pdf - Lufthansa Technik News

Staff Magazine of Lufthansa Technik Group
March 2015
Component Services
Engine and Component Services
One round-trip ticket
to Bangkok please!
Total Component Support
for Thomas Cook
Extensive partnership
with Honeywell
manage/m® customer training
for Nok Air in Thailand.
Six-year TCS® contract for supporting the four carriers of the airline group.
Capability enhancement for the entire Honeywell
component range and overhaul of A350 APU.
Intellectual Property Management
VIP & Executive Jet Solutions
Innovation and research
A strong patent
“VIP market will recover”
My friend, the robot
Patience has been rewarded:
After years of struggle, the US patent
for GuideU has finally been awarded.
Walter Heerdt, Senior Vice President VIP & Executive
Jet Solutions, on the completion market.
Securing competitiveness
with automation solutions.
.> more
Published by:
Lufthansa Technik AG, Corporate Communications, Bernd Habbel HAM TV/I, Weg beim Jäger 193, 22335 Hamburg, Germany, Phone: +49-40-5070-3667, Fax: +49-40-5070-8534, E-mail: [email protected]
dlh.de, Editor: Christopher Hess, Design/Technical Implementation: Jespersen Communication
1 | Lufthansa Technik NEWS | March 2015
Ameco Beijing
Lufthansa LEOS
One round-trip ticket to Bangkok please!
Cabin modification
for China Eastern Airlines
TaxiBot used in real operations
In February, Ameco started
overhauling and repairing
the PW4000 engines powering six Boeing 767 from
Shanghai Airlines. The cabin
modification will be completed by the end of June.
After extensive testing the innovative towbar-less tractor is
used at Frankfurt airport. Following approval by the European Aviation Safety Agency (EASA), Lufthansa LEOS has commenced operations with the innovative TaxiBot aircraft tractor, developed by Israel
Aerospace Industries (IAI) with Lufthansa LEOS’ extensive support
and cooperation.
manage/m® customer training for Nok Air. Scarcely back from his
previous customer visit, it was time for manage/m® product Manager
Michael Weidemann to pack his bags once more. This time for a week
to his next customer – Nok Air in Thailand. Following expansion of
Nok Air’s fleet with the inclusion of another aircraft type, the Thai lowcost carrier’s workforce has expanded accordingly. The two new Q400
type aircraft will be handled for the first time as a new fleet with
manage/m® as previously was the case with the Boeing 737NG and
ATR72. It was therefore important to explain the manage/m® processes, the procedures involved and the operation of the system to the
customer. Employees from engineering, planning and quality management in particular took part in the training from the customer’s side.
In good spirits in front of
a shiny aircraft: Michael
Weidemann (5th from
right) and Cengiz Armutlu
(6th from right) at Bangkok Don Mueang Airport
with course participants
from Nok Air.
Photo: private
Nok Air has since concluded a TOM agreement (Technical Operations Management) with Lufthansa Technik Maintenance International,
which among other things provides for the presence of a Fleet Manager locally with the customer. And this role now has a new name to go
with it: Cengiz Armutlu has been ensuring the smooth implementation
of technical operations processes for the customer in Bangkok since
November and was also actively involved in the manage/m® training.
Weidemann again used this opportunity to provide the customer with
some impromptu tips and tricks regarding system handling and to present new functions from the manage/m® world. “Among other things, I
introduced the customer to our new Customer Work Instruction, which
can be used to create personalized job tickets. Cengiz Armutlu and I
explained in detail how this function can be adapted to the Nok Air processes. The customer was very impressed.” The customer’s enthusiasm
for manage/m® and Lufthansa Technik has also been further strengthened by Weidemann’s visit: “This is one reason why we maintain close
contact with our customers and also take on such long journeys. Personal interaction is extremely important, especially when it comes to IT support, and will remain a top priority for us in the future.”
Jamila Jadran, LHT
China Eastern Airlines has selected Ameco Beijing to provide
cabin modification of its Boeing 767 fleet. The 767 fleet belongs to
Shanghai Airlines, a wholly owned subsidiary of China Eastern. Ameco
finished a cabin modification of a Boeing 767 belonging to Shanghai
Airlines in January. Further cabin modifications are scheduled from April
to June. The deal covers cabin refurbishment and business class modification, the latter including engineering design, airworthiness certificate
and interior material package manufacture.
Yao Ran, Ameco (Photo: Li Kayan)
A Chinese word “Fu”
brings happiness to you
From left to right: Bert Gochermann, Executive Director of Human Resource Division, Geidel Ullrich, Executive Director of Finance Division,
and Dr. Hans Jürgen Loss, Executive Director of Operation Division.
On February 19, Ameco Beijing’s staff celebrated the traditional Chinese New Year festival in a special way. Just a couple
of days before the Chinese Spring Festival, Ameco staff wrote the
Chinese word “Fu” – 福, meaning good fortune, on the red paper in
the form of calligraphy and send them to the colleagues, friends, and
family members as best wishes. In China, it is a folk custom that most
of the families stick the word “Fu” onto the doors, and it means the
good luck and happiness will come all over the year. “Fu” will bless
people with health, joy, and harmony.
Yao Ran, Ameco (Photo: Li Kayan)
At a media event held at Frankfurt Airport on 19 February, the TaxiBot’s towing procedures were demonstrated for local and international journalists, while taxiing a Lufthansa Boeing 737 to the take-off
Photo: Jürgen Mai
TaxiBot (NB) is a towbar-less 800-hp strong hybrid-electric aircraft
tractor, controlled by the pilot and intended for towing aircraft between the gate and the runway with the aircraft’s engines turned-off.
After extensive testing, the TaxiBot is now being used in real flight
operations at Frankfurt Airport.
A special nose wheel cradle in the TaxiBot registers all the steering
movements and transfers these to navigate the tractor’s eight wheels.
This enables the pilot to steer the tractor from the cockpit using “Pilot
Control Mode” after pushing back from the gate, until it is released
at the runway.
The aircraft engines are not required to start up until the TaxiBot is
separated from the aircraft. Accordingly, a memorandum of understanding was signed between Lufthansa LEOS and IAI for widebody
aircraft certification testing. The test phase will be performed using
a Boeing 747-400 and is expected to be completed by the end of
2 | Lufthansa Technik NEWS | March 2015
Component Services
Total Component Support
for Thomas Cook
Andreas Sauer
Thomas Schröder
Dr. Axel Kerner
Seven Domke
Six-year TCS® contract for supporting the four carriers of the airline
Andreas Sauer was appointed Managing Director of Lufthansa
Technik Intercoat in Kaltenkirchen on February 1. Prior to this,
Andreas Sauer was Managing Director of H&K Dienstleistungsgesellschaft im Gesundheitswesen mbH and General Manager
of Global Service at PENTAX Europe GmbH. Thomas Schröder
took on the role of interest group representative for national and
international organizations on February 1. Dr. Axel Kerner has
been responsible for the “GAP” (Growth Acceleration Program)
project since February 2. Seven Domke was appointed to the
role of Project Manager for “Special Logistic Projects” at Lufthansa
Technik Logistik Services effective March 1. He will be succeeded as Head of Customer
Logistics by Dr. Rüdiger
Schulte-Bisping was appointed Head of Business Development in the Base Maintenance
Dr. Rüdiger
division as of March 1.
New concept for success and learning processes
Ameco Beijing
Asia: Pilot area for new roles in sales
Debut for engine PBH services
A Corporate Key Account Manager has been responsible for looking after particularly important customers at Lufthansa Technik since
January 1 together with an interdisciplinary team. So how does this
work in practice? The Asia/Pacific sales region is the pilot area for the
new concept and is also already the most advanced in terms of implementation. The Corporate Key Account Teams as they are known
are a core element of the WE GROW growth project.
“Three Key Account Managers each support two customers here in
Asia,” explains Gerald Steinhoff, who heads up the Asia/Pacific sales
region. One of the biggest challenges has been and continues to be
handing over responsibilities during operation without the customer
experiencing any negative side effects. This is also the reason why
no responsibilities were reassigned while projects were still underway. “For me, the new concept makes the transformation at Lufthansa
Ameco signed an engine power-by-the-Hour (PBH) contract
with Shanghai Airlines, a wholly owned subsidiary of China Eastern
Airlines. Based on the contract, Ameco will provide engine overhaul,
repair and other value-added services on 14 PW4000s powering
six Boeing 767s of Shanghai Airlines. This is the first time for Ameco
to provide engine services under a PBH model. Ameco and China
Eastern Airlines have been cooperating for many years by providing
mutual services. “China Eastern Airlines is one of our most important
and closest partners since the start-up of our company. The powerby-the-hour model is an innovation for our cooperation and it is also
a trust of our customer to our maintenance capability,” said Zhuxiao,
Ameco’s executive director of Sales and Supply.
Zhang Na, Ameco
Lufthansa Technik will provide a Total Component Support TCS®
for the Airbus A320 and A330 fleet of the four airlines of Thomas
Cook Group plc, one of the world’s leading leisure travel groups. The
contract has started in February 2015 and will run over a period of six
years. It also comprises the support of 25 new Airbus A321 aircraft
which will be delivered to Thomas Cook Group Airlines within 2013
to 2016. The contract covers services for the four Thomas Cook subfleets, Thomas Cook Airlines Belgium, Thomas Cook Airlines United
Kingdom, Thomas Cook Airlines Scandinavia and Condor in Germany.
The TCS® comprises component repair and overhaul services as
well as material pooling, transportation services and home base sup-
The components for the A321 and A330 fleets of the four airlines will
be repaired in the Lufthansa Technik shops in Hamburg and Frankfurt.
Photo: Michael Penner
port in Brussels, Manchester, London Gatwick, Copenhagen and Berlin-Schönefeld. Lufthansa Technik will provide technical support via its
international network, whereas the component repair will take place
at the Lufthansa Technik sites in Hamburg and Frankfurt.
Technik really tangible. We find the new responsibilities less of a challenge than, on one hand, mustering the will to part from customers
we have supported for many years and devoting all our energies to
developing new potential. On the other hand, however, the existing
good personal contact with the customer should continue to be nurtured,” says Steinhoff.
The verdict on the new role concept seems to Steinhoff to be largely positive: “Our customers already feel that we are making important
decisions faster than before.” An initial meeting of the three Corporate
Key Account Managers will take place in Asia in March. A platform for
exchanging experiences four times a year will be established for the
wider region in the future.
Kai Raudzus, LHT
» Divisions » Corporate Sales & Marketing TS
» Departments » TS/W WE GROW
3 | Lufthansa Technik NEWS | March 2015
Engine and Component Services
Extensive partnership with Honeywell
Capability enhancement for the entire Honeywell component range and overhaul of A350 APU. With a 25 percent
share of the component range and as the only manufacturer of
the Auxiliary Power Unit (APU) for the A350, Honeywell is by far
the largest and most important original equipment manufacturer
(OEM) for this future type. The intention of the cooperation is to
develop capability both for the complete Honeywell component
range as well as for the HGT1700 APU in the new Airbus A350
as quickly as possible. “As a result of the cooperation, we are
embracing technologies that would not have been economical
without the utilization by Honeywell, for example the Supplemental Cooling Systems (SCS),” says Michael Scheferhoff, Head of
Mechanical Equipment about the cooperation with Honeywell.
Tim Mahoney (sitting,
left), Chief Executive
Officer of Honeywell,
and August Wilhelm
Henningsen, CEO of
Lufthansa Technik,
shake hands at the
signing ceremony.
Photo: Sonja Brüggemann
Because all MRO services for the HGT1700 are being provided
in the APU Shop in Hamburg, this means a significant increase
in numbers and hourly volumes for the APU business unit. “This
represents both an opportunity and a challenge for our small
unit. The program has the potential to multiply the current APU
in-house business and is therefore worth every effort,” says Matthias Berg, Honeywell APU Program Manager in the APU Services business unit. Furthermore, Lufthansa Technik is responsible
– in close cooperation with the OEM – for the engineering and
development of repair processes. Like airline customers from all
around the globe, Honeywell components and APUs will also
be repaired in the future at Lufthansa Technik. Airbus already
has some 800 orders for the A350, including 25 aircraft that are
to be used starting in 2016 by the Lufthansa Passenger Airline.
Lufthansa Technik has already received numerous orders from
future A350 operators and is currently in negotiations with others. Intensive sales activities should secure success in this large
potential market.
Astrid Heinel/Silke von Estorff, LHT
Engine Services
Master plan 2015:
“Let’s get started”
Being proud of his staff,
Bernhard KrügerSprengel explains the
joint goal: “We are the
number one for engine
MRO after the OEMs.”
The product division is well-positioned with the new business model. Now it is tackling new challenges.
A lot has been achieved in Engine Services since 2011. Costs have
been successfully reduced by 20 percent and capacity utilization increased from 220 engine overhauls in 2012 to 262 last year. More
than 85 percent of the division’s orders for overhauls in 2014 came
from external customers. Engine Services is growing again. Technik
NEWS spoke about this to Bernhard Krüger-Sprengel, Senior Vice
President Engine Services.
So is the new business model proving itself?
The new structure works. Thanks to the newly established centers
– Engine Disassembly, Assembly and Testing (DAT), Engine Parts
(EPAR) as well as Engine Management Services (OVH) – the Engine
Services division is successfully positioned to attract new orders in
a market that looks set to be dominated in the future by original
equipment manufacturers (OEMs). In addition to new contracts with
Aerolíneas Argentinas, Air Canada, Air Tahiti, VietJet and SAA, we
have also performed overhauls for the first time directly for the engine
manufacturer General Electric (GE).
What developments do you foresee in the engine maintenance
market? Where do we need to act?
and staff discuss the focal
points of the
master plan.
Apart from traditional
customers, i.e. airlines,
OEMs will become increasingly important for
us in the future. They are
currently developing their
overhaul networks for the engine generation of the next 30 years.
Only a handful of suppliers will make it into these networks. We have
a good opportunity to gain a foothold with GE and the other two major OEMs (Pratt & Whitney, Rolls-Royce) in 2015 in the same way as
we have already reached agreement with Honeywell. We will get to
work in April as the first and only shop worldwide for the A350 APU.
Creative ideas, innovative technologies and know-how are essential
prerequisites to prevailing in the OEM network in the future. Pressure
on costs and differentiation demands the best ideas and new processes and at the same time strict cost optimization.
What are the next steps for the division? What’s in the master
Manufacturers have very precise expectations: One hundred percent fulfillment of requirements, nothing less, is demanded. The processes in the workshops have to be adapted to the OEM requirements.
This will be challenging for all of us – both in terms of EPAR repairs
as well as in the DAT Shops. We have to further extend the range of
additional services we offer on the market. We have made a good start
together with Rolls-Royce with Mature Engine Management (optimization of engine costs for mature engine types). Pratt & Whitney and General Electric are yet to come. Our objective for 2015 is to gain a foothold
with GEnx with the new engine types in addition to GE90 with Quick
Turns (specific intervention). The worldwide Airline Support Team network (AST®) is to be further enhanced in Montreal and Shenzhen with
the AST® stations and proven skills extended to the new engine types.
How can we continue to prevail as a leading provider?
Competition remains tough – we have to reduce our costs further
for the current types. We also have to achieve the best possible mix
of used, overhauled and new parts especially in the area of materials.
Silke von Estorff, LHT (Photos: Sonja Brüggemann)
4 | Lufthansa Technik NEWS | March 2015
Marketing and Sales
VIP & Executive Jet Solutions
Marketing conference in Hamburg
“VIP market will recover”
The desire for a strong brand and customized marketing
communication based on good international cooperation –
this is primarily what united the more than 30 participants at
Lufthansa Technik Group’s second marketing conference in
Hamburg. At the invitation of André Fischer, Head of Corporate
Marketing & Sales Management, the representatives of the newly
founded marketing group met with their marketing counterparts
from the business units and subsidiaries. In addition to sharing
information on corporate strategy and current projects, a wealth
of ideas were developed in workshops on how to address the
different target groups in Lufthansa Technik and their needs even
more successfully in the future. Greater consideration of local
and regional idiosyncrasies through all marketing activities was
a focal point of the discussion. Some of the ideas developed at
the conference will now be followed up in marketing.
Kai Raudzus, LHT
Component Services
Contract extension for Wamos Air
Spanish charter airline Wamos Air and Lufthansa Technik have extended their existing cooperation. Since 2003
Lufthansa Technik is providing a Total Component Support TCS®
for the Boeing 747 fleet of Spain’s third largest long-range airline.
On the occasion of the integration of a fifth 747-400 into the contract, the agreement was recently extended for further two years.
The Total Component Support TCS® agreement covers component repair and overhaul services as well as pooling at Wamos
Air’s main base in Madrid.
ed. (Photo: Wamos Air)
Walter Heerdt, Senior Vice President VIP & Executive Jet Solutions, on the one-of-a-kind completion business, the buyer’s market
and cost reductions.
The hangars and workshops in the VIP & Executive Jet Solutions division are still full. But predictions for the near future no
longer seem as promising, right?
That is correct. Apart from the retrofit layover of the long-haul fleet,
to date we only have one additional 747-8 as a follow-up project in
the area of completion. VIP business is not immune to financial and
political crises, especially in growth markets and otherwise traditionally strong markets.
So the market therefore looks completely
different today than it did a few years ago?
Depending on the way you look at it, there
are some 13 widebody lines in existence at
present worldwide, which at standard market
turnaround times would be able to equip between seven and nine widebodies. Two widebody contracts were awarded in 2014, the
largest of which we were able to secure for
ourselves. Unfortunately the situation with narrowbody business looks somewhat similar. The
expectations for 787 completions have dampened significantly. But the VIP market was always cyclical and will recover.
As head of sales you have been active in
promoting the WE GROW project. Are there
changes to your new division resulting from this project?
The things we have to change in general for sales apply to the
same degree for our business. Apart from strengthening competi-
tiveness, we have to engage more actively in the markets and position ourselves accordingly for this. This relates to better regional
presence, cooperation with Product Sales and the sales units in the
subsidiaries and establishment of corporate key accounts.
2014 will presumably go down in history as the year of the
special mission aircraft. This should surely also serve as proof
of the quality product offered by Lufthansa Technik?
We really had a very good year in the VIP Maintenance Business
Unit. The result: On-time performance and customer satisfaction are
all at a high level. Yet we must keep working on our competitiveness. We are shortlisted for most tenders, but are rarely on the top
step of the podium. The second place finisher
is ultimately the first loser.
Why is Lufthansa Technik often too expensive these days in the VIP segment?
We need to fully differentiate here in terms
of the reasons. Because of the complicated
and very heavily fragmented processes in the
area of completion, the number of man hours
required for the projects has risen sharply.
This is impacting administration to an increasing extent, such as for example engineering
processes. We have to change this. Our intention is to reduce our costs by 40 percent.
How are you addressing this topic?
We have launched the FIRST project. My
focus is on cooperation and team spirit, with
the objective of processing more projects
faster and more efficiently with the existing staff capacity. The market
will recover, and we want to remain at the forefront of the VIP and
executive jet business.
Bernd Habbel, LHT/ed. (Photo: Sonja Brüggemann)
Landing Gear Services
Gulf Air extends landing gear contract
Gulf Air, the Kingdom of Bahrain’s national carrier, and
Lufthansa Technik have early extended their existing cooperation in
landing gear overhaul for the airline’s Airbus A320, A321 and A330
fleet. The new contract, which commenced in February 2015, will end
in December 2020. The contract comprises landing gear overhaul
and exchange for complete shipsets. The overhaul work will be executed at the Lufthansa Technik landing gear shop in Hamburg, Germany. Lufthansa Technik first entered into a landing gear agreement
with Gulf Air in 2011 and has performed ten overhaul events in total,
to date.
5 | Lufthansa Technik NEWS | March 2015
Intellectual Property Management
A strong patent
Patience has been rewarded: After years of struggle, the US patent
for GuideU has finally been awarded.
Lufthansa Technik has now received the US patent for its “silicone
matrix” in GuideU. This comes after the company filed for a patent
for key features of GuideU in 2009 and received the German and
European patent some two years later. Silicone matrix has already
been used as standard in GuideU products on the market since
GuideU is the next phase in the development of Guideline®, the
maintenance-free emergency-exit marking system, which shows
crew and passengers the way to the aircraft’s exits in an emergency
situation. In addition to a wider choice of colors with the same high
luminosity, GuideU is lighter than its tried and tested predecessor
Guideline® and the profile can be supplied with any curvature compared with the formerly straight profile. GuideU is also completely
moisture-resistant and flatter as well as impact- and scratch-resistant, which means that it can be used for both textile areas and wet
areas. “The silicone matrix was a critical invention for successfully
achieving these properties,” says Wolfgang Sutter, Development
Engineer and Product Manager for GuideU.
“We received European patent protection quite early on
for our product’’ innovations, but continuous rejections
of our US patent application for the silicone matrix
demanded strong argumentation on our part as
well as strategic changes to the protection
claims,” continues Wolfgang Sutter.
A patent is known to only ever be
issued if an invention is not only
new but also innovative. Specific tests were carried out
and documented in the
The US patent for the “silicone matrix” in
GuideU comes after Lufthansa Technik
has received the German and European
patent already a few years ago.
20 colours allow the GuideU non-electric floor path marking system to fit any
cabin floor design.
course of the process to emphasize and define the innovations more clearly in a bid to convince the US examiners of the inventive activity. “Our remonstrations
finally succeeded in the last response to official communications: The luminosity required for emergency-exit markings in aircraft can only be achieved with
the special material properties of our silicone matrix,”
says patent attorney Rico Kolossa. “Because of the
vast amount of time and effort we had to invest, it was
all the more gratifying for us to receive such a strong
patent for GuideU some five years down the road.”
The US patent granted has a very broad protection
scope and is therefore very difficult to circumvent. The
US patent can now be maintained until 2029.
Rico Kolossa (right)
and Wolfgang Sutter
with certificate.
Susi Debus (Photos: Sonja Brüggemann,Matthias Liebich)
GuideU is lighter
than its tried and
tested predecessor
and the profile can
be supplied with
any curvature.
GuideU shows
crew and passengers the way to
the aircraft’s exits
in an emergency
6 | Lufthansa Technik NEWS | March 2015
The laser welding machine allows complex
welding processes,
thus opening up new
fields of application in
the repair process of
engine parts.
Innovation and research
My friend, the robot
Florian Kloth examines samples in the electroplating shop. The
automated analysis of galvanization baths improves quality
assurance and contributes to a reduced workload.
Securing competitiveness with automation solutions
Already in its second generation, the workscoping robot joins different measuring tasks, which had to be done manually before,
into an automated entire process.
What once seemed unimaginable is almost taken for granted in
many fields today: robots and people are no longer competitors
but work side by side in many companies. Their roles are clearly
defined, with people leading and robots providing assistance and
relief while ensuring lasting and consistent quality at high levels
of productivity. “Not only do our robots and other automation processes help us become more productive and efficient than before,
but this way many of our employees are relieved from physically
demanding and monotonous work,” said Gerrit Rexhausen, “Auto-Pro+” project leader.
In order to better evaluate the potential of selected automation processes in the aviation industry, and to do so independently of the
product divisions (PD), Lufthansa Technik in Hamburg is participating in the “Auto-Pro” aviation research program. The objective of the
platform-based overall project is to evaluate the potential for selected
automation processes and to verify it in two prototype applications.
The cooperative project is intended to generate efficient automation
solutions and to promote the exchange of expertise among the project partners in the city of Hamburg. The project is divided into three
complementary sub-projects that differ in terms of both their concepts
and their technologies; each is carried out by different project partners.
The purpose of the comprehensive “Auto-Pro+” sub-project is to
evaluate the potential of future automation solutions at Lufthansa
Technik by determining exactly where the greatest benefits are and
what can lead to further automation of the processes. The sub-project’s results will serve as a reliable basis for the evaluation of all
automation projects. The partners are Lufthansa Technik, the Zentrum für Angewandte Luftfahrtforschung (ZAL, Center for Applied
Aeronautical Research), which is also the coordinator for the overall
Auto-Pro project, and the Hamburg University of Applied Sciences.
In the “Auto-Pro I” sub-project run by Lufthansa Technik and
the Technical University of Hamburg-Harburg, the “MORFI” robot
demonstrator is to undergo further refinement. To this end, a process analysis and an evaluation of maintenance for commercial
aircraft were performed with the objective of ascertaining how well
they could be automated using a mobile robot. The PD-independent evaluation of known and future processes allows a better assessment of their suitability for automation as well as a more exact
calculation of possible cost reductions and sales growth. “Building
on the results of the ‘Auto-Pro+’ sub-project, in the future we want
to generate even more high-potential implementation projects with
double-digit project efficiency increases that will materially contribute to our savings targets,” said Gerrit Rexhausen.
Susi Debus (Photos: Sonja Brüggemann)