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DGLR 31.8.2004
MTU Maintenance Hannover
Flowline in Engine Maintenance
Ferdinand ExlerManaging Director
MTU Maintenance Hannover GmbH
31. August / 01. September 2004
Symposium
DGLR 31.8.2004
MTU Maintenance Hannover
MTU – The Roots from 1945 to Today
BMW
Siemens & Halske
1957 BMW Triebwerkbau
1958 MAN Turbomotoren
Daimler-Benz
1965MAN Turbo
1969MTU (50% DB/50% MAN)
1965MAN takes overBMW TriebwerkbauBMW withdraws
1985DB takes over a 50% share of MANMANwithdraws
1989MTU becomes a subsidiary of newly established Deutsche Aerospace
1995Deutsche Aerospace renamed Daimler-Benz Aerospace
1998Daimler-Benz Aerospace renamed DaimlerChrysler Aerospace
2000MTU becomesa DaimlerChryslercompany
S/Funk 2003/2
1979Foundation of MTU Maintenance GmbH
2004DaimlerChrysler sells MTU to KKR
MTU Maintenance Hannover
DGLR 31.8.2004
MTU Maintenance Hannover
JT8DBoeing MD-80-Family V2500
Airbus A319, A320, A321, Boeing MD-90
PW2000
Boeing 757, Boeing C-17, IL-96M/T CF6-80
Airbus A300, A310, A330Boeing 747, B767, MD-11 PW4000G Boeing 777
PW500Cessna BravoCessna Excel PW300
Learjet 60, Do 328JET, IAI GalaxyHawker 1000 C250-C20
Bo105Jet Ranger EJ200
EF2000 EurofighterTyphoon
RB199PanaviaTornado
Larzac Alpha Jet
J79 F4-Phantom II
T64Sikorsky CH53-GTyne
Transall,BreguetAtlantic TP400
Airbus A400M
MTR390Eurocop-ter Tiger
PW6000Airbus A318
GP 7000
Airbus A380
S/Funk 2003/3
The Product Application Range
MTU Maintenance Hannover
DGLR 31.8.2004
MTU Maintenance Hannover
MTU’s Core CompetenciesGovernment engine
business
Design, development and production
Maintenance
• Low-pressure and high pressure turbines
• High-pressure compressor
• Overall propulsion system integration capability
• Low-pressure and high-pressure compressors
• Engine control and moni-toring unit
• System integration
• Provider of integrated solutions for civil engines and industrial gas turbines
• New repair processes• Integration of new
development, manu-facturing and repair processes
• System integration• Training and logistics
support• New maintenance
concepts
Commercial enginebusiness
S/Funk 2003/4
MTU Maintenance Hannover
DGLR 31.8.2004
MTU Maintenance Hannover
MTU Aero Engines/MTU Maintenance WorldwiMTU Aero
Engines North America Inc.
Vericor Power Systems Inc.
MTU Maintenance Canada Ltd.
MTU Maintenance do
Brasil Ltda.
MTU Maintenance Hannover GmbH
Ceramic Coating Center SA
(*major joint ventures )
MTU Aero Engines GmbH
ATENA Engineering GmbHEurojet Turbo GmbH*
MTU Turbomeca Rolls-Royce GmbH*
Turbo-Union Ltd.*
MTU Maintenance Berlin-Brandenburg GmbHMTU Aero Engines GmbH, Entwicklungs- und KonstruktionszentrumPratt & Whitney Cananda Customer Service Center Europe GmbH*
Airfoil Services Sdn Bhd*
MTU Maintenance Zhuhai Co.Ltd.
International Aero Engines AG *
DGLR 31.8.2004
MTU Maintenance Hannover
MTU Maintenance Hannover 2004
Flow-Line: Tear-Down/Built-Up High-Tech-Repair (Laser Drillingr) Test run
Employees 1308Apprentices 76
MTU Maintenance Hannoverfounded on November 10, 1979
MRO of the engines CF6-50, CF6-80, PW2000, V2500, CFM56
DGLR 31.8.2004
MTU Maintenance Hannover
CF6CF6--5050 A300B2/B4A300B2/B4B747B747--200/300200/300 DC10DC10--15/15/--3030
CF6CF6--80C280C2
CFM56CFM56--77
V2500V2500
PW2000* B757B757 CC--1717
A319A319 A320A320--200200 A321A321 MD90MD90
B737B737--600/600/--700/700/--800/800/--900900
B747B747--200/200/--300/300/--400400 MDMD--1111 A300A300--600600A310A310--200/300200/300B767B767--200/300200/300
*) am Oktober 2004 wieder in Hannover gewartet (derzeit in München)
Products 2004 - MTU Maintenance Hannover
PW6000PW6000 A318A318
DGLR 31.8.2004
MTU Maintenance Hannover
0
200
400
600
800
1000
1200
1400
1600
Empl
oyee
s
1995 1996 1997 1998 1999 2000 2001 2002 2003
Overall
Apprentices
Employees - MTU Maintenance Hannover
DGLR 31.8.2004
MTU Maintenance Hannover
Shop Visits - MTU Maintenance Hannover
0
50
100
150
200
250
300
350
400
Shop
Vis
its
1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003
CF6-50 CF6-80C2
V2500 CFM56-3/ -7
PW2000
DGLR 31.8.2004
MTU Maintenance Hannover
19811981
Company Key Driver:Company Key Driver:Company Company --FoundationFoundation
OrderOrder--Portfolio:Portfolio:CF6CF6--50 50 OverhaulOverhaul
19851985Company Key Driver:Company Key Driver:
QualityQuality
MTU Key DriverMTU Key Driver
Qua
lity
Qua
lity
OrderOrder--Portfolio:Portfolio:-- CF6CF6--50 50
OverhaulOverhaul
19901990
Company Key Driver:Company Key Driver:IndividualIndividual WorkscopingWorkscoping
OrderOrder--Portfolio:Portfolio:CF6CF6--80 80 OverhaulOverhaulV2500 V2500 OverhaulOverhaulPW2000 PW2000 OverhaulOverhaul
Indi
vidu
alIn
divi
dual
Wor
ksco
peW
orks
cope
OrderOrder--Portfolio:Portfolio:-- CF6CF6--50 50
OverhaulOverhaul-- PiecePiece PartsParts-- CF6CF6--80 80
OverhaulOverhaul-- V2500 V2500 OverhaulOverhaul-- PW2000 PW2000
OverhaulOverhaul
19951995
Shop
Shop
-- Vis
itVi
sit
Cos
tC
ost
OrderOrder--Portfolio:Portfolio:
-- CF6CF6--50 50 OverhaulOverhaul-- PiecePiece PartsParts-- CF6CF6--80 80 OverhaulOverhaul-- V2500 V2500 OverhaulOverhaul-- PW2000 PW2000
OverhaulOverhaul
On
On --
Tim
eTi
me
Del
.D
el.
OrderOrder--Portfolio:Portfolio:
-- CF6CF6--50 50 OverhaulOverhaul-- PiecePiece PartsParts-- CF6CF6--80 80 OverhaulOverhaul-- V2500 V2500 OverhaulOverhaul-- PW2000 PW2000 OverhaulOverhaul-- CFM56CFM56--77
Company Key Driver:Company Key Driver:ShopShop--VisitVisit--CostCost 20002000
Company Key Driver:Company Key Driver:OnOn--TimeTime--DeliveryDeliveryRepairRepair DevelopmentDevelopment
OrderOrder--Portfolio:Portfolio:CFM56CFM56--77
Rep
air
Rep
air
Dev
elop
men
tD
evel
opm
ent
Key Driver of MTU Maintenance Hannover1981 to 2000
DGLR 31.8.2004
MTU Maintenance Hannover
New Engine and Maintenance Demands
0
5000
10000
15000
20000
25000
30000
35000
1980
1982
1984
1986
1988
1990
1992
1994
1996
1998
2000
2002
2004
2006
2008
2010
2012
2014
2016
2018
2020
2022
Umsa
tz [M
io. U
SD]
New EngineMRO Business
Gulf-War11.09.01
2004
*) Sources: New engines: MTU Market Forecast (2003) 2003-2022; MRO: MTU Maintenance+Aerostrategy (2004, without LLPs) for illustration purposes only, not for company financial/business calculations.
DGLR 31.8.2004
MTU Maintenance Hannover
0
5000
10000
15000
20000
25000
30000
35000
1980
1982
1984
1986
1988
1990
1992
1994
1996
1998
2000
2002
2004
2006
2008
2010
2012
2014
2016
2018
2020
2022
Umsa
tz [M
io. U
SD]
NeutriebwerksgeschäftMRO Geschäft
Company-Situation in 2000:
- Shop Overflow
- Bottleneck Space
- Turntime Delays
- Unpredictable Delivery-Dates
- tougher customer requirementin terms of:
* technics* logistics* finance
- Higher degree/ amount of individual customer treatment
DGLR 31.8.2004
MTU Maintenance Hannover
MTU Key DriverMTU Key DriverQ
ualit
yQ
ualit
y
Indi
vidu
alIn
divi
dual
Wor
ksco
peW
orks
cope
Shop
Shop
-- Vis
itVi
sit
Cos
tC
ost
On
On --
Tim
eTi
me
Del
.D
el.
OrderOrder--Portfolio:Portfolio:
-- CF6CF6--50/ 80 50/ 80 OverhaulOverhaul-- PiecePiece PartsParts-- -- V2500 V2500 OverhaulOverhaul-- PW2000 PW2000 OverhaulOverhaul-- CFM56CFM56--3/73/7
Rep
air
Rep
air
Dev
elop
men
tD
evel
opm
ent
Key Driver of MTU Maintenance Hannover
DGLR 31.8.2004
MTU Maintenance Hannover
ENGINE DISASSYENGINE DISASSYINTOINTO
SUBSUB--ASSEMBLIESASSEMBLIES
EMU EMU -- DISASSYDISASSYINTO PIECE PARTS INTO PIECE PARTS
(CLEANING AND(CLEANING ANDINSPECTION)INSPECTION)
CUSTOMECUSTOMERR
BENEFITBENEFIT
„„ON LINE“ON LINE“ REGULAR BREGULAR BMTU PRESENTATIONMTU PRESENTATION
BYBYDESIGNATED DESIGNATED
ENGINEERENGINEER•• SUMMARY OF SUMMARY OF ENGINEENGINE
REMOVALSREMOVALS•• SUMMARY OF SUMMARY OF ENGINEENGINE
PERFORMANCEPERFORMANCE•• SUMMARY OF SUMMARY OF FINDINGSFINDINGS•• CORRECTIVE CORRECTIVE ACTIONSACTIONS•• WORKSCOPESWORKSCOPES
CHANGESCHANGES•• SERVICE BULLETINSERVICE BULLETIN
RECOMMAND:RECOMMAND:•• LINE MAINTENANCELINE MAINTENANCE
RECOMMENDATIONRECOMMENDATION
DETAILED TECHNICALDETAILED TECHNICALDISCUSSIONSDISCUSSIONS
(CUSTOMER/OEM/MTU)(CUSTOMER/OEM/MTU)
CustomerCustomer
WRB WRB LEVEL ILEVEL I
QUALITYQUALITYDES. ENGINEERDES. ENGINEERCUST.SERVICECUST.SERVICE
PROD.CONTROLPROD.CONTROLWORKSCOPE CHANGESWORKSCOPE CHANGES
AS REQUIREDAS REQUIREDBSIBSI--FINDINGFINDING
INCOMING INSPECTIONINCOMING INSPECTION
WRBWRBENGINEENGINE
CUST.INFO CUST.INFO (RFR)(RFR)INCOMING INCOMING INSP.INSP.CUST.REQUICUST.REQUIREM:REM:
WRBWRBEMUEMU WORKSCOPE CHANGESWORKSCOPE CHANGES
AS REQUIREDAS REQUIREDEMUEMU--FINDINGSFINDINGS
HDW:HDW:--CONDITIONCONDITION
QUALITYQUALITYDES. ENGINEERDES. ENGINEER
SHOPSHOP WRB WRB LEVEL IILEVEL II
WRBWRBPIECEPIECEPARTPART
HARDWARE HIGHL.HARDWARE HIGHL.SCRAP PART PROGR:SCRAP PART PROGR:
Special Special RepairsRepairsRepairRepair DevelopmentDevelopment
QUALITYQUALITYDES. ENGINEERDES. ENGINEER
INSPECTORINSPECTORREPAIR DEPARTREPAIR DEPART WRB WRB
LEVEL IIILEVEL IIIINDIVIDUALINDIVIDUALTECHNICALTECHNICAL
REQUIREMENTSREQUIREMENTS
ENGINE ASSEMBLYENGINE ASSEMBLYAND AND
MODULE MANAGEM.MODULE MANAGEM.
INDIVIDUALINDIVIDUALREPAIR WORKSCOPEREPAIR WORKSCOPE
INDIVIDUALINDIVIDUALTAT TAT -- REQUIREMENTSREQUIREMENTS
CUST.SERVICECUST.SERVICE
CONTROLLINGCONTROLLING
MANUFAC.MANUFAC.
LOGISTICLOGISTIC
QUALITY QUALITY
InternaInternallCOSTCOST
CONTROLCONTROL
PRODUCTIONPRODUCTIONCONTROLCONTROL
ENGINEERINGENGINEERINGTEAMTEAM
Individual Workscoping
DGLR 31.8.2004
MTU Maintenance Hannover
ExampleExample: : OnwingOnwing TimeTime
CF6-50C2ONWING LIFE PRIOR TO MTU SHOPVISIT
0
500
1000
1500
2000
2500
3000
0 5 10 15 20 25 30
NO. OF ENGINES
CSSV AVERAGE
1490 CSSV
CF6-50C2ONWING LIFE OF MTU BUILT ENGINES
0
500
1000
1500
2000
2500
0 5 10 15 20 25 30
NO. OF ENGINESCS
SV
AVERAGE1685 CSSV
DGLR 31.8.2004
MTU Maintenance Hannover
0
5000
10000
15000
20000
25000
30000
35000
1980
1982
1984
1986
1988
1990
1992
1994
1996
1998
2000
2002
2004
2006
2008
2010
2012
2014
2016
2018
2020
2022
Umsa
tz [M
io. U
SD]
NeutriebwerksgeschäftMRO Geschäft
PresentPresent
FutureFutureChangeChange--ProcessProcess
•• TransparencyTransparency in in termsterms of of MaterialflowMaterialflow & & ShopShop--StructureStructure
•• visiblevisible customercustomervaluevalue addedadded
•• individualindividual WorkorderWorkorder--MgtMgtwithwith respectrespect to to customercustomerrequirementsrequirements
•• Minimum Minimum TurntimeTurntimeCapabilitiesCapabilities
Linear Linear extrapolationextrapolationof of thethe currentcurrent SystemSystem
oror
SomethingSomething elseelse ????
DGLR 31.8.2004
MTU Maintenance Hannover
Something else ?
CIM
TOC
TPS
TQM
Kanban
Lean Production
Coverage of:
DGLR 31.8.2004
MTU Maintenance Hannover
Modern MRO System FlowLine TM
Volume basedproduction systems
• Low steeringexpence
• Reliable Standard procedure
• Transparent material flow
• Planed standardroutines
Individual Work Scopingwithin Workstation System
• Optimized customerexpence
• Customized shop visitsolution
• Engineering controlledshop visits
• Individual processesconflic
t
DGLR 31.8.2004
MTU Maintenance Hannover
5 days 3 days 2 days 21 days 3 days 5 days 2 days
customer41 internal TAT
MTU-Shop-Structure
Engine TearDown
LPT TearDown
HPT TearDown
HPC TearDown
Combustor
Cleaning
Inspection
Fan TearDown
Coating
Compressor
Blade
Fan Case
Machining
Non Welding
Vane 1
Vane 2
Vane 3
Welding
LPT BuildUp
HPT BuildUp
HPC BuildUp
Fan BuildUp
Engine BuildUp Test Cell
Proz
essb
efun
d
DGLR 31.8.2004
MTU Maintenance Hannover
MTU-Network for the Simulation Application (eM-Plant)
5 days 3 days 1 day Linie-Sim 3 days 5 days 2 days
DGLR 31.8.2004
MTU Maintenance Hannover
ABCDEFGHIKLMN D ' L'K 'I'H 'G 'F'E 'C 'B'
21
20
19
18
17
16
15
14
13a
12
11
10
9
8
7
6
5
4
3
2b
1
0
1'
2'
3 '
4 '
13b
2a
5'
6'
7 '
OPQRSTUVWXYZZ'Y 'X '
8'
H1
Personnel Car-Park
M otor C yclesFactory
Propert y Border
Property Border
Gas Storage
Refuse Disposal
Filte
rSt
atio
n
M 1
Canteen
Test
be n
ch
O ffice building
Social Tract / Rest Room s
Soci
al tr
act
Tes t
ben
ch
SecurityO fficersPersonnel Car-Park Personnel Car-Park
TearDown
BuildUp
Production Area
Airfoils
Repair Lines
Parts
StorageEnergi
e
Eng
ine
Del
iver
y
TestIn
spec
tion
DGLR 31.8.2004
MTU Maintenance HannoverABCDEFGHIKLMN D' L'K'I'H'G'F'E'C'B'
21
20
19
18
17
16
15
14
13a
12
11
10
9
8
7
6
5
4
3
2b
1
0
1'
2'
3'
4'
13b
2a
5'
6'
7'
OPQRSTUVWXYZZ'Y'X'
8'
H1
Personnel Car-Park
Motor CyclesFactory
P rope rty Bo rder
Property Border
Gas Storage
Refuse Disposal
Filte
rSt
atio
n
M1
Canteen
Test
ben
ch
Office building
Social Tract / Rest Rooms
Soci
al tr
act
Test
ben
ch
SecurityOfficersPersonnel Car-Park Personnel Car-Park
Fan CaseEMU
Module
Tear
Down
Plasma
HeatTreatment
Laboratory
Galvanik
FPI
Cleaning
FAN - Module
Insp
ectio
n
Mac
hini
ng
Education[Ground Floor]
ACC[Ground Floor]
Education[Ground Floor]
Composite
FAN
Docks
Eli[Upper Floor]
FAN
Pow
er S
tatio
n]S
uppl
ies]
Eng
ine
Del
iver
y
Energie
Eng
ine
Tear
dow
n
De-Oiling
HPT - LPT Vane Line
Growth
HPT - LPT Blade Line
HPT - FAN Airfoil
Combuster Line
Welding Line
Non Welding Line
Coating Line
Storage
EMU-
Eng
ine
Bui
ldup
EMU
Module
BuildUp
Fan Case
DGLR 31.8.2004
MTU Maintenance Hannover
Key Benefits of the modern MRO System FlowLine TM
• Neutral Shop Structure• Minimization of que-days at engine induction
• Visible Customer Value Added in terms of• Material Flow Status• Man power activity (Labour)
• Customized Shop Visit Solutions• Reliable short Turn-Around-Times• Early Predictable Cost Estimation
DGLR 31.8.2004
MTU Maintenance HannoverAdministration BuildingAdministration Building
2
7
6
4
1
8
2 - Induction (20)-Modul-Flowlines
(FAN/Core) (5-6)- Hospitality
Shop
7 - Engine build (19)- Grinding Center (9)- Modul Assembly(11-13)
4 - Main Inspection (1)- Airfoil Inspection (36)
6
- Parts & CombustorRepairline (25-32)
1 - Apprenticeshop
8 - Testcell
Shop Tour
5
5
- Waterjet Stripping(16)- NDT (17+18)- Chemical clean (22)
3 3