining the approval was a logical next step. To meet the requirements for obtaining Using the electron microscope the tiniest particles become visible. the approval, special trainings were performed, including the analysis of test filters and discussion of the results. The final audit was conducted by an expert from GE. Armed with this new approval, Lufthansa Technik s Laboratory Services has expanded its capabilities by an important element, underlining its approach to offering its customers the most comprehensive capability spectrum. Aircraft Engineering Services // A new name for the acclaimed think-tank of Lufthansa Technik Engineering: By renaming its renowned Maintenance Management Services Aircraft Engineering Services (AES), Lufthansa Technik is stepping up the focus on SCAMT services for its customers from the branding and visibility in the market perspectives. Under the new designation of Aircraft Engineering Services, the MRO provider s maintenance specialists will continue the success of what hitherto have been its Maintenance Management Services, offering the same content. The focus of activities will in future be increasingly on aviation-law related tasks. Maintenance Management Services has already provided support to operators in the past in managing airworthiness tasks. EASA regulations allow operators to subcontract the performance of Subcontracted Continuing Airworthiness Management Tasks (SCAMT), while the operator remains ultimately responsible vis-a-vis the aviation authority. The Aircraft Engineering Services department, rebranded as of 1 January 2014, will continue to be the organization within Lufthansa Technik that is responsible for SCAMT. Philipp Krusemeyer Phone [email protected] The first step in analyzing the filters is to carry out a predefined filter-washing process to gather all debris for analysis. In a second step the debris collected is Dirk Schulenburg Phone [email protected] For more information:

26 26 Events & Exhibitions Lufthansa Technik Connection Cabin solutions for America Photo: Sven de Bevere Lufthansa Technik presented its two latest products for the aircraft cabin the GuideU floor path marking system and the HelioJet cabin lighting system at the recent Aircraft Interiors Expo Americas show. // American carriers are increasingly backing new, efficient aircraft. To save fuel, more and more attention is being paid to aircraft weight. American airlines are therefore particularly interested in cabin furnishings that improve passenger comfort, require little maintenance and at the same time save weight. These requirements are satisfied by Lufthansa Technik s new GuideU 1000-series and HelioJet cabin products. When presented at Aircraft Interiors Expo Americas, they met with a lot of interest from American aircraft manufacturers and airlines alike. Together with SCHOTT Lighting and Imaging Lufthansa Technik presented HelioJet, a new LED lighting technology for the aircraft cabin that uses approximately one fifth of the LEDs required by conventional LED lights. A special procedure ensures that the light is evenly distributed. HelioJet also has the advantage of requiring very little in the way of maintenance. GuideU 1000-series, the latest version of the Lufthansa Technik non-electric floor path marking system, was also on show. Designed to fit every common cabin floor material GuideU provides for a very easy installation, a broad choice of colors and a lifetime without maintenance. The patented GuideU system features a most efficient and light-weight design, saving more than 15 percent weight versus competing products. With Dubai as one of the world s booming hubs, Lufthansa Technik is expanding its offering here. Reliable partner in the Middle East The Middle Eastern aviation market is strongly growing. At Lufthansa Technik Middle East Services (LTMES), headquartered in Dubai, Lufthansa Technik is continuously expanding its range of technical services for the region s customers. The Dubai Airshow at the end of 2013 visibly underlined Lufthansa Technik s role as reliable partner for the Middle East and Africa region, providing high-quality technical solutions for both private and commercial aircraft operators. Lufthansa Technik Middle East Services (LTMES) bundles all the contact partners for sales, logistics, technical training and the component business, and makes them available in Dubai. Lufthansa Technik Middle East Services Managing Director Ziad al Hazmi outlines the development: We have already added local employees to strengthen both our customer service in the area of component support and the sales office for our regional VIP customers. Now we are considering expanding The product sales team in America. The Lufthansa Technik booth at the Dubai Airshow with ample lounge space for business meetings.

27 Lufthansa Technik Connection Events & Exhibitions 27 Meet us at... MRO Middle East 5-6 February 2014 Booth 316 D ubai On site: Ziad al Hazmi is Managing Director of Lufthansa Technik Middle East Services January 2014 Bahrain Bahrain Airshow The Bahrain International Airshow has established itself as one of the most elite business-to-business events February 2014 Dubai MRO Middle East The MRO Middle East Conference and Exhibition brings together decisionmakers from airliness and suppliers. our material support services, deploying specialized personnel for our customers in the region and providing line maintenance services for customers outside Lufthansa. Composite repairs ARC Owing to rising demand for on-site technical services for nacelle components, repair operations for Airframe Related Components (ARC ) will be expanded in early With a local facility in place, spare part provision and repairs can be offered more efficiently to customers in the region. Depending on the required service, repairs can be undertaken either at the customer site or in Dubai without creating additional transport expenses, or be organized within the Lufthansa network. Catering for the rapid growth of the aviation industry in the Middle East and the continual increase in aircraft movements in the region, Lufthansa Technik Middle East Services will also begin to offer the highly efficient service Cyclean Engine Wash at its facility in Dubai as well as at the region s airports. There have already been a lot of definite enquiries from airlines interested in using the service. Cyclean Engine Wash The Cyclean process frees the engines, in particular the fan and compressor blades, from dirt such as sand, mud, dust and pollen. Once cleaned, the engines are more thermally efficient in operation and use up to one percent less kerosene for the same level of performance. This reduces costs and is better for the environment. For us and our customers, the performance of the engines, protecting the environment by reducing CO 2 emissions, and cost savings from extended on-wing time are foremost considerations, says Oliver C. Winter, Program Manager Cyclean Engine Wash at Lufthansa Technik. Ziad al Hazmi: Our new services in Dubai will help us fulfill the wishes of our airline and VIP customers even better February 2014 Singapore Singapore Airshow Asia s largest aerospace and defence event ranges among the most renowned air shows in the world February 2014 Moscow Aircraft Maintenance Russia The annual platform in Russian and the CIS for discussing the main issues of aircraft maintenance and repair March 2014 Johannesburg MRO Africa The next MRO Africa will again be a place to network with leading players from Africa and around the world. Preview Highlights from the next issue: Innovation Management Aircraft recovery Fleet manager portrait Cyclean is now offered on site in the region. Ziad al Hazmi Phone [email protected] For more information:

28 28 Products & Services Lufthansa Technik Connection World of services No matter if you are a regional start-up, a small or mid-sized carrier, a private or governmental operation, or a legacy airline: Our range of products and services can be tailored for commercial and private fleets of every mix, kind and age. 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 Support (TBS ) Total Material Operations (TMO ) Total Component Support (TCS ) Total Engine Support (TES ) Total Landing Gear Support (TLS ) 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 Engine Services Landing Gear Services VIP & Executive Jet Solutions Logistics & Training Special Services The world s leading manufacturer-indepenent MRO provider offers a product portfolio reaching beyond traditional MRO services from the manual. Composite Repairs (ARC ) Engine Parts & Accessories Repair (EPAR) Maintenance Management Services (MMS) Aircraft Leasing & Trading Support (ALTS ) AOG Services Surface treatment Cabin & IFE Products Lufthansa Technik has successfully established a line of cabin products. Cabin Management & IFE Systems Aircraft & Cabin Equipment Connectivity Patient Transport Solutions eservices Lufthansa Technik s Technical Operations Websuite manage/m allows operators to manage their technical operations via a web-based system. For more information: Hotline 24/7 AOG desk Hotline Airbus A300 A310 A300 A318 A310 A319 A318 A320 A319 A321 A320 A330 A321 A330 A340 A A380 Airbus A300 P&W JT9D, PW , GE CF6-80C2 Airbus A310 JT9D, PW , CF6-80C2 Airbus A318 CFM56 Airbus A319 CFM56-5, V2500-A5 Airbus A320 CFM56-5, V2500-A5 Airbus A321 CFM56-5, V2500-A5 Airbus A330 CF6-80, PW , Trent 700 Airbus A340 CFM56-5, Trent 500 Airbus A380 Trent 900

29 Products & Services 29 Lufthansa Technik Connection Boeing 737 Regionals Boeing 737 CRJ Bombardier CRJ GE CF34 CFM56-3 CRJ NG 737 Boeing 737NG Q-Series Bombardier Q400 PW100, PW150 CFM56-7B Q-Series NG/MAX Boeing 747 JT-9D, PW4000, CF6-80C E-Jets ERJ 190 Embraer E-Jets 170/175, 190/195, GE CF34 Boeing 757 RB Boeing 767 PW , CF6-80C Boeing 777 Business Jets Airbus Corporate Jets Boeing 787 Engine Services* CFM56, V2500-A5 Boeing Business Jet 787 MD-11 CF6-80C2, PW MD11 MD-80 MD-80 BBJ Airbus Corporate Jetliner CFM56-7B *schedule to be defined MD-11 ACJ Bombardier Bombardier Boeing Business Jet (BBJ) Challenger, Learjet, Global Express. CF34 Challenger Family Embraer Embrear Executive Jets Embraer Legacy, Lineage. CF34

30 30 Contacts Lufthansa Technik Connection Senior Vice President Marketing & Sales Walter Heerdt p f [email protected] Vice President Marketing & Sales Wolfgang Weynell p f [email protected] Key Account Govt. & Special Mission Aircraft Hans Indlekofer p f [email protected] Key Account VIP & Executive Jets Joachim von Holtzapfel p f Let s talk about solutions Director Sales USA and Canada Robert Gaag p f [email protected] Director Sales Western Europe (acting) Georgios Ouzounidis p f [email protected] Director Sales Central Europe André Fischer p f [email protected] Director Sales Latin America and Caribbean Jörg Femerling p f [email protected] Director Sales Middle East, Africa Wieland Timm p f [email protected] Local representatives Australia and Pacific Roland Wunderlich p f BeNeLux Rudi Preud'homme p f rudi.preudhomme@ lht.dlh.de Canada Dan Hepworth p China Steven Wang p f [email protected] India Wolfgang Hartl p f Italy Georgios Ouzounidis p f Japan Hidenori Sato p f Turkey Fulya Türköz p m

31 Lufthansa Technik Connection Affiliates & Corporations 31 Director Sales Eastern Europe and CIS Dmitri Zaitsev p f [email protected] Key Account Lessors & Banks Harry Seeger p f Director Sales South East Asia and Australia Robin Johansson p f [email protected] Dubai Ziad Al Hazmi p f [email protected] United Kingdom Paul Conway p Director Sales East Asia Richard Haas p f [email protected] Worldwide Michael Struck p f Lufthansa Technik Airmotive Ireland Phone Fax [email protected] Lufthansa Technik AERO Alzey Phone Fax [email protected] Lufthansa Technik Brussels Phone Fax [email protected] Lufthansa Technik Budapest Phone Fax [email protected] Lufthansa Technik Phone Fax [email protected] Lufthansa Technik Intercoat Phone Fax [email protected] Lufthansa Technik Landing Gear Services UK Phone Fax [email protected] Lufthansa Technik Logistik Services Phone Fax [email protected] Lufthansa Technik Maintenance International Phone Fax [email protected] Lufthansa Technik Malta Phone Fax [email protected] Lufthansa Technik Milan Phone Fax [email protected] Lufthansa Technik Philippines Phone Fax [email protected] Lufthansa Technik Services India Phone Fax [email protected] Lufthansa Technik Shenzhen Phone Fax [email protected] Lufthansa Technik Sofia Phone Fax [email protected] Lufthansa Technik Turbine Shannon Phone Fax [email protected] Lufthansa Technik Vostok Services Phone Fax [email protected] Lufthansa Technical Training Phone Fax [email protected] Lufthansa Bombardier Aviation Services Phone Fax [email protected] Lufthansa LEOS Phone Fax [email protected] Airfoil Services Phone Fax [email protected] Ameco Beijing Phone ext 4100/4101 Fax [email protected] BizJet International Phone Fax [email protected] Hawker Pacific Aerospace Phone Fax [email protected] Heico Aerospace Phone Fax [email protected] IDAIR Phone Fax [email protected] lumics Phone [email protected] N3 Engine Overhaul Services Phone Fax [email protected] Shannon Aerospace Phone Fax [email protected] Spairliners Phone Fax [email protected]

32 Welcome home. No matter how exclusive your wishes are, Lufthansa Technik VIP & Executive Jet Solutions can implement them. With our dedication to unrivaled perfection, we set new standards in interior completion. Our customers receive both the latest technical solutions and outstanding designs. It all adds up to VIP solutions that will leave you breathless. Lufthansa Technik AG, Call us: lufthansa-technik.com/vip-services More mobility for the world