An MTU Aero Engines Company. Accessory repair and LRU management Competence and excellency in MRO solutions

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Kristopher Franklin
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1 An MTU Aero Engines Company Accessory repair and LRU management Competence and excellency in MRO solutions

Repair beats replacement MTU Maintenance is the world s largest independent provider of commercial engine maintenance services.

years of experience in the development and production of aircraft engines.

and industrial gas turbines under the umbrella of MTU Repair Services.

all of which stand out for their unique expertise in the field of accessory and component repairs as well as specialized

True to its motto repair beats replacement, MTU Maintenance continues to develop its inhouse repair capabilities.

2 Repair beats replacement MTU Maintenance is the world s largest independent provider of commercial engine maintenance services. A business unit of MTU Aero Engines, Germany s leading engine manufacturer, MTU Maintenance benefits from its parent s over 75 years of experience in the development and production of aircraft engines. MTU Maintenance has grouped all activities relating to the repair of components, modules and accessories for aircraft engines and industrial gas turbines under the umbrella of MTU Repair Services. The company operates a worldwide network of maintenance, repair and overhaul shops, among them renowned centers of excellence, all of which stand out for their unique expertise in the field of accessory and component repairs as well as specialized high-tech repair processes. True to its motto repair beats replacement, MTU Maintenance continues to develop its inhouse repair capabilities. It has a strong focus on innovative high-tech MRO-processes as well as custom-tailored management solutions that offer its customers added value and reduced maintenance costs. Airlines, maintenance providers and parts brokers alike are relying on MTU Maintenance s competence and excellence in parts, accessory and LRU repair and management solutions. 2

MTU Repair Services MTU Repair Services provides comprehensive services, its

an all-round carefree solution comprising maintenance and repair, technical and

Thanks to its one-of-a-kind repair expertise, MTU Repair Services is setting

Apart from OEM repair processes (in accordance with the engine standard manual or

3 MTU Repair Services MTU Repair Services provides comprehensive services, its portfolio covering the whole range from all major internal engine components to modules and accessories. In addition, customers can opt for MTU s Total Part Care (TPC ) service package, an all-round carefree solution comprising maintenance and repair, technical and logistic support and spare part services. Thanks to its one-of-a-kind repair expertise, MTU Repair Services is setting benchmarks in the industry worldwide. Apart from OEM repair processes (in accordance with the engine standard manual or special repairs), MTU Repair Services uses high-tech methods that are developed in-house and are certified by regulatory agencies, such as the Federal Aviation Administration (FAA) and the European Aviation Safety Agency (EASA). 3

High-performance engineering MTU Maintenance has specialized in repair development, not only for engines in which MTU has a development or production stake, but also for engines that do not form part

To ensure the necessary transfer of knowledge they closely cooperate with universities and research institutions.

4 High-performance engineering MTU Maintenance has specialized in repair development, not only for engines in which MTU has a development or production stake, but also for engines that do not form part of the company s OEM portfolio. The key to success is a highly qualified team of engineers that can draw on an extensive in-house OEM experience and know-how. To ensure the necessary transfer of knowledge they closely cooperate with universities and research institutions. MTU s goal is to develope and provide intelligent solutions, which result in significant cost reductions for the customer. MTU has a distinct advantage over its competitors: The company combines technical expertise in complete engine maintenance with the specialist know-how of an engine manufacturer that also develops innovative engine components and materials. MTU owes its success also to the highly advanced technologies it developed under the many military programs in which it had or has a stake. Laser powder cladding is one of MTU s repair specialties. Services: Hardware condition monitoring Development and approval of alternative repairs and processes Best practices engineering, technical support and consulting Failure and damage analyses MTU Aero Engines is headquartered in Munich. 4

MTU Plus repairs: Top quality with high-tech processes As a production facility and independent provider of MRO services, MTU Maintenance can draw on extensive experience and technical expertise in

These repairs have been branded as MTU Plus repairs. They are approved by aviation authorities, such as the FAA and the EASA.

MTU Plus processes are based on first-class know-how and satisfy the most demanding criteria, extending the service life of components, increasing repair yield and improving part functionality.

In close cooperation with each customer, MTU Maintenance further optimizes highly efficient processes and develops new repairs which are unique in the world of engine maintenance.

5 MTU Plus repairs: Top quality with high-tech processes As a production facility and independent provider of MRO services, MTU Maintenance can draw on extensive experience and technical expertise in the development of repair processes which are independent of or complement those of the OEMs. The result are high-tech repairs, developed in-house and unrivaled worldwide. These repairs have been branded as MTU Plus repairs. They are approved by aviation authorities, such as the FAA and the EASA. These innovative and highly cost-effective advanced repair technologies enable MTU to meet individual customer requirements with even greater flexibility. MTU Plus processes are based on first-class know-how and satisfy the most demanding criteria, extending the service life of components, increasing repair yield and improving part functionality. MTU-repaired parts stand out by their above average performance and extended on-wing times. In close cooperation with each customer, MTU Maintenance further optimizes highly efficient processes and develops new repairs which are unique in the world of engine maintenance. Engine accessories, for example, can be given a second lease on life, thus reducing capital expenditures, saving resources and protecting the environment. An accessory is being tested in an oil flow stand. Benefits: Highest quality standards High repair yields Reduced maintenance costs Improved reliability Thanks to its comprehensive and leading-edge repair expertise MTU Maintenance can repair all core components and the majority of accessories of an engine. The company uses highly sophisticated repair processes to restore parts to top-notch condition. MTU has extensive expertise in technologically advanced repair processes. LVPS plasma spraying is part of MTU's repair portfolio. 5

Accessory repair and LRU management A worldwide leader in engine MRO services, MTU Maintenance also refurbishes and repairs engine accessories.

MTU Repair Services offers a first-class comprehensive spectrum of in-house repairs, which is constantly being widened and fine-tuned.

significantly reduced. This pays off for the customers as their engines are returned as quickly as possible to revenue service. The repair of accessories requires expertise and experience.

The company has been supporting commercial customers for many years, and MTU Aero Engines has been handling practically all aviation propulsion systems in service with the German Air Force and is

6 Accessory repair and LRU management A worldwide leader in engine MRO services, MTU Maintenance also refurbishes and repairs engine accessories. Accessories include parts which are not integral to the engine but are essential for its operation, such as starters, fuel and hydraulic pumps, actuators, sensors, valves and tubing. MTU Repair Services offers a first-class comprehensive spectrum of in-house repairs, which is constantly being widened and fine-tuned. Customers benefit in many ways from this additional competence: MTU Maintenance performs repairs of the highest quality that satisfy the most stringent standards, while turnaround times are significantly reduced. This pays off for the customers as their engines are returned as quickly as possible to revenue service. The repair of accessories requires expertise and experience. MTU Maintenance has both. The company has been supporting commercial customers for many years, and MTU Aero Engines has been handling practically all aviation propulsion systems in service with the German Air Force and is responsible for their technologically advanced accessories. In addition, a dedictated team of engineers is committed to the development of new accessory repair processes. Engine accessory portfolio: IAE V2500 CF6-50 CF6-80 CFM56 PW2000 CF34 GE90 IGT accessory portfolio: LM2500/LM2500+ LM5000 LM6000 MTU Maintenance has developed all-round carefree service packages under which it not only repairs line-removed accessories but also provides support for all of the customer s line replaceable units (LRUs) that include engine accessories such as oil coolers, starters or fuel pumps. Customers can choose from several support levels ranging from maintenance and repair services to comprehensive LRU management and support programs. Full LRU management is part of MTU Maintenance s Total Part Care (TPC ) program. Services: Bench checks Repairs Overhaul (refurbishments) MTU Maintenance s repair portfolio also includes accessories. Accessories are put through their paces at MTU Maintenance Canada, MTU s center of excellence for accessories. 6

Global network with one face to the customer True to the principle of one face to the customer, MTU Repair Services handles all aspects of accessories repair for aircraft engines and industrial gas

Each customer has one contact to take care of all of his repair needs no matter where in the world the work is carried out.

It was set-up in cooperation with the German Air Force.

7 Global network with one face to the customer True to the principle of one face to the customer, MTU Repair Services handles all aspects of accessories repair for aircraft engines and industrial gas turbines within the MTU Maintenance group. MTU Repair Services can draw on the support of a global network of accessory repair shops which are located in Europe and North America. Each customer has one contact to take care of all of his repair needs no matter where in the world the work is carried out. Streamlined operation structures ensure smooth and fast processing of repair orders. MTU Aero Engines operates a large accessory test and repair center in Erding, near Munich, Germany. It was set-up in cooperation with the German Air Force. For decades, the location has been servicing nearly all engines on behalf of the customer and is responsible for technologically advanced accessories both for military and commercial engines. MTU Maintenance Canada in Richmond, British Columbia is the North American member of the MTU Maintenance network of companies. The company operates a shop in the vicinity of Vancouver s international airport where it repairs both engines and accessories and performs engine tests. It is the group s center of excellence for accessories. MTU Maintenance Hannover in Langenhagen, Germany is the flagship facility of the group s worldwide MRO network and the center of excellence for the maintenance, repair and overhaul of large commercial engines, hightech repairs and repair development. Throughout its locations, MTU Repair Services offers a wide portfolio of in-house accessory repairs. It features fuel system test benches for components such as nozzles, pumps and governors, pneumatic system test benches for all pneumatic components such as valves, starters, pressure switches as well as hydraulic and lubrication system test benches for components including actuators, pumps, oil coolers, valves, filters and regulators. In addition to individual component repair and overhaul, MTU also offers LRU (Line Replaceable Unit) management services. Regional coverage Accessory and LRU Service Centers Service Center Americas MTU Maintenance Canada Service Center Europe, Africa and Middle East MTU Maintenance Hannover MTU Aero Engines Service Center Asia-Pacific (planned) MTU Maintenance Zhuhai MTU Aero Engines operates a center for technologically advanced accessories in Erding, near Munich. Vancouver-based MTU Maintenance Canada is MTU s centre of excellence for accessories. MTU Maintenance Hannover is the group s flagship for MRO services. 7

One-stop shop solutions for engine accessories While other maintenance providers source out the repair of engine accessories and Quick Engine Change (QEC) items to third parties, MTU Maintenance

The in-house capabilities that were originally developed to better serve the company s own network are now also being offered directly to airlines, overhaul shops and parts brokers.

8 One-stop shop solutions for engine accessories While other maintenance providers source out the repair of engine accessories and Quick Engine Change (QEC) items to third parties, MTU Maintenance offers one-stop maintenance services for accessories. The in-house capabilities that were originally developed to better serve the company s own network are now also being offered directly to airlines, overhaul shops and parts brokers. One-stop systems expertise MTU Repair Services offer a comprehensive spectrum of fast and reliable accessory repairs, which is constantly being widened and fine-tuned. Customers benefit from MTU s expanded capabilities in several ways: Accessory repair activities benefit greatly from in-house development know-how, and many new repair techniques for accessories have been introduced. Due to its long-standing expertise and experience, both in engine MRO as well as in parts and accessory repair, MTU Maintenance assumes overall system responsibility and provides a world-class service that substantially reduces maintenance turnaround times and costs. A turbine starter test stand part of MTU s extensive equipment. MTU Maintenance now offers complete maintenance solutions, covering engine and accessories. Customers can rely on a single point of contact to resolve all their technical needs, thus reducing their administrative load. MTU Maintenance offers a wide portfolio of in-house accessory repairs. 8

Accessory repairs at MTU quality standards MTU Maintenance performs repairs of the highest quality that satisfy the most stringent standards.

9 Accessory repairs at MTU quality standards MTU Maintenance performs repairs of the highest quality that satisfy the most stringent standards. A global company, MTU Maintenance holds certifications from the world s three most significant aviation authorities: EASA, FAA, and CAAC. Individual locations additionally hold all applicable approvals issued in their respective countries and required from their customers. The customer s needs for efficiency and cost-effectiveness are the driving force behind the work of MTU Maintenance. MTU Aero Engines approvals and certificates: IQNet Business Excellence Class (IBEC) EMAS GQA Certificate OHSAS 18001:2007 Production Organization Approval according to EASA Part 21G Design Organization Approval according to EASA Part 21J Maintenance Organization Approval according to EASA Part 145 Maintenance Organization Approval according to CFR 145 Maintenance Organization Approval according to CCAR 145 Aviation Organization for Military Aircraft MTU Maintenance Canada approvals and certificates: Transport Canada (TCCA) Approved Maintenance Organisation (AMO) Approved Training Organisation (ATO) Civil Aviation Authority of Singapore (CAAS) Civil Aviation Department Hong Kong (CAD) MTU Maintenance Hannover approvals and certificates: OHSAS 18001:2007 EMAS AZWV Design Organization Approval according to EASA Part 21J Maintenance Organization Approval according to EASA Part 145 Maintenance Organization Approval according to CFR 145 Maintenance Organization Approval according to CCAR 145 ISO certified MTU Maintenance locations: MTU Aero Engines: ISO 9001:2008 ISO 14001:2004 EN 9100:2009 MTU Maintenance Canada: ISO MTU Maintenance Hannover: ISO 9001 EN 9100 EN 9110 In addition, the Hannover and Vancouver locations are active members of the Coordinating Agency for Supplier Evaluation (C.A.S.E.). The agency has created an internationally recognized aviation quality standard, compliance with which is regularly audited. At all locations, work processes are clearly defined and documented in integrated management systems. Regular audits, optimizations and re-certifications ensure high levels of transparency and effectiveness. 9

10 In-house accessory maintenance, repair and overhaul capability Nomenclature CF34 CF6-50 CF6-80 CFM56 GE 90 PW2000 V2500 LM 2500/5000/6000 ATA Air Conditioning Thermal Sensor ATA Electrical Power Cooler IDG Harness IDG Oil Pressure Relief Valve ATA Fire Protection Actuator Fuel Shut Off Fire Detector Harness ATA Hydraulic Power Pressure Switch ATA Pneumatic Cabin Air Solenoid Valve High Stage Temperature Sensor ATA Power Plant Drain Module Engine Mount Aft Engine Mount Fwd Harness TMF Lead Vibration Pick-Up ATA Engine Bellcrank Vane Support Engine Mount Fwd Fan Speed Trim Probe Harness Manifold Assembly Nozzle Oil Probe Sensor Shrouded Fuel Nozzle Feeder Tube Tube ATA Engine Fuel and Control Actuator Variable Geometry Data Entry Plug Electrical Cable Filter FMU Fuel Pump Harness HMU Manifold Assembly MEC Nozzle Fuel Nozzle Oil Probe Sensor Servo Fuel Heater Switch Thermocouple Tube Valve ATA Ignition Ignition Exciter Ignition Lead Nomenclature ATA Air Actuator Ballscrew Actuator LPC Master Actuator LPC Slave Actuator Master Ballscrew Actuator VBV Actuator VSV Feedback Cable VBV/VSV Flex Shaft Sensor Stop Mechanism Valve Valve Actuator TC Valve Plate Valve TCC ATA Engine Indication Accelerometer Cable Detector Junction Box Probe Sensor Thermocouple Thermocouple Harness Thermocouple Lead Thermocouple Twin Element Transducer ATA Oil Cooler Detector Heat Exchanger Oil Pump Oil Tank Sensor Switch Thermocouple Transducer Transmitter Valve ATA Starting Pneumatic Starter Switch Valve Starter Control Wire List Harness CF34 CF6-50 CF6-80 CFM56 GE 90 PW2000 V2500 LM 2500/5000/

Accessory component and LRU support programs As part of MTU s Total Part Care (TPC ), an innovative one-stop-shop service solution provided by MTU Maintenance for individual engine and industrial gas

Such integrated service packages are the key to success, reliable operations and short turn-around times.

Each program can be further adapted to satisfy the customers needs. Integrated service packages are the key to success for the operator.

11 Accessory component and LRU support programs As part of MTU s Total Part Care (TPC ), an innovative one-stop-shop service solution provided by MTU Maintenance for individual engine and industrial gas turbine parts, customers can adapt their specific repair needs to include full management of accessories and Line Replaceable Units (LRUs). Such integrated service packages are the key to success, reliable operations and short turn-around times. Furthermore, TPC can assist the operator to streamline its organization and drive cost reductions. MTU Repair Services offers three basic levels of accessory and LRU support. Each program can be further adapted to satisfy the customers needs. Integrated service packages are the key to success for the operator. Level I MTU Maintenance acts as the operator s vendor during an off-wing engine shop visit at one of its facilities and offers fixed pricing for all LRU and accessories handled during a shop visit including material supply and major repairs/overhauls. Program benefits MTU Maintenance ensures cost control and cost predictability for individual shop-visit related accessory management. Customers benefit from MTU Maintenance s in-depth engine MRO system knowledge and competence as well as access to its pool of new and used parts. Level II A Level II support program represents a partnership between MTU Maintenance and the operator and offers a one-stop-shop solution for all accessory and LRU repairs, no matter whether they are removed during line maintenance or during an off-wing shop visit. Program benefits The operator deals with one major supplier for all his LRUs and accessories. MTU Maintenance controls all vendors and passes on volume discounts it is able to negotiate with its suppliers. In addition, MTU Maintenance is able to offer fixed pricing for all major component workscopes. Due to a high level of no fault found and customized workscopes and by eliminating vendor administration, customers benefit from further cost reductions. Level III A Level III support program provides a fully integrated technical and logistical support solution for the operator. Program benefits One vendor handles all LRUs and accessories removed during the engine shop visit. While vendor control is performed by MTU Maintenance, vendor administration for the customer is reduced to a minimum. In combination with a power-by-the-hour rate, cost predictability is further improved. Exchange and material replacement programs are available and can be designed according to the customer s needs. In combination with accessory support levels II & III, customers are offered the ultimate LRU service solution to keep their business up and running 24 hours a day, seven days a week. The following options are available: Pool access: Pool inventory will be put on stock at the worldwide network of MTU Maintenance facilities to guarantee a seamless up-front exchange process and support any customer LRU-removals for a determined parts list. Main base kit (MBK): A quantity of determined accessories will be located directly at the customer base to immediately support line maintenance events. Pool access and MBK: A combination of both options to perfectly support the customer s flight operations. 11

12 An MTU Aero Engines Company MTU Aero Engines GmbH Dachauer Straße Munich Germany Tel Fax MTU Maintenance Hannover GmbH Münchner Straße Langenhagen Germany Tel Fax AOG MTU Maintenance Canada Ltd Russ Baker Way Richmond, BC V7B 1B4 Canada Tel Fax MTU Repair Services Tel Fax AOG Sales North America Tel Fax Sales South America Tel Fax Sales Europe/Middle East/Asia Tel Fax AOG GER 10/15/MUC/00000/DE/EB/E

MTU Maintenance Berlin-Brandenburg An MTU Aero Engines Company. Excellent service for industrial gas turbines. GE LM2500, LM5000 and LM6000

MTU Maintenance Berlin-Brandenburg An MTU Aero Engines Company Excellent service for industrial gas turbines GE LM2500, LM5000 and LM6000 Compelling capabilities Experience MTU Maintenance Berlin-Brandenburg