1.2014 January/FebruaryThe Lufthansa Technik Group Magazine

Component loan, exchange and sale

Availability around the clockNew aircraft services

Spot landing for 787 services

Lufthansa Technical Training

Hands-on MRO experience

Regional markets

Reliable partner in the Middle East

2 | Content

Lufthansa Technik Connection is a complimentary information service for Lufthansa Techniks family and friends. Published every two months. This and earlier issues can be downloaded from our websitewww.lufthansa-technik.com/connection

Publisher Lufthansa Technik AG Tilman Tesseraux Marketing & Sales HAM TS/M Weg beim Jger 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, HamburgDesign: Art Works! Werbeagentur, HamburgPhotos: Lufthansa Technik AG, Lufthansa AG Printing: Beisner Druck GmbH & Co. KG

Lufthansa Technik Connection 1.2014

Technical Training Erfurt training center: 4 Hands-on MRO experience InterviewwithAndreasKaden: 6 A fantastic training environment

eServices manage/m: Plug & Play 7

Component Services SingleComponentAvailability: 8 Fast, flexible and available worldwide! InterviewwithIsabellAmann: 10 Quality and reliabilityRepairTechnology: 21 The meaning of SMART

Aircraft Services StarFlyer: 11 Lease return and more Maintenance & Engineering: 20 15 years of cooperation with MIATAircraftEngineeringServices: 25 Strong focus on SCAMT

Employee Portrait Jana Ludwig: 12 Taking off into the world of MRO

New AircraftBoeing787: 16 Spot landing for the Dreamliner

Technology & Innovation Landing gear components: 14 Precision coupled with reliability Integratedbushingproduction 18

Engine ServicesAcousticpanels: 24 Quiet, please!LaboratoryServices: 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

21

Hands-on MRO experiencePractical experience in an approved EASA Part-145 training environment is now on offer at the Erfurt training center of Lufthansa Technical Training.

4

The meaning of SMARTSRU Manufacturing and Repair Technology is dedicated

to developing andperforming new repairs.

Availability around the clockSingle Component Availability (SCA) is Lufthansa Technik redesigned

portfolio for the loan, exchange and sale of components.

8Spot landing for 787 servicesLufthansa Techniks expanded portfolio of Boeing 787 services is valued by more and more customers.

16

Lufthansa Technik Connection 1.2014 News | 3

Boeing 777F phase-inLufthansa Technik Maintenance International // At the end of 2013, Luft-hansa 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 de-partments. Thus, for example, the dock has been remodelled, em-ployees trained and over a million euros has been invested in tool-ing and operating resources. //

Support for 787 nacellesContract with UTC Aerospace Systems // Lufthansa Technik and UTC Aero-space Systems have signed a long-term contract to provide rotable provisioning and MRO services for Boeing 787 nacelle components designed and manufac-tured by UTC Aerospace Systems Aerostructures business. Heike Hartmann, Director of Lufthansa Techniks Airframe Related Component (ARC) business unit (photo left), said: This agreement is a further milestone for our roadmap to estab-lish 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. //

Boeing 767 fleet overhaul Ameco Beijing // Ameco Beijing and Business Air have signed a three-year contract for the airlines entire Boeing 767 fleet overhaul. The first layover starts in January 2014. The cooperation between Ameco and Business Air started in September 2012. Ameco has provided Business Air with Boeing 767 airframe overhaul and PW4000 engine leasing and overhaul services. //

Support and training for Arik AirPartnership // Lufthansa Technik and Nigerias Arik Air, the largest airline in western Africa, are expanding their partnership in the technical care of the airlines 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 contractBoeing 737 // Norwegian Air Shuttle and Lufthansa Technik have extended the current wheels & brakes services contract for the airlines Boeing 737 fleet. The new contract also covers pooling and home-base lease services for the carriers growing Boeing 737-800 fleet currently comprising 69 aircraft. In the past we have made good experi-ence with Lufthansa Techniks support and they facilitate Norwegians sustained growth. Thats 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 Shuttles preferred technical partner. //

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.

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.

Lufthansa Technik Connection 1.20144 | News

The only thing we cant do is fly, says Andreas Kaden, Managing Director of Lufthansa Technical Training (LTT), and sums up the unique offering of the com-panys 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 pro-fessionally equipped workshops with specialist tools and materials for the aerospace indus-try. 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 partici-pants during their practical assignments.

EASA Part-145 environment in Erfurt.

SAA continues cooperationTES 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 SAAs Boeing 737-800 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. //

Engine support for Pakistan InternationalPW4000, 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 PIAs fleet. Signed at the Dubai Airshow by Samin Uddin Naqvi, PIAs Director Engi-neering 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 partner-ship follows the recent signing of a three-year contract covering technical services for the Pratt & Whitney Canada PW127 engines in PIAs fleet of six ATR42 turboprop aircraft, to be provided by Lufthansa Techniks subsidiary Lufthansa Technik AERO Alzey. The first engine is currently undergoing overhaul. //

Lufthansa honors Father of the 747Joe Sutter // Boeing engineer Joe Sutter (92) changed aviation history when he spearheaded the design and development of the worlds first Jumbo Jet, the Boeing 747, more than 40 years ago. In honor of his dedication to aviation and long-stand-ing 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 Lufthansas successful 50-plus year partnership with Boeing, said Nico Buchholz, Lufthansas Executive Vice President Fleet Management, who presented the award on behalf of the Lufthansa Executive Board. //

Cooperation with Spirit AeroSystemsThrust 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 cowl-ings. Under this agreement, Lufthansa Technik and Spirit AeroSystems will utilize each others repair facilities and capabilities in the Europe, Middle east and Africa (EMEA) region as well as other support elements for each companys respective repair and overhaul services. We are looking forward to working closely together with one of the worlds largest designers and manufacturers of thrust reversers and cowlings, said Heike Hartmann, Director of Lufthansa Techniks Airframe Related Component (ARC) business unit. //

Lufthansa Technik Connection 1.2014 New Aircraft | 5

Just recently, the German Federal Aviation Office (LBA) approved the Erfurt training center as a learning environment in accor-dance 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 sub-sequently 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 air-craft 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 submit-ted to the LBA by the aircraft mechanic or avionics technician when applying for a Category A or Category B Aircraft Mainte-nance License (AML).

As Andreas Kaden points out: Lufthansa Technical Training is the only training pro-vider in Germany that offers participants their own EASA Part-145 training environ-ment 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 capa-bilities to allow the entire practical experience section to be carried out at our own training

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 Groups

training specialist for the MRO industry.

center. International customers in particular can benefit greatly from this because often they dont 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 +49-69-696-2751info@ltt.dlh.de

Scan the QR code for more information.

invested more strongly in distance learning products to enable blended learning, which is the optimum mix of classroom instruc-tion, distance learning and the use of new media. Were also looking at virtual class-rooms again with the goal of minimizing the necessity of travel for our customers.

What highlights do you see in Lufthansa Technical Trainings portfolio, today and in the future?One important highlight is our training cen-ter at Erfurt Airport in Germany, where weve been offering hands-on training since 2008. Weve got a fantastic training environment there that youll 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 cant do is fly. And theres more: the German Federal Aviation Office

The market for technical training is fairly dynamic at the moment. What is Lufthansa Technical Trainings current situation?Andreas Kaden: Lufthansa Technical Training has already undergone a transfor-mation over the last few years. We posi-tioned ourselves to be even more up-to-date, including our training media and content. Our portfolio of web-based train-ing 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 the-oretical 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 2013. 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 custom-ers employees spend less time away from work. That alone offers a significant eco-nomic 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 train-ing course. Beyond that, we have also

A fantastic training environmentTraining 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.

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 require-ments. 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 dont 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 cus-tomers in particular the option of having us administer their training. That is, we would take on all the organization, including par-ticipant registration, travel arrangements, lodging, all the way to documenting the results which is where there are legal requirements to consider. This would ide-ally be managed using a web-based tool. We already have the software environment we need to take over the complete admin-istration of participants, including record-keeping. Im firmly convinced that managed training solutions like these offer custom-ers genuine added value, and we hope to be able to offer them as of mid-2014.

But they apply primarily to regular training, the kind that appears in course catalogs. What about customized training for individual training needs?Its 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

Lufthansa Technik Connection 1.20146 | Technical Training

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-orient-ed 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 its usually the operations own productive employees who serve as train-ers, 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 cant 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.

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 stor-age 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 oper-ations. 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 pro-cess costs while at the same time data security is significantly increased, under-lines Fliegner who is optimistic about the products 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 Techniks manage/m module m/modification/software is a com-prehensive application for tracking aircraft software configurations. The applica-tion 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 seam-less integration of portable data loaders, making the use of any physical media unnecessary.

Erik Abels Phone +49-69-696-91628 erik.abels@lht.dlh.de

Plug & PlayThe 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.

Lufthansa Technik Connection 1.2014

8 | Component Services Lufthansa Technik Connection 1.2014

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 Techniks service according to their needs. Some customers require logistics services along with the actual aircraft component, while others prefer to arrange their own transport.

Component Services | 9 Lufthansa Technik Connection 1.2014

As one of the worlds leading MRO providers, Lufthansa Technik is ideally placed to offer component loans, exchanges and sales. Lufthansa Techniks 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 under-standing of the airline business, which is why our customers are always approach-ing us for component loans and sales, saysIsabellAmann,whoheadsuptheLufthansa 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 trans-parent access to aircraft components around the clock to and from every desti-nation around the globe.

Dedicated Sales and Loan Team

Single Component Availability (SCA) is the logical extension of Lufthansa Techniks established portfolio of services and cus-tomer solutions. However, a large number of SCA inquiries are triggered by un-planned events such as AOG situations. Hence, SCA inquiries often arrive at Lufthansa Techniks 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

// With Single Component Availability (SCA), Lufthansa Technik makes loans, exchanges and sales of aircraft compo-nents available on a case-by-case and non-contractual basis to every customer. The component portfolio includes line replaceable units (LRUs) and engine-related components for all Airbus and Boeing commercial aircraft as well as selected regional platforms such as the Bombardier Q400 and CRJ. //

Hot

line

+49-40-5070-4308 SCA

Hotline24/7

For more infor-mation about SCA please scan the QR code

Lufthansa Technik Connection 1.201410 | Component Services

Isabell Amann, Team Manager Loan & Exchange, talks about the customer benefits of Lufthansa Techniks Single Component Availability (SCA).

Quality and reliability

Why is Lufthansa Technik so well qualified for the loan, exchange and sale of aircraft components?Isabell Amann: To start with, we have a material inven-tory worth more than a billion euros, which enables us to provide non-routine components rapidly. Were locat-ed at the heart of the operations of over 230 airlines with more than 2,500 aircraft. This means were familiar with the problems operators face, especially in AOG situa-tions, and were not restricted to a single aircraft type.

What warranties does Lufthansa Technik offer for components?Were renowned for our high level of repair and com-ponent logistics expertise. We can offer the quality and reliability that customers expect of components pur-chased or borrowed from us. Thats 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 e-mail or phone. We established a dedicated Sales and Loan Team number and e-mail 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 addi-tional online platforms to expand our customer chan-nels. And if a part doesnt appear online, its always worth calling or e-mailing the Sales and Loan Team.

Isabell AmannPhone +49-40-5070-60196isabell.assmann@lht.dlh.de

Hot

line

+49-40-5070-4308 SCA

Hotline24/7

SCA customers can tailor Lufthansa Techniks service according to their needs. Some customers require logistics services along with the actual aircraft component, while others prefer to arrange their own trans-port. Lufthansa Technik has an extended logistics network and the necessary capabili-ties at its disposal to provide global com-ponent 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 Availabil-ity to deliver the quality and responsiveness that Lufthansa Technik Component Services isknownfor,saysIsabellAmann.

SCA Hotline +49-40-5070-4308sca-component-services@lht.dlh.deSITA: HAMAOLH

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

Lufthansa Technik Connection 1.2014 Aircraft Services | 11

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 customers

lease returns, among others.

Lufthansa Technik has been providing technical support to StarFlyer since the airline began operating in 2006. Now StarFlyer, which is currently operating a fleet of eleven Airbus A320 aircraft, has extended the Total Technical Support (TTS) agreement. The integrated technical sup-port we receive from Lufthansa Technik allows us to focus optimally on flight opera-tions, emphasized Tatsuji Fukuro, a mem-ber 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 Exec-utive Human Resources, Engine & VIP Services of Lufthansa Technik.

Total Technical Support TTS

Within the frame of the TTS contract Luft-hansa 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 Techniks 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 customers 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 Ger-man registration was put through a care-ful lease return check. Already at the first day of the return work, a specialist com-posites 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 Execu-tive, points to a current trend in lease con-

tracts: Today, at lessors 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 Connec-tion 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 2015. Founded seven years ago with initially three Airbus A320s, StarFlyer offers domestic service to destinations in Japan.

Ralf SchulzePhone +49-40-5070-64706ralf.schulze@lht.dlh.de

Performing a careful check, the Airbus twin jet is prepared for return to its owner.

For the lease return work, the aircraft was ferried to Lufthansa Technik Philippines.

For more information about ALTS please scan the QR code

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 Lud-wig studied Transport Engineering at Dresden University of Technol-ogy. After the interme-diate diploma she decided to specialize inAir Transport Technology and Logistics. Her first direct contact with Lufthansa came dur-ing an internship in Revenue Management for the Lufthansa long-haul fleet. During a second internship she worked in process optimization for the A380 produc-tion at aircraft manufacturer Airbus. I real-ized during my studies and the internships that working merely in systems engineering would not be my goal for a later employ-ment, says Jana Ludwig. Im more inter-ested in projects and interfaces. And I wanted to obtain a deeper understanding of other departments.

Off to a good start with StartTechnik

On completing her diploma thesis she therefore applied for the StartTechnik trai-nee program at Lufthansa Technik. I was attracted by the flexibility of this program, and as a result I am seeing a lot of the

company and, as they say, Im 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 didnt know exactly what I wanted to do career-wise. So for me its a great opportu-nity to get to know many people, see how things are interconnected within the com-

pany and work in different areas.

After a long selec-tion process Jana Ludwig received her acceptance, and finally started at the company in October 2012. The first three

weeks were spent on an introduction course involving lectures, tours and workshop vis-its that was attended by all trainees starting their program in 2012, with activities in Frankfurt and Hamburg. The trainees them-selves 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 Engi-neering at Lufthansa Technik Logistik Ser-vices, where she worked on a project in the Aircraft Components Services depart-ment. Lufthansa Techniks component pool warehouse was relocated to Frankfurt. This involved a complete change to the component admission and issue process-es, 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 pro-duction and the project team we were able to find the best solutions, she says enthu-siastically. It wasnt 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

I got to know a lot of fantastic colleagues who are very enthusiastic and totally committed to their products. Jana Ludwig

A lot of self-initiative, mobility and flexibility is expected of the Lufthansa Technik trainees.

12 | Employee Portrait Lufthansa Technik Connection 1.2014

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.

Employee Portrait | 13 Lufthansa Technik Connection 1.2014

On graduating from high school Jana Ludwig studied Transport Engineer-

ing at Dresden University of Technology. After the intermediate diploma she decided to specialize in Air Transport Technology and Logistics.

Jana Ludwig

Management in Aircraft Engineering, at Line Maintenance in Frankfurt. I definitely want-ed to take a look at strategic processes, as this was something I hadnt touched on at all during my university studies, she explains. One task was to reform the way the business units products are presented and to high-light the benefits for customers. During my research I got to know a lot of fantastic col-leagues 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 bud-dy, a former trainee, and a mentor from the management of Lufthansa Technik. I meet my mentor regularly. She assists me by giv-ing 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.

14 | Technology & Innovation Lufthansa Technik Connection 1.2014

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

Landing gears, the legs of commer-cial 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

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 techno-logical groundwork for this was laid by the development of a grinding process with inte-grated quality assurance that could be mon-itored online. Under the Grinding project,

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).

Lufthansa Technik Connection 1.2014 Engine Services | 15

which was supported by the Federal Min-istry of Education and Research (BMBF), a number of new techniques were devel-oped that will help to systematically elimi-nate damage to work pieces during the grinding process.

Sensor technology

To avoid overheating the component that is being ground, first of all a suitable tem-perature sensor was developed. This sus-pends 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 spe-cial 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.

The fiber optic cable is embedded in the grinding wheel.

A further outcome of the Grinding project is a laser-based measurement system that measures the component throughout machining. This system pre-vents 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 pro-cess 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 gath-ered, 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 char-acteristics, 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 compo-nents and in widening its technological edge in the area of landing gears.

CF34-10E MRO for Air Astana

Lufthansa Technik AERO Alzey // Kazakhstan national carrier Air Astana (KZR) has signed an exclusive-agree-ment with Lufthansa Technik AERO Alzey (LTAA) for the provision of MRO services for the carriers fleet of CF34-10E powered Embraer 190 aircraft. Air Astana introduced the first of twelve planned Embraer 190 into the regional operation in May 2011. 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 agree-ment for our new E-Jet fleet with Luft-hansa 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 agree-ment is a result of LTAA commitment to the regional aircraft engine market to provide the most flexible and compre-hensive 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 | New Aircraft Lufthansa Technik Connection 1.2014

Spot landing for the Dreamliner

Lufthansa Techniks 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 air-lines 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 success-ful 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 Air-craft Production Inspection Program which supplements services such as start-up support, line maintenance, engine change

teams, engineering support and VIP com-pletions. 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 pro-vide full component support for Air Cana-das 787 fleet, the contract with TUI Travel focuses on the 787 engine-related compo-nents of the GEnX. These two new agree-ments are a good example of how Lufthansa Technik has the flexibility to adapt its com-prehensive 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 2014. Under

the agreement, Lufthansa Technik will pro-vide Air Canada with a wide-ranging service portfolio, including the supply of serviceable parts from Lufthansa Techniks extensive 787 component pool, the maintenance, re-pair and overhaul of removed components, home base lease, transportation logistics, reliability reporting and seamless IT inte-gration. The largest Canadian airline has placed firm orders for 37 Boeing 787s, with a further 23 options.

Air Canada is the newest TCS customer.

Lufthansa Technik Connection 1.2014 New Aircraft | 17

Please continue on page 10

The selection of a component support provider for our 787 fleet is an extremely important decision, said Alan Butterfield, Vice President Engineering and Mainte-nance 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 on-site program manager at Air Canadas 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 engine-related components of the 787s GEnx-1B engines. In this case Total Component Support covers a subset of the 787 com-

ponents but still incorporates all services, including MRO, pooling and provisioning of home bases tailored to each airlines particular requirements. Now that these two new customers have joined Lufthansa Techniks service network, the MRO pro-vider handles a significant share of the material support requirements of current and future 787 fleets.

Japan Airlines, Ethiopian Airlines and several TUI Travel airlines are among the continuously increasing customer base for comprehensive material support.

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Lufthansa Technik Connection 1.201418 | New Aircraft

From phase-in to line maintenance

To ensure that the integration of the Boeing 787 into an airlines 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 inspec-tors 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 sub-sequent aircraf t operation. 50 Boeing 787 production in-spections have al-ready been com-missioned 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

comprehensive engineering support for the latest Boeing aircraft, from start-up support to all engineering services during the air-craft life. In Munich and Frankfurt Lufthansa Technik is already performing line mainte-nance 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 pro-vides rotable provisioning and MRO servic-es for Boeing 787 nacelle components,

offering the full spec-trum of life cycle sup-port services on both General Electric and Rolls-Royce engine na-celles. 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 Techniks many years experience of com-posite 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 prep-arations 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 industry-leading independent and tailor-made services for the Dreamliner.

Dirk WinklerPhone +49-40-5070-3310dirk.winkler@lht.dlh.de

Lufthansa Technik clearly demon-strated their commitment and ability to ensure the integrity of our 787 long-haul operation from day one. Alan Butterfield

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 dur-ing a hard landing the forces can exceed the weight of the aircraft by a sub-stantial factor the harsh operating condi-tions of landing gears often cause corrosion in the drilled holes and on the flange sur-faces 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 there-fore 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 individ-ual dimensions has to be fabricated for each bore. After replacement, the component with the new bushings installed must pre-cisely 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-

sions and the corresponding order infor-mation 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 manu-ally 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 mea-suring arm, a lot of time can be saved, component measurement can be signifi-cantly 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 trans-fer the data and perform the associated administrative tasks is drastically reduced. Only the data for the new bushing dimen-sions must still be entered into the CNC machine manually, but in the future this too will be automated.

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, inte-grated system. As a result only a few, opti-mally interconnected interfaces are now required. Linking the measurement meth-ods 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 subsid-iaries and affiliates of the Lufthansa Technik Group that are involved in landing gear overhauls. A patent application for a mobile measurement system that incor-porates the results of the Software Devel-opment Bushings research project, has already been filed.

Technology & Innovation | 19 Lufthansa Technik Connection 1.2014

Bushing manufactured on lathe.

The bushing is inserted into the landing gear component.

Semi-automatic measuring arm in use.

Measuring a bushing diameter with an outside micrometer.

Lufthansa Technik Connection 1.201420 | Aircraft Services

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 MIATs M&E Organization continued with line and base maintenance of the Boeing 737NG fleet, Lufthansa Technik won a contract for Total Component Sup-port (TCS) of the aircraft type. The same applied to the Boeing 767aircraft that was integrated into the fleet in 2013. For this type too Lufthansa Technik has taken on the provision of component support. In the same year the European Aviation Safety Agency expanded MIATs scope of approv-al for performance of the 767-300ER line and base maintenance.

Gaining independence

Last year Lufthansa Technik and MIAT cel-ebrated 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 partners 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 hands- on assistance, know-how transfer and training of the MRO provider as it moved towards self-sufficiency. Today MIATs 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 ZaitsevPhone +49-40-5070-5404dmitri.zaitsev@lht.dlh.de

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 part-ner 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 univer-sal service program, ranging from compo-nent 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 MIATs own M&E Organization.

Over the years MIAT developed with a sense of purpose, systematically acquiring and expanding its own maintenance com-petencies. The real breakthrough happened in March 2005 when the quality of prepara-tions was recognized by the European Avi-

15 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.

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.

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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 Techniks 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 connec-tion with products, at Lufthansa Technik the name is spot-on. The SMART team of Component Services is staffed by a group of experienced engineers focused on im-

proving 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 Techniks 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 large-volume repair. These days even the contract production of parts in large unit numbers is nothing unusual for the team.

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Preparing a Main Fuel Pump Housing for machining.

22 | Component Services Lufthansa Technik Connection 1.2014

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 compo-nent 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 pro-duction of individual parts in the facilities of Lufthansa Technik. The instruments used in this connection extend across all the strands of technology avail-able in the SRU and Manufac-turing Center, from machining to surface technology and beyond. In this way the cus-tomer receives a certified

part from a one-stop shop ready for installa-tion. 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 out-let air of the cooler to the bypass flow of the engine. As typical re-pairs such as replac-ing individual vanes using TIG welding proved to be of limit-ed value, Lufthansa Techniks engineersdeveloped 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 condi-tion, with form, fit, function and fatigue equivalent to an OEM part. The big differ-

ence 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 didnt 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 cor-rosion. The replacement parts manufac-tured by Lufthansa Technik are the equiva-lent of OEM parts in terms of form, fit, func-tion and fatigue, and brought only half of the cost with them.

The handling of a Service Bulletin con-cerning Boeing 777 aircraft is a typical case of a component repair performed by SMART. SB 777-55A0018 requires the replacement

of existing horizontal stabilizer pivot pins 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 horizon-

tal stabilizer to the stabilizer support bulk-head, 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 opera-tional condition again. This process cuts

The close connection to Lufthansa Groups airlines gives us highly detailed knowledge of the requirements of every single aircraft component. Sabrina Hornig

A mechanic carefully performs a visual check before plating.

IDG oil cooler after repair. A new cascade the grey casting has been welded to its core.

The plating shop offers a comprehensive portfolio of processes. These pins are chrome-plated.

Lufthansa Technik Connection 1.2014 Aircraft Services | 23

the cost of a new pivot pin kit set in half.

When it comes to the development of improvements to SRUs, customers bene-fit not just from the technical competence of the MRO market leader. As Sabrina Hornig of Product Engineering and Plan-ning points out: The close connection to Lufthansa Groups airlines gives us highly detailed knowledge of the require-ments 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 devel-oped, 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 indi-vidual 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 lengthen-ing the service life of the components. In this way Lufthansa Techniks customers benefit twice over a solution that truly deserves the name SMART.

Sabrina Hornig Phone +49-40-5070-68167 sabrina.hornig@lht.dlh.de

Customer advantages

Proprietary developments Cost reduction Extended service life Reduced scrap rate Availability improved Increased reliability

Participants at the Lufthansa Technik Maintenance International Custom-er 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 inno-vation topics, to the 787 engineering. There was also a briefing on the latest developments in manage/m. The attend-ees 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, Line Maintenance Manager EasyJet, con-curred: The conference is very well struc-tured 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 Luft-hansa Technik Maintenance International management. The session was kicked off by Altfried Nessel, CCO of Lufthansa

Technik Maintenance International, who recapped on the suggestions for im-provement 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 discus-sion and the exchange of experiences. Participants were particularly complimen-tary about the speed with which Lufthansa Technik Maintenance International always comes up with solutions for different cus-tomer 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 Line Maintenance Stations TUI-fly, who had come directly from the Inter-national 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 +49-69-696-46929altfried.nessel@lht.dlh.de

Replacing the aluminum brackets with plastic eliminated failures due to corrosion.

LTMI Customer Forum

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.

Lufthansa Technik Connection 1.201424 | Engine Services

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 emis-sions 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 annular-shaped 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 con-ducted in collaboration with the German Aerospace Center (DLR) and supported by the Federal Ministry of Economics and Technology (BMWi), two hard wall acous-tic panel variants for CF6-80C2 have been developed and tested. The acoustic mea-surement took place at Lufthansa Techniks engine test cell in Hamburg using DLRs unique microphone array that has been developed especially for indoor measure-ments. 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 Entwick-lungaktiverSchallschutzmanahmenimLuftverkehr) 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, pub-lic administrations, academic institutions and research to develop perceptible noise-reduction measures. This manifests itself in concrete efforts, such as the con-tinuous modernization of the aircraft fleet, the ongoing optimization of the existing fleet and the use of noise-reducing proce-dures in daily flight operations.

Dr. Gerd Saueressig Phone +49-69-696-90890gerd.saueressig@dlh.de

Lufthansa Technik Connection 1.2014 Aircraft Services | 25

Oil filter analysis for CFM56

Lufthansa Techniks 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 wash-ing out wear debris and small particles and trapping them in the filter. The analy-sis of these particles caught in the filter is an important way of evaluating the technical health of an engine, which is

why the engine manufacturer requires that regular examinations are carried out. Lufthansa Techniks Laboratory Services is now licensed to conduct oil filter analy-sis for the CFM56 engine series. This kind of examination is required, among others, by the following Service Bulletins: CMF56-5B SB72-0670, SB72-0671, SB72-0808 and SB72-0833.

Training and audit

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

Aircraft Engineering Services // A new name for the acclaimed think-tank of Lufthansa Technik Engineering: By renaming its renowned Maintenance Manage-ment 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 Engi-neering Services, the MRO providers maintenance specialists will continue the success of what hitherto have been its Mainte-nance 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 Manage-ment 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 Luft-hansa Technik that is responsible for SCAMT.

Philipp KrusemeyerPhone +49-69-696-87331philipp.krusemeyer@lht.dlh.de

Strong focus on SCAMT

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

classified and described by size, mate-rial 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

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 Techniks Laboratory Services has expanded its capabilities by an important element, underlining its approach to offering its customers the most comprehensive capability spectrum.

Dirk SchulenburgPhone +49-40-5070-64696dirk.schulenburg@lht.dlh.de

CFM56 oil filter analysis has been added to the capability spectrum of Lufthansa Techniks Laboratory Services.

Using the electron microscope the tiniest particles become visible.

Lufthansa Technik Connection 1.201426 | Events & Exhibitions

Reliable partner in the Middle East

The Middle Eastern aviation market is strongly growing.

At Lufthansa Technik Middle East Services (LTMES), head-

quartered in Dubai, Lufthansa Technik is continuously expanding

its range of technical services for the regions customers.

The Dubai Airshow at the end of 2013 visibly underlined Lufthansa Techniks role as reliable partner for the Middle East and Africa region, provid-ing high-quality technical solutions for both private and commercial aircraft oper-ators. Lufthansa Technik Middle East Ser-vices (LTMES) bundles all the contact part-ners 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 custom-ers. Now we are considering expanding

Cabin solutions for America

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 passen-ger comfort, require little maintenance and at the same time save weight. These requirements are satisfied by Lufthansa Techniks new GuideU 1000-series and HelioJet cabin products. When present-ed 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 approxi-mately one fifth of the LEDs required by conventional LED lights. A special pro-cedure ensures that the light is evenly distributed. HelioJet also has the advan-tage 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 mainte-nance. The patented GuideU system features a most efficient and light-weight design, saving more than 15 percent weight versus competing products.

The product sales team in America. The Lufthansa Technik booth at the Dubai Airshow with ample lounge space for business meetings.

With Dubai as one of the worlds booming hubs, Lufthansa Technik is expanding its offering here.

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Lufthansa Technik Connection 1.2014

Meet us at...

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

16 18 January 2014 | Bahrain

Bahrain AirshowThe Bahrain International Airshow has established itself as one of the most elite business-to-business events.

05 06 February 2014 | Dubai

MRO Middle EastThe MRO Middle East Conference and Exhibition brings together decision- makers from airliness and suppliers.

11 14 February 2014 | Singapore

Singapore AirshowAsias largest aerospace and defence event ranges among the most renowned air shows in the world.

25 26 February 2014 | Moscow

Aircraft Maintenance RussiaThe annual platform in Russian and the CIS for discussing the main issues of aircraft maintenance and repair.

18 21 March 2014 | Johannesburg

MRO AfricaThe next MRO Africa will again be a place to network with leading players from Africa and around the world.

PreviewHighlights from the next issue:InnovationManagementAircraftrecoveryFleetmanagerportrait

Events & Exhibitions | 27

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 techni-cal services for nacelle components, repair operations for Airframe Related Com-ponents (ARC) will be expanded in early 2014. 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 avi-ation 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 regions 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 pol-len. 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 perfor-mance of the engines, protecting the envi-ronment by reducing CO2 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.

Ziad al HazmiPhone +971-440-57-550 ziad.al-hazmi@lht.dlh.de

5-6

Februa

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Dubai

MRO

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Booth 316

On site: Ziad al Hazmi is Managing Director of Lufthansa Technik Middle East Services.

Cyclean is now offered on site in the region.

Lufthansa Technik Connection 1.201428 | Products & 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 ServicesTotal Support Services are the first choice for any customer wanting to enjoy cost-efficient and reliable flight operations and focus on his core business at the same time. Total Operational Support (TOS) Total Technical Support (TTS) Total Base Maintenance Support (TBS) Total Material Operations (TMO) Total Component Support (TCS) Total Engine Support (TES) Total Landing Gear Support (TLS)

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

Special Services The worlds 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

eServicesLufthansa Techniks Technical Operations Websuite manage/m allows operators to manage their technical operations via a web-based system.

A380

A380

A319

A330

A340-300

A310

A318

A320

A321

A340

A330

A310

A300

A318

A319

A321

A320

World of services Airbus

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

A300

Airbus A300 Line Maintenance Base Maintenance Component Services Engine Services: P&W JT9D, PW4000-94, GE CF6-80C2

Airbus A310

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

Airbus A318

Line MaintenanceBase MaintenanceComponent ServicesEngine Services: CFM56

Airbus A319 Line MaintenanceBase MaintenanceComponent ServicesEngine Services: CFM56-5, V2500-A5

Airbus A320 Line MaintenanceBase MaintenanceComponent ServicesEngine Services: CFM56-5, V2500-A5

Airbus A321 Line MaintenanceBase MaintenanceComponent ServicesEngine Services: CFM56-5, V2500-A5

Airbus A330

Line MaintenanceBase MaintenanceComponent ServicesEngine Services: CF6-80, PW4000-100, Trent 700

Airbus A340

Line MaintenanceBase MaintenanceComponent ServicesEngine Services: CFM56-5, Trent 500

Airbus A380

Line MaintenanceBase MaintenanceComponent ServicesEngine Services: Trent 900

Hot

line

+49-40-5070-4308Hotline24/7

AOG desk

Lufthansa Technik Connection 1.2014 Products & Services | 29

737

737

737NG/MAX

737 NG

747-8

757

777

MD11

MD80

767

787

787

777

747-8

757

767

MD-11

MD-80

RegionalsBoeing

CRJ 700

CRJ

E-Jets

Q-Series

Q-Series

ERJ 190

Boeing Business Jet (BBJ)

Airbus Corporate Jetliner

Challenger Family

Embrear Executive Jets

Embraer

Boeing Business Jet

Airbus Corporate Jets

Bombardier

Boeing 737

Line MaintenanceBase MaintenanceComponent ServicesEngine Services: CFM56-3

Boeing 737NG

Line MaintenanceBase MaintenanceComponent ServicesEngine Services: CFM56-7B

Boeing 747

Line MaintenanceBase MaintenanceComponent ServicesEngine Services: JT-9D, PW4000, CF6-80C2

Boeing 757 Line MaintenanceBase MaintenanceComponent ServicesEngine Services: RB211-535

Boeing 767

Line MaintenanceBase MaintenanceComponent ServicesEngine Services: PW4000-94, CF6-80C2

Boeing 777

Line MaintenanceBase MaintenanceComponent Services

Boeing 787

Line MaintenanceComponent ServicesEngine Services**schedule to be defined

MD-11

Line MaintenanceBase MaintenanceComponent ServicesEngine Services: CF6-80C2,PW4000-94

MD-80

Line MaintenanceBase MaintenanceComponent Services

Business Jets

ACJ

Line MaintenanceBase MaintenanceComponent ServicesEngine Services:CFM56, V2500-A5

BBJ

Line MaintenanceBase MaintenanceComponent Services Engine Services:CFM56-7B

Bombardier

Challenger, Learjet,Global Express.Line MaintenanceComponent ServicesEngine Services:CF34

Embraer

Legacy, Lineage.Line MaintenanceBase MaintenanceComponent ServicesEngine Services: CF34

Bombardier CRJ

Line MaintenanceBase MaintenanceComponent ServicesEngine Services: GE CF34

Bombardier Q400

Line MaintenanceBase MaintenanceComponent ServicesEngine Services: PW100, PW150

Embraer

E-Jets 170/175, 190/195, Line MaintenanceBase MaintenanceComponent ServicesEngine Services: GE CF34

Lufthansa Technik Connection 1.201430 | Contacts

Key Account VIP & Executive JetsJoachim von Holtzapfelp +49-40-5070-3514f +49-40-5070-8331joachim.vonholtzapfel@lht.dlh.de

Lets talk about solutions

Local representatives

Senior Vice President Marketing & SalesWalter Heerdtp +49-40-5070-2524f +49-40-5070-2101hamtssek