Lean works E-Jet component support Strong in the Middle East
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The Lufthansa Technik Group Magazine 4.2013 July/August
Regional Aircraft Services
E-Jet component support
Regional Sales
Efficient maintenance
Strong in the Middle East
Lean works Lufthansa Technik Philippines
The A380 overhaul expert
2 | Content Lufthansa Technik Connection 4.2013
Training in Asia
Training
With a broad training portfolio and several facilities in the region
• Lufthansa Technical Training: 5
Lufthansa Technical Training has the right solutions at hand.
Training for a booming region
eServices
• manage/m®: 7
m/material online shop
5 Aircraft Services
• Lean methods:
The maintenance factory
• Lufthansa Technik Philippines:
The A380 overhaul expert
8
12
• Interview with Dr. Loss
8
and Werner Luehmann: 14
The maintenance factory “Safe and cost-efficient operations”
• Adhesive foil: 17
Using Critical Chain Project Management, Lufthansa
Foiling is flexible and fast
Technik Maintenance International established itself as
a lean maintenance factory.
Regional Sales
• Local presence: 18
Gearing up for the Middle East
Employee Portrait
• Harry Haber: 20
Kerosene in the blood
Regional Aircraft Services
• Spairliners: 22
Component support for E-Jets
• Lufthansa Technik Logistik Services: 23
Strong in the Middle East Distribution logistics for Saab
Lufthansa Technik is expanding its presence
Innovation & Technology
and local capability.
• Laser-based repair: 24
State-of-the-art blade restoration
Events & Exhibitions
• VIP exhibits: 27
18
New trade fair stand design
Categories
• News 3 - 4, 26
• Personalities 23
• Events & Exhibitions 27
• Products & Services 28
• Contacts 30
Component support for E-Jets
Spairliners has added E-Jet component support to its portfolio.
Lufthansa Technik Connection
is a complimentary information service for Lufthansa Technik’s
family and friends. Published every two months.
This and earlier issues can be downloaded from our website
www.lufthansa-technik.com/connection
Publisher
Lufthansa Technik AG
Tilman Tesseraux · Marketing & Sales · HAM TS/M
22
Weg beim Jäger 193 · 22335 Hamburg, Germany
Infoline +49-40-5070-5553 · Fax +49-40-5070-8860
marketing.sales@lht.dlh.de · www.lufthansa-technik.com
Editorial Production
Editorial office: Flightlines, Hamburg
Design: Art Works! Werbeagentur, Hamburg
Photos: Lufthansa Technik AG, Lufthansa AG
Printing: Beisner Druck GmbH & Co. KG
Lufthansa Technik Connection 4.2013 News | 3
Best MRO provider in Europe nice® HD for
Two awards for Lufthansa Technik // At this year’s Aircraft Technology Engineering &
Maintenance Awards ceremony, Lufthansa Technik scored a double success, winning
Challenger 350
the much sought-after awards in two out of twelve categories: “Best Airframe MRO Pro- Bombardier // Lufthansa Technik’s
vider – EUROPE” and “Best Engine MRO”. The awards were determined on the basis Innovation business unit has been
of an internet vote by industry experts, who in turn were not allowed to vote for their own selected by Bombardier Aerospace
company. Compared with many other industry awards, to supply cabin management and
the Aircraft Technology Engineering & Maintenance in-flight entertainment (CMS/IFE)
Awards are highly prestigious, as the prizewinners systems on its new Challenger 350
are determined not by an interest-based jury but by aircraft program. This latest
thousands of experts from the industry. Lufthansa announce comes after Bombardier’s
Technik invited selected customer representatives selection of the nice® HD system on
to attend the awards ceremony as guests. // the Learjet 70, 75 and 85 aircraft
programs. So far Lufthansa Technik
At the Awards Gala Dinner hosted by media company UBM
Aviation and held to coincide with the Airline Purchasing &
has delivered more than 300 ship-
Maintenance Expo Europe trade show in London, Paul Conway, sets of the first generation nice®
Sales Director UK and Ireland (left), accepted the two awards and its successor, nice® HD, to
on Lufthansa Technik’s behalf from the hands of Phil Callow, Bombardier Aerospace. //
CEO of UBM Aviation.
Lufthansa takes delivery of milestone Jumbo
50th Boeing 747-8 // Boeing celebrated the 50th delivery of a 747-8. Lufthansa,
the launch customer of the passenger version, took delivery of the milestone air-
craft almost one year after the first revenue flight of the 747-8 Intercontinental. It
is the airline’s seventh 747-8 and its 82nd 747 overall. “Lufthansa is very proud
to have the next Boeing 747-8 entering our fleet – almost exactly one year after
the launch flight from Frankfurt to Washington, DC,” said Nico Buchholz, Executive
Vice President Fleet Management, Deutsche Lufthansa. “After one year of opera-
tion and now seven aircraft
in the fleet, the aircraft has Best VIP cabin outfitter
proven and delivered the
Airbus award // For the second year in suc-
excellent economical and
cession Lufthansa Technik was named by
ecological performance.
Airbus Corporate Jets as the “Best VIP cabin
We are very happy with
outfitter” for the work done in its completion
the reliable operation of
centers in Hamburg/Germany and at BizJet
the 747-8.” //
International in Tulsa, Oklahoma, in the United
States. The award recognizes the best of the
Airbus Approved Outfitting Centers in 2012.
Dr. Hans Schmitz, Senior Vice President VIP &
Executive Jet Solutions at Lufthansa Technik
Presidential visit to Hamburg (photo below: left), accepted the award at the
Federal President of Germany // On the occasion of his first visit to EBACE 2013 in Geneva, saying: “I would like
Hamburg, Federal President Joachim Gauck (3rd from right) was to thank all Lufthansa Technik employees
welcomed on the facility of Lufthansa Technik by the President of the within our VIP business for their permanent
Hamburg City Parliament, Carola Veit (far left). At Lufthansa Technik engagement and discipline. We are extremely
Gauck spoke to Chairman of the Executive Board August Wilhelm proud that we have been able to keep our
Henningsen (2nd from left) and visited the Jumbo hangar. Inside an high level of performance and quality in our
Airbus A330 the Head of state evidently enjoyed having the overhaul VIP business which has led to this re-acknowl-
work explained to him edgement by Airbus Corporate Jets.” //
and he also sat down at
the aircraft controls.
Gauck then headed off
for his next engagement
– opening the International
Garden Show at midday
in the presence of 1,500
guests. //
4 | News Lufthansa Technik Connection 4.2013
200th heavy maintenance for United
Ameco Beijing // Lufthansa Technik’s Chinese affiliate Ameco Beijing recently redelivered
737NG support the 200th heavy maintenance check for United Airlines, representing a new milestone
for the mutual cooperation. The cooperation began in 2005 with the selection of Ameco
for Pegasus Airlines Beijing as MRO provider for United’s Boeing 777 fleet. It went through the first contractual
Base maintenance // Pegasus period when Ameco Beijing performed 53 Boeing 777 heavy maintenance checks for
Airlines, the leading low-cost air- United. In March 2010, the overhaul services had been expanded further with heavy
line in Turkey, and Lufthansa maintenance and “International Premium Travel Experience” (IPTE) cabin modification
Technik have signed a base program on United’s Boeing 777 fleet as well as heavy maintenance on Boeing 747 fleet.
maintenance contract for three Since June 2012, Ameco Beijing has been entrusted with United’s Boeing 747 line mainte-
C-checks for the carriers Boeing nance which has been more than 100 times by now. //
737NG aircraft at Lufthansa
Technik Sofia. Sertac Haybat,
General Manager and Member
of The Board of Pegasus Airlines,
stated: “We have been very sat-
isfied with the base maintenance
work Lufthansa Technik delivered
to us. It is therefore not surprising
that we would trust Lufthansa
Technik to deliver the same qual-
ity and level of service at a very
competitive price once again.” //
Cooperation with Liebherr Aerospace
Exchange of know-how // Liebherr-Aerospace & Transportation SAS, Toulouse (France), and Lufthansa
Technik have recently entered into a long-term cooperation. The agreement stipulates the bilateral
exchange of know-how and process and repair documentation of a wide range of components for air
management systems, flight control and actuation systems as well as landing gears developed and
manufactured by Liebherr-Aerospace. The cooperation strengthens the companies’ relationship and
offers promising prospects for the development of customer service solutions. Liebherr-Aerospace &
Transportation SAS is one of ten divisional control companies within the Liebherr Group and coordinates
all activities in the aerospace and transportation systems sectors. //
Pillar in the overhaul network
Lufthansa Technik Malta 10th anniversary // With a workforce
of 600 and well over 500 checks and aircraft modifications under
Stay up to date!
its belt, Lufthansa Technik Malta has developed into an important Customer Newsletter // The Lufthansa Technik’s
pillar in the overhaul network of Lufthansa Technik in the ten years online customer newsletter Connection Flash supple-
since it started in 2003. “We are proud of the way the company ments our popular bi-monthly Lufthansa Technik
has developed over the years, but we are still developing,” said Group Magazine Connection with first-hand news
Stephan Drewes, CEO of the subsidiary of Lufthansa Technik, on on innovative technologies and developments, new
the occasion of the celebrations to mark the tenth anniversary of services and offers, and future
aircraft overhaul operations at events. Please follow this link
Malta International Airport. to sign up for Connection Flash:
Since a new hangar complex www.lufthansa-technik.com/
was opened in 2009, the joint customer-newsletter //
venture between Lufthansa
Scan the QR code to subscribe online.
Technik and Air Malta has also
been offering support services
for long-range aircraft. As well
as working on up to three
narrowbody aircraft, up to two
widebodies in the Airbus A330/
A340 family can be handled
at the same time. //
Lufthansa Technik Connection 4.2013 Training | 5
Training for a booming region
The demand for technical training in Asia is high. With its three dedicated teams, a broad
training portfolio and several facilities in the region Lufthansa Technical Training has the right
solutions at hand.
T
he aviation industry in Asia is boom- Among the training services offered by er of the Training Centre Philippines. The
ing, resulting in high demand for Lufthansa Technical Training in Manila and training establishment in Manila, Lufthansa
well trained, skilled labor. As the Singapore are type training for all the pop- Technical Training Philippines, is approved
Lufthansa Technik Group’s training special- ular Airbus and Boeing aircraft, basic train- by the Civil Aviation Authority of the Philip-
ist, Lufthansa Technical Training has local ing, Human Factors courses and training pines (CAAP). In cooperation with the two
facilities in Manila, the Philippines, in Sin- sessions on the subject of aviation legisla- biggest aeronautical training establishments
gapore and Taiwan, from which it offers a tion. “Basic training and A320 type training in the Philippines, Jocson College and
wide range of training services. To meet for younger staff are especially popular as Feati University, around 1,500 students are
the growing demand, the company is also a lot of aircraft of this type are on order in
stepping up its cooperation with universities. Asia,” says Jochen Harms, General Manag-
� Please continue on page 6
6 | Training Lufthansa Technik Connection 4.2013
Lufthansa Technical Training offers a vast array of
services for the Asian market, ranging from basic
type training to consulting services.
currently being trained for Category A invite students from outside Singapore “The biggest demand is for basic train-
maintenance work on a five-year program. onto courses with a duration of more than ing,” he adds. “And it is here that our strength
Most of the practical on-the-job training is 30 days, for which student visas are lies: our facilities are the very best in the
carried out at Lufthansa Technik Philippines. obtained. Classrooms, workshops and region and are particularly well geared
To cope with the exacting market in Asia, instructors trained to towards basic train-
“
a new IT landscape has been installed at Lufthansa Technical ing.” When it comes
Lufthansa Technical Training Philippines Training standards to practical training,
and preparatory work aimed at obtaining are available at co- Our facilities are the very best the China Aviation
EASA Part-147 approval is under way. “In operation partner Te- in the region and are particularly School near Hsinchu,
Malaysia alone the aviation industry will masek Polytechnic. well geared towards basic Taiwan, boasts
need 16,000 staff over the coming years,” Another country training. among other things
Rainer Grünzfelder
says Jochen Harms, illustrating the huge in which Lufthansa ten training aircraft
demand. The company has therefore Technical Training is widely ranging in
made contact with 200 universities in Asia active in Asia is Taiwan. “With a population size, as well as 17 turbine engines and 20
with a view to establishing possible coop- of about 23 million, Taiwan itself has its piston engines. Trainers and simulations
eration. Looking ahead to the future, he limits as a market region, but there are a are available for every aircraft system, so
says: “The universities are very interested, lot of airlines and, thanks to the opening that a large number of students can be
and there are a lot of offers and requests up of contact with China, air travel is also trained at the same time.
for cooperation.” booming here,” says Rainer Grünzfelder, In addition to its Taiwanese CAA Part-
In Singapore too Lufthansa Technical General Manager of Lufthansa Technical 147 approval, the location also has the
Training is also certified by the local Training Taiwan. Thus, for example, students Mongolian MCAA Part-141 approval.
authority – the Civil Aviation Authority of come to Taiwan from Mongolia, China and Students are not only referred through the
Singapore (CAAS) – and is thus able to Singapore. partner schools of the China University of
Science and Technology, a cooperation
partner with several partner universities all
over Asia, but a lot come to Taiwan from
different Asian countries for practical train-
ing and at the same time to gain some for-
eign experience.
Conversion to EASA system
One special service offered by Lufthansa
Technical Training Taiwan is consultancy.
For two years the training specialists have
been assisting with the conversion of the
Taiwanese aviation regulations from an
FAA system to an EASA system. Here they
perform all the local services as well as
managing projects. The direct partner on
the project is Evergreen Aviation Technol-
With air travel booming in Taiwan, it is one of
the Asian markets where Lufthansa Technical
Training is active.
Lufthansa Technik Connection 4.2013 eServices | 7
Enhanced m/material
online shop
ogy, the maintenance organization of m/material is the manage/m® web application managing
the airline Eva Air. All license holders,
of whom there are 1,800 in Taiwan,
all aspects of a customer’s material contract with Lufthansa
will need to upgrade their licenses as Technik. The new online shop offers customers a number of
a result of the regulatory change. At
the moment Lufthansa Technical Train-
new features offering greater user-friendliness.
ing Taiwan is the only training estab-
lishment that has the requisite approval
T
for the relevant conversion training he m/material online shop pro- One novelty is the possibility of order-
and conversion examination. This year vides instant access to Lufthansa ing different materials as a single order
more than 200 license holders have Technik’s material catalog, pro- to be delivered to a single site through
already converted their licenses. viding availability and price of con- a combined ordering process. This
sumables and expendables (C&E). can now be accomplished by simply
Going “down under” With m/material being the manage/m® uploading an Excel list – m/material
application to manage all aspects of then automatically creates the order.
When it comes to training young staff for a customer’s material contract, the m/material can be customized for
the Asian market, Lufthansa Technical online shop manages different kinds every customer. Both the contact per-
Training is also looking beyond the of orders – from pool requests to pur- son at Lufthansa Technik and the cus-
Asian continent: for example, the train- chase (covering line replaceable units tomer’s contract data are stored in the
ing service provider has entered into a as well as consumables and expend- system and therefore available instantly.
collaborative agreement with the Aus- ables), to loan and even 1:1 exchange. The same is true for the contract con-
tralian Kangan Institute. Thanks to this ditions, as the contract framework of
agreement, the Kangan Institute’s Avi- each customer is part of his profile.
ation Industry Training Centre (AITC) is Customers can thus order any items,
able to offer its students an EASA Part- always keeping to their contractual
66 CAT B1 or B2 license – a qualifica- framework conditions.
tion that is also popular among Asian The m/material online shop’s excel-
students in Australia. lent usability is based on its intuitive,
self-explaining structure. Working reli-
ably and securely using all common
Lufthansa Technical Training browser types, it is a stand-alone web
Philippines application for material order and moni-
Jochen Harms toring with a global function. Project
Phone +63-2855-9555 manager Georg Pelda states: “The first
jochen.harms.dlh.de Starting with an easy to use search launching customers are already using
function, customers can submit mate- the system, much to their satisfaction.
Lufthansa Technical Training Taiwan rial orders and monitor them through- Moreover, in the second half of the
Rainer Gruenzfelder out the whole delivery process. Thanks year we plan to enable other customers
Phone Taiwan +886-932-198-862 to the quick order process, requesting using systems such as TRAX or AMOS
Phone China +86-159-022-40-870 material only takes a few simple clicks. to use these new functions as well.”
rainer.gruenzfelder@dlh.de
8 | Aircraft Services Lufthansa Technik Connection 4.2013
Focusing ressources and man power on a
single C-check is one of the keys to success
for Critical Chain Project Management.
The maintenance factory
Following the reorganization of production processes to Critical Chain Project
Management, Lufthansa Technik Maintenance International in Frankfurt has finally
established itself as a maintenance factory for events through to C-checks.
Customers benefit from shorter layovers and a standardized transparent reporting.
Lufthansa Technik Connection 4.2013 Aircraft Services | 9
W
e start fewer things at the same for Critical Chain Project Management, a “maintenance factory” with the performance
time, but allocate more capacity lean method of planning and managing pledge of taking on complex and “difficult”
to individual tasks – and as a projects that puts the main emphasis on the checks even at very short notice.
result we finish more quickly.” Such is the resources required to execute project But, as Thomas Mützel points out: “This
simplified common denominator to which tasks. This contrasts with more traditional approach significantly increases the vari-
Dr.-Ing. Thomas Mützel reduces the princi- methods which emphasize task order and ability of the tasks that ultimately have to
ple that has dictated the way of working in rigid scheduling. be completed for a check. It’s contrary to
Base Maintenance at Lufthansa Technik a classic series production, for example in
Maintenance International since last year. Last-minute, complex automobile industry, where the process
Today Thomas Mützel is Section Manager and difficult checks and work lists and the parts that will be
Airbus A330/A340, but in his previous needed are exactly known before produc-
capacity as Team Manager, Lean Produc- For Lufthansa Technik Maintenance Inter- tion gets under way. Even when we know
tion & Quality, at this Lufthansa Technik national the possibility of switching to CCPM the airplane extremely well, we never know
Group company that specializes in main- appeared to be the way forward if the com- exactly what awaits us down the line on
tenance work for international customers, pany was to respond better than it had up a check.” The mix of C-checks and the
he was responsible for the methodical to now to the growing and increasingly shorter A-checks adds another dimension
process transition. differentiated requirements of the market. to the complexity of the work processes and
CCPM is the “magic formula” behind The company which was launched on the also to personnel and material planning.
this approach, which is still relatively new market five years ago has positioned itself
in the MRO industry. The acronym stands within the Lufthansa Technik Group as a
� Please continue on page 10
10 | Aircraft Services Lufthansa Technik Connection 4.2013
Before and after:
The effect of CCPM on work in progress
Cargo Comp.
Avionics
Tail
Incomings Finals &
Doors Run up
Preparation Run up Engines
phase Wings
Cabin
Sheet metal
Before (top) and after
Landing gear
changing the maintenance
A/C arrival processes to Critical Chain
Project Management: Work
packages are broken down
Cargo Fuselage Panel Closing into smaller units, each with
Tail D & I
D&I D&I
Finals &
a start and an end. The units
Incoming Volume of work 1 Volume of work 2
s
Engine D&I Run Up
are then integrated into the
Preparation FK2
phase
FK1 Run up Avionics
D&I
Doors
D&I
Gears
D&I
Wings
D&I
Avionics S&R process chain on the basis
Cabin D&I Cabin S&R Cabin Installation
of how many resources and
Sheet
how much time they require.
metal FK 2 Sheet metal S&R
D&I
In the past these complex framework Maintain low work in progress experience suggests that a plan compris-
conditions had two primary consequenc- ing a series of milestones is based on
es. Firstly, the uncertainty made it difficult Multi-tasking is the primary source of wast- estimates. The result is that the intervals
to predict where bottlenecks could be ed capacity in a project environment. This between milestones are calculated so as
expected in the production process and challenge is countered by the first rule, which to incorporate a safety margin and hence
sometimes the predictions were wrong. says that the number of projects running are overly generous. This classic path
This in turn led directly to multi-tasking simultaneously – the work in progress (WIP) – does not allow for any early warning sys-
and as a result to inefficient use of highly must be minimized. Because maintenance tem. If a major problem only becomes
skilled staff. Before CCPM, firefighting was work is almost always performed under obvious at a milestone, the plan falls apart
the order of the day. And secondly, experi- time pressure, there is always a feeling that as the next task is waiting after that mile-
ence showed that predictions of how long projects or subtasks of projects need to be stone. Furthermore classic planning pro-
a given work package would take regular- started early on. In order to finish the tasks cedures are based on local efficiencies
ly proved to be little more than speculation, in time highly skilled employees have to such as productivity.
with corresponding implications for plan- alternate between tasks. CCPM follows a different path. Work
ning certainty. This multi-tasking applies not only to packages are broken down into smaller
The success of layover planning and its support processes, engineering and mate- units, each with a start and an end. These
application on the basis of Critical Chain rial support but also to managers, who are units are integrated into the process chain
Process Management depends on a few overloaded by too many simultaneous on the basis of how many resources and
important far-reaching rules being in place tasks. “Instead of running two tasks, each how much time they require.
and consistently followed in practice. In at 80 percent capacity, we prefer to invest
the closed system of all the work associat- 110 percent in one task. The effect is a lot Effective buffer control
ed with a layover in the hangar the critical greater,” says Thomas Mützel. The classic
issue is always the allocation of capacity approach to planning a project entails a Based on the knowledge that in the past
between the various work packages. At series of milestones. As a matter of princi- the time necessary to accomplish a given
Lufthansa Technik Maintenance Interna- ple project managers determine whether task was planned too conservatively, the
tional this process runs according to three the project is where it needs to be in terms scheduled times have now been cut signif-
rules. of the next milestone. At the same time icantly. This “time saving” is then put into a
transparent buffer. On the one hand the
buffer is available when unexpected prob-
lems arise – they can now be worked
through in a hassle-free fashion – and on
the other hand it makes it possible to deal
more effectively with situations where the
work is finished ahead of time. This also
has the effect of reducing work in progress
significantly Finally the change in prioritiza-
tion logic from worker productivity (every-
one has to perform on 100 percent) to a
lead time focus (do less in a faster way)
leads to a drastic reduce in WIP.
But even with these rules there is one
overriding principle, as Thomas Mützel
points out: “We don’t start at all until we
The hangar of Lufthansa Technik Maintenance International in Frankfurt.
Lufthansa Technik Connection 4.2013 Aircraft Services | 11
The unusual approach generates directly measureable results in regards to punctuality.
have gathered together all the documenta- “old habits” and, for example, when one earlier,” says Mützel. It goes without saying
tion and the materials required to complete job is done immediately start – in uncoor- that Lufthansa Technik Maintenance Inter-
the activity.” At the start of the project dinated fashion – work that does not fit into national is gaining in efficiency and com-
plan there is therefore an item known as the new system. “We grew up in an indus- petitiveness as a result.
“Full Kit 1”. try in which firefighting was the order of the
This coordinated start is followed by a day due to multi-tasking,” says Thomas Transparent reporting
depanel and inspection phase, in which Mützel. “Trusting that at the end of the day
the entire aircraft is opened up and the things would go quicker if you were to start With this process model it is especially
components and systems are inspected fewer things at the same time, was an important to have good communications
and, where necessary, dismantled. All the unusual challenge.” with the customer. Standardized reporting
routine items are carried out during this The first check based on Critical Chain is now in place, with customers now being
phase. By contrast, pre-CCPM, they would Project Management was carried out in notified in a highly transparent manner of
“
already start by the autumn of 2011. the progress of the check, how much of
working through the Since then, the han- the buffer time has been used up, the cur-
findings and non- That approach significantly gar in Frankfurt has rent status of the aircraft and of individual
routine work. Once increases the variability of the often presented an assemblies. Furthermore there is a clear
the inspection phase tasks that ultimately have to be unusual sight. focus on which problems have to be
is over, the second completed for a check. Although one aircraft solved by the MRO provider or in coopera-
part of the project Thomas Mützel is a hive of activity, tion with the customer.
plan covering all the it may be that a sec- In this way, thanks to CCPM, Lufthansa
rest of the check is drawn up. This is based ond aircraft is apparently standing neglect- Technik Maintenance International is well
precisely on the actual findings and reliably ed in the hangar. Whereas in the past, equipped for the future and for stronger
contains the actual work that still has to be given the task mix described above of demand. “The more work there is in the
carried out. A-checks through to complex C-checks pipeline, the more effective become the
involving up to 4,000 man hours, the advantages of this system,” says Thomas
Shop load specific management workforce would be working on all fronts Mützel.
simultaneously, today a C-check is put
For the purposes of check management on hold and the resources are put into a Dr.-Ing. Thomas Mützel
according to CCPM Lufthansa Technik short-notice A-check. As soon as this check Phone +49-69-696-69863
Maintenance International uses the Con- is finished, everyone goes back to the thomas.muetzel@lht.dlh.de
certo planning and execution software C-check. What’s more, C-checks are no
from Realization. But, according to Mützel, longer carried out in parallel, but one at a
as well as suitable software it is equally time (see figure on page 10).
important “that we ensure on a daily basis This unusual approach in the hangar Critical Chain
that we maintain a project status with as may take some time for customers to get Project Management
low as possible a workload (low work in used to, but ultimately they are convinced
// Critical Chain Project Management
progress).” To make this concept work it is by the directly measurable results of this
(CCPM) is a lean method of planning and
very important that event managers are approach: C-check layovers have been
managing projects that puts the main
constantly on site, find time to talk to the cut by between 15 and 20 percent.
emphasis on the resources required to
staff, continually analyze which tasks are Punctuality, which in any case is high for
execute project tasks. This contrasts with
necessary and constantly revise their view C-checks, is also virtually 100 percent for
more traditional methods which empha-
of the progress of the project. One major A-checks. “In the final analysis we now
size task order and rigid scheduling. //
challenge here is to avoid falling into the always finish either on time or a little bit12 | Aircraft Services Lufthansa Technik Connection 4.2013
The A380 overhaul expert
After Lufthansa Technik Philippines has completed its first C-checks on an A380, the Asian
center of excellence for A380 overhaul services in the Lufthansa Technik Group is gearing up to
increase its capability further.
D
uring the second quarter of 2011, largest passenger airliner ever built. As expanded suite of services. Lufthansa
Lufthansa Technik Philippines experts in base maintenance for Airbus Technik Philippines’ technical personnel
broke ground to start construction type aircraft, Lufthansa Technik Philippines are now certified to perform C-checks on
of its third widebody hangar able to had been entrusted by Qantas Airways to the aircraft. This service has already been
accommodate the Airbus A380. A year of carry out cabin modification works for its performed in conjunction with the cabin
comprehensive preparatory work followed, entire A380 fleet. Since the start of this reconfiguration and wing rib repair tasks
comprising personnel trainings in Frankfurt campaign in 2012, six A380s of the Aus- for the two A380s that followed within the
and in Manila, obtaining certifications and tralian airline have already been modified. first quarter of this year.
completing facility requirements, among A major wing rib modification was per- “Qantas Airways is one of our most
others. Then the 8,500-square meter han- formed in parallel with most events. When valuable customers. We first served the air-
gar construction with tool room, storage the company added the A380 capability, line’s A330 fleet with C-checks starting in
and office facilities was ready to serve the the goal was set towards achieving an 2006. The long-standing history with theLufthansa Technik Connection 4.2013 Aircraft Services | 13
“Ready and geared up”
Marek Wernicke, Senior Vice President for Base Maintenance
at Lufthansa Technik Philippines, talks about the role of his
company in Asian aviation.
Connection: What is your philosophy and Lufthansa Technik Philippines can grow
how does it translate into operations? together with other facilities in the global
Marek Wernicke: Our goal is to be the network and develop new products for
number one MRO provider in Asia, and we these new generation aircraft. It is important
also want to be regarded as a one-stop that we grow our business side-by-side
shop. This means that we should be capa- with the life cycle of these aircraft. Of course,
ble of offering comprehensive solutions training our employees will be a crucial part
that meet our customers’ needs today and of our formula. They must have the skills to
in the future. Our philosophy is focused on address the future maintenance needs of
the customer and we constantly drive our- these new aircraft. The bottom line is that
Qantas group and our growing expertise selves to create and deliver value at every Lufthansa Technik Philippines is ready and
for Airbus aircraft made us a trusted part- point of contact. At the end of the day, it’s geared up to familiarize with the new fleet
ner Qantas can rely on,” shares Sebastian all about releasing the aircraft on time and of aircraft and to prepare for their needs in
Radeke, Senior Sales Executive and Busi- providing a pleasant experience for the the future.
ness Development at Lufthansa Technik customer. How important is innovation
Philippines. Lufthansa Technik Phillipines has put a in our business?
Performing the C-checks together with stronger focus on its base maintenance Innovation is something that I take seriously.
other tasks as one package offers A380 business. What benefits can customers We innovate to become more flexible, agile,
customers substantial savings. Lufthansa expect from this change? cost-effective and more productive. We
Technik Philippines can carry out a major Our focus is driven by the fact that we see started the year 2013 with the launch of a
modification on the wings as well as to the high growth potential in base maintenance project to identify opportunities to become
aircraft’s cabin in parallel to a C-check. and we want to grow. A particular area is more efficient and apply Lean production
This not only results in lower costs, the inte- the increasing fleet of Airbus aircraft in use methods and processes.
grated work also has minimal effect on and lined up for delivery in Asia. Lufthansa Another part of innovation deals with “put-
turnaround times: All layovers which includ- Technik Philippines specializes in the main- ting ourselves in the shoes of our custom-
ed C-check, cabin and wing rib modifica- tenance of Airbus aircraft and we want to ers” and finding ways to save them money.
tions were performed on time. Qantas participate in the growth. This is evident for example when we repair
Airways has sent four more A380s to parts and components of our customers’
Lufthansa Technik Philippines for cabin aircraft instead of replacing them with new
reconfiguration. The campaign was com- parts. Innovation is also seen in the way we
pleted in July 2013. manage our projects with the latest tools
and methods. We want every working rela-
Preparing the future tionship with every customer to be mutually
positive and we ensure this by having addi-
As Lufthansa Technik’s center of excellence tional ways to communicate with each other.
for Airbus base maintenance in Asia, Luft- What is in store for Lufthansa
hansa Technik Philippines is gearing up for Technik Phillipines in 2013 and in
further expansion of its A380 capability. the years to come?
The Manila-based facility is presently in the We are optimistic about the future. From
process of completing all necessary train- We not only have the space to grow, we our meetings with customers, we are now
ing, equipment, certifications and further will also be open to discuss building new seeing a developing demand until 2014.
requirements to be able to provide bigger facilities. Our restructuring efforts are The year 2013 is going to be all about re-
checks in order to offer a total service solu- geared towards improved productivity and structuring and improvements. At the end
tion for its A380 customers. “We look for- customer focus. We also certainly want to of this year, we will also be in a better posi-
ward to further sharing our growing exper- reduce turnaround times while keeping our tion to discuss possibilities of increasing
tise with Qantas and other A380 operators standards high. capacities in our facility, which of course will
in the future,” says Radeke. With the industry preparing itself for new be in parallel with confirmed demand and
generation aircraft, what is Lufthansa growth. And, as mentioned previously, we
Technik Philippines doing to secure its will invest in new technologies and training
Sebastian Radeke position? to upskill our people for the new generation
Phone +63-2-855-2222 ext. 8534 We welcome these new generation aircraft. aircraft and for them to be at par with the
sebastian.radeke@ltp.com.ph As part of the Lufthansa Technik Group, world’s best aviation professionals.14 | Certification & Rulemaking Lufthansa Technik Connection 4.2013
“Safest possible operations
under cost-effective conditions”
Representatives of Lufthansa Technik are actively involved in amending existing rules
reating new rules. Dr. Hans-Jürgen Loss, Vice President Quality Management,
and c
and Werner Luehmann, Manager Regulatory Compliance & Authorities Liaison, spoke
to Connection about the significance of this work and some recent results.
F
or an MRO provider it goes without Connection: Why is Lufthansa Technik rules and ask: are they logical, linear, pos-
question that aviation regulations involved in drawing up aviation law? sible to adhere to, do they really make
have to be observed. But Lufthansa Dr. Hans-Jürgen Loss: Lufthansa Technik things safer, is the intended function really
Technik does not stop at that. The latest is keen to be involved in our own interests accomplished in an effective manner?
development is the creation of EASA Part- and in the interests of our customers. It is Authorities appreciate input based on
M, Subpart J, which is expected in early important for someone with practical expe- practical experience in maintenance or
2014, will allow the almost total transfer of rience in the application of aviation law to operations – we are able to offer that vital
airworthiness responsibility to a Continuing execute influence. As the counterpart to information. After all, the intention of imple-
Airworthiness Management Organization the authorities, we add the finishing touch menting a rule for enhanced safety is one
(CAMO). in many subject areas. We scrutinize the thing, shaping it for easy and compelling
implementation is another part of it.
What areas are you
particularly involved in?
Dr. Loss: We look ahead at trends in the
industry and at other stakeholders, so we
are involved in a number of subjects. Our
primary objective is always the safest pos-
sible flying operations under cost-effective
conditions. Here, every element in the
chain, from operations to the proportion
contributed by the maintenance providers,
plays a part.
How would you characterize your rela-
tionship with the authorities?
Dr. Loss: Having dealt with them in a
respectful manner for many years, we
have developed a relationship of trust with
the authorities that constitutes an excellent
basis for working together. This applies
above all to the European EASA, to the FAA
and goes on with several other national
authorities. This relationship of constructive
collaboration has often enabled us to
influence things in a way that promoted
our interests.
Dr. Hans-Jürgen Loss was Vice President Quality
Management until the end of June 2013, taking
over as Executive Director Operations at Ameco
Beijing in China at the beginning of July.Lufthansa Technik Connection 4.2013 Certification & Rulemaking | 15
Werner Luehmann, Manager Regulatory
Compliance & Authorities Liaison
Werner Luehmann: One example of a
development that we initiated is the discus-
sion regarding Continuing Airworthiness
Management Organizations (CAMO), as in
Subpart J. Today there is one Subpart G,
which says that a commercial operator has
to have its own technical operations man-
agement in the form of a CAMO. “Active
control and direct involvement” is required
for the operator. For small operators and
especially for start-ups, but also for airlines
integrating a new fleet into their pool, this is
difficult or expensive to accomplish. Sub-
part J will provide an additional option to
leave this responsibility with an experienced
CAMO, like Lufthansa Technik. When will Lufthansa Technik Are there any other current
Dr. Loss: In Europe it was a highly contro- offer this service? examples of how you have had
versial subject that was discussed for Dr. Loss: If the legal procedures will work a constructive influence?
years. Lufthansa Technik got involved in as announced we expect to offer this Luehmann: We are also working on a lot
this subject early. We provided detailed “Contracting of CAMO” service from the of other matters, for example, material
comments, held discussions with EASA next year. The airline will then still have a certificates. This is a major problem
and the national authorities, and at the post holder maintenance having the com- across the industry. For example, we have
end EASA acknowledged us for having petence to contract out the CAMO work been able to eliminate a few problems
supported this issue. package after a risk assessment. The with the new release of the EASA Form 1.
operator just has to be qualified to con- Thus, copies of certificates will now be
What was the outcome of these efforts? tract the service and be able to accept it. accepted as well as originals. There was a
Luehmann: Subpart J is expected to be The present requirement for “active con- lot of discussion over this issue – in the
implemented shortly. This will then mean trol and direct involvement” will be past copies were not acceptable. In the
that, as an alternative to the present pro- dropped. context of electronic data transmission this
cedure, airlines will also be able to con- Luehmann: This means of course that we is of course a huge advantage.
tract a CAMO to assume airworthiness will be offering the customer an even Dr. Loss: In some cases we have also
responsibility. So in the near future Luft- more comprehensive product. We will requested to refrain from unnecessary
hansa Technik will be able to take the now be able to offer the entire package of rulemaking. For example, EASA wanted to
responsibility and carry out airworthiness every conceivable organizational approv- introduce a “multiple release”. Different
management tasks. At the same time this al, meaning design, maintenance and companies involved in one layover would
will mean that the contractual partner can CAMO. This has obvious attractions for
reduce its headcount. the customer. � Please continue on page 1616 | Certification & Rulemaking Lufthansa Technik Connection 4.2013
A
have to release their own maintenance role. An MRO provider makes an SMS t first sight, adhesive foils may seem
work, while at the same time there had not for itself, but for its customers, for an unusual alternative to painting,
to be a “primary” maintenance organi- the operators. Here we advanced a but in practice this has evolved into
zation that assumed overall responsi- major step towards structured safety an attractive product offered by Lufthansa
bility. This was an infringement of the concepts at reasonable cost. Technik. The specialists in surface design
separation between performing main- offer a variety of services for the applica-
tenance and the responsibility for con- What role do industry tion of foils to aircraft, ranging from the
tinuing airworthiness. Together with organizations play in your work? simple production of adhesive foils to the
other partners we prevented this rule Dr. Loss: In many subject areas the complete solution. This starts with design
from being adopted. only way to progress is through these consultancy, covers application of the foils
organizations, the authorities will not at the customer’s site and ends only when
What is your assessment of the talk to individual industry partners the foils are removed without a trace at the
legislative process in Europe? without the involvement of the industry end of a campaign.
Dr. Loss: The process by which avia- trade organizations. Within those But before the foiling process can get
tion law is made in Europe is actually organizations we develop a common under way, usually Lufthansa Technik is
exemplary. Rulemaking is often pre- position with other industry partners asked to provide support with the design.
ceded by standards, for example, as and take jointly influence. At the
issued by the ICAO. One example is national level the organization that we
the Safety Management System (SMS). work with is the German Aerospace
We at Lufthansa Technik did not want Industries Association (BDLI), at the
to wait for a specific regulation in European level it is the Association of
Europe. We analyzed the ICAO stan- European Airlines (AEA). International-
dard to identify what added value it ly we also work with the Aeronautical
contained for us. We introduced those Repair Station Association (ARSA),
elements and now we are tackling the based in the US. I can say that it is not
subject of safety hazards and risk least down to our efforts that today
assessment in a more structured way ARSA acts as an international organi-
than before. As a result, Lufthansa zation.
Technik has in place a risk manage-
ment system that complies with the All this involvement must cost quite a
ICAO requirements. bit. How do you justify the expense?
Luehmann: In this context the fact that Dr. Loss: Aviation law is often viewed
we work well with our customers and as cement, but at the end of the day
not only with Lufthansa German Air- it is also in a state of flux. We are
lines, our closest counterpart and part- working on making this foundation
ner, naturally also plays an important ever safer.
Summary: Rulemaking support
// Lufthansa Technik is directly involved in creating new rules and Foiling is the fast and flexible alternative to painting,
amending existing ones. Due to its strong practical experience the MRO whether a small warning sign must be replaced or
the entire aircraft is “repainted” in a night shift.
provider is an important counterpart to the legislating bodies. Often,
finishing touches are put to a new regulation in order to ensure that it
is achieving its intended function, i.e making aviation safer. In some
instances, unnecessary rulemaking can be refrained from. //Lufthansa Technik Connection 4.2013 Aircraft Services | 17
Foiling is flexible and fast
In many cases the use of adhesive foils is actually a better choice than painting due to the flexibility
and design variety of the foils and the speed with which they can be applied. Lufthansa Technik’s
graphics shop covers the full range of services from the creation of customized foils to support for
classic painting methods with paint stencils.
In this area the foil shop has already accu- ensuring smooth flying operations, as creation of paint stencils for use with clas-
mulated extensive experience. There are technical markings also fall within the scope sic paint technology. The specialists can
no limits on the design and color scheme of this area. Once a mandatory informa- also prepare technical drawings that will
that can be used. The finished design is tion on a placard is no longer legible the serve as templates for painting operations.
then printed with UV resistant ink on foil aircraft may have to be grounded to reme- To cover these requirements the foil shop
sheets with a width of up to 1.23 meters dy the defect, causing an expensive AOG. has three state-of-the-art printers and a
and applied to the aircraft. Larger designs It is therefore no wonder that Lufthansa laser cutting machine. This ultra-modern
are achieved through the juxtaposition of Technik uses only the highest quality basic equipment and the experienced team
multiple sheets. There is nothing magical materials tested for longevity as suitable make Lufthansa Technik’s graphics shop
about the speed: depending on the size of for technical markings in its aircraft foils. the first choice when it comes to speed
the design, it is even possible to “repaint” This means that the finished foils delivered and flexibility.
an aircraft in a single night shift, without to the customer come with a “Form 1”,
any need for a longer layover. signifying that they are fully approved for
But the significance of the paintwork on aircraft use. Dr. Georg Fanta
an aircraft goes beyond the visual effect. It As well as direct foiling, the graphics Phone +49-40-5070-1182
plays a very much underestimated role in shop also supports its customers with the georg.fanta@lht.dlh.de
Lufthansa Technik uses only the highest
quality materials for adhesive foils.18 | Regional Sales Lufthansa Technik Connection 4.2013
Gearing up for the Middle East
Expanding the local presence of the Lufthansa Technik Group, Lufthansa Technik Middle East
(LTMES) was established two years ago. Now LTMES is rapidly increasing its local capability, with
composite repair services, comprehensive component services and a local Cyclean® Engine
Wash capability being established.
L
ufthansa Technik is gearing up for an es hundreds of customers worldwide. The the end of this year, allowing local and
increased demand in the Middle East. key to SCM success is the quick and indi- international customers to make use of the
Two years after the establishment of vidual quotation and fulfillment of outstand- product regionally.
Lufthansa Technik Middle East, Ziad al ing customer services. With the individual In cooperation with Lufthansa Technik
Hazmi, General Manager Gulf, is confident order handling customers always remain Group companies from around the world
that Lufthansa Technik’s concrete offerings independent and flexible. LTMES will shortly be able to allocate quali-
are able to satisfy the regional demand. At In addition to short turnaround times and fied mechanics and technicians to regional
the beginning of March, for example, the higher reliability Lufthansa Technik’s com- customers for long period assignments.
reverser shop commenced a Trent 700 ponent services offer, a 24/7 AOG service This will allow customers and operators to
thrust reverser repair for a major Middle East guarantees that problems are solved right make use of Lufthansa Technik's experience
carrier. Thus regional aircraft operators now now. 365 days a year, 24 hours a day a and know how without long training periods
have direct local access to Lufthansa Tech- team of 50 staff organized in three shifts and associated costs.
nik’s renowned experts in composites und ensure that every customer is supplied with
bonded structures for all common nacelle the materials required in an emergency as Local contacts
types. In addition to shop capabilities for quickly as possible so that expensive down
smaller repairs, composite spare parts (Air- time can be minimized. Complementing the capability buildup in
frame Related Components, ARC®) pools Dubai, line maintenance services will now
are being established for both the CFM56- Cyclean® for efficiency be available locally. Operations will be
5B and the GE90. Other composite or expanded further with an increased local
nacelle parts will be added in accordance Washing a jet engine on a customized cycle customer service team to support custom-
to regional customer demands. leads to a cleaner and therefore more effi- ers with various after sales services and
cient compressor. To achieve the minimum account management. Furthermore, sales
Component sale, exchange & loan downtime necessary to perform the wash- representatives for commercial and VIP
ing process as an integral part of aircraft customers are now present locally, as well
Lufthansa Technik maintaines a large com- operations, Lufthansa Technik developed as on-site representatives from Lufthansa
ponent pool for a wide spectrum of aircraft completely new equipment which makes Technical Training, Lufthansa Technik
types with local stocks at airports all over the engine washing a quick and easy process. Logistik Services and Lufthansa Technik
globe. Now these services are available Meanwhile the revolutionary engine washing Airframe Related Components (ARC®). With
from the Dubai Airport free zone for regional technology, Cyclean®, has proven its worth this strong buildup of the local presence in
customers. In addition to the contractual in thousands of successful washes. Dubai, customers are ensured the best
services Lufthansa Technik offers material A dual nozzle arrangement sprays water possible service locally, from the leading
and component loan, exchange and out- heated to 70 °C (160 °F) with up to 100 bar independent MRO provider.
right sale on a case-by-case basis. The (1,450 psi) directly into the core engine.
dedicated warehouse is established with the Contrary to conventional washing methods,
corresponding manager available. Logistics a fine and evenly distributed water mist
and the necessary customs processes have follows the gas path. This ensures efficient Ziad Al Hazmi
been established, enabling aircraft opera- cleaning of the compressor and at the same Phone +971-440-57-550
tors in the Middle East to profit from quality time minimizes the amount of residual water ziad.al-hazmi@lht.dlh.de
component maintenance on their doorstep – remaining within the engine. The advanced
with communication lines being kept short equipment ensures easy preparation, short Airframe Related Components (ARC®)
and response times quick. washing times and washing results second Heiko Osterode
The Single Component Maintenance to none. The Cyclean® washing service will Phone +971-56-6826876
(SCM) business of Lufthansa Technik servic- be set up in Dubai ready for operation by heiko.osterode@lht.dlh.deLufthansa Technik Connection 3.2013 Personalities | 19
20 | Employee Portrait Lufthansa Technik Connection 4.2013
Harry Haber is at home both on site and in the shop. As always only a phone call away of helping his customers.
Kerosene in the blood
“I have blood group Jet A-1”, says Harry Haber, “Father” of Lufthansa Technik’s
mobile Airline Support Teams (AST®), talking about himself. Aircraft are his passion
and especially innovative repair solutions for engine problems.
W
hen Harry Haber talks about Aircraft have always interested Harry Recalling the close contact and exchange
his work, the enthusiasm in his Haber, and after completing his appren- of ideas and information with the other air-
voice is unmistakable. “You ticeship as a toolmaker in 1970 he joined lines, Harry Haber says: “As a result, I was
have to be committed heart and soul to the maintenance team of Lufthansa Technik right in the middle of the action.” At the be-
your work in order for your job to be fun. in Frankfurt as an aircraft mechanic. On ginning of the 1990s the engineer took his
“
And who else can say that they virtually graduating with a courage in his hands
created their own job?” he laughs. Luft- degree in Mechanical and put his idea, that
hansa Technik’s “Flying Doctors”, the Engineering he start- We bring the expertise and the company should
mobile teams that travel out on special ed work in produc- the tools out on site, exploit the perform technical
missions to perform on-site engine repairs tion planning in the layovers and as a result save work on engines at
– a success model that has since been engine shop in 1977. our customers a lot of money. the customer’s site for
adopted for other areas of the aircraft as At that time the CF6- Harry Haber a fixed price, to Wolf-
well – originated in the 1990s based on an 50 engines for the gang Mayrhuber, who
idea that Harry Haber had. then ATLAS alliance were looked after from later became the CEO of Lufthansa Technik.
“I believe we are the maddest people Frankfurt. The airline alliance between This would be the precursor from the tech-
in the market as far as creative problem- Lufthansa, Air France, Alitalia, Sabena and nical and human resources point of view
solving is concerned,” he says. “The more Iberia had been founded with the aim of for providing certain engine repair services
creatively and solution-oriented we work, lowering the amount they would have to on a mobile basis. Haber succeeded in
the more attractive our services are to spend on investment and ongoing technical convincing his superiors, and the new Air-
customers,” says Haber support costs for their still small aircraft fleets. line Support Teams (AST®) product wasYou can also read
