Category: PRs

by Rustom Sutiara

The mere mention of sourcing aircraft components from pooling silos to an aircraft lessor will be met with a somewhat pregnant pause and a firm yet professional response: “Not on our aircraft!” The question is, why there is so much caution with regard to the utilization of pooled spares? Let’s take a look at the concerns. Is a mutual lessor/operator balance possible?

The Leasing Perspective
The lessor’s mission is to maintain asset value. That means redelivering the aircraft with as many of the original titled parts as possible. Lessors recognize that operators dip into pooled spares in order to get out of an operational corner. The principle is even more prevalent with large fleets. To this effect, the regional and low cost carrier model, where cost control is critical, are more likely to utilize pooled parts than their somewhat more cash-rich legacy or full-service counterparts. In the main, lessors prohibit the use of pooled components onboard. However some lessors do cite notable exceptions to the rule, where pooling agreements are with Tier 1 OEMs and major international airlines, and do not reject pooled parts on their aircraft. If an operator wants to utilize a spares pool, there is no reason this cannot be incorporated into the leasing agreement.

However, the lessors’ main concern is the utilization of rogue parts, which demonstrates both safety and reliability issues when examined closely in terms of the component trace. Not least, the more commercial objective of “time-value and utility” forces them to avoid pooled parts on their aircraft. Low reliability and rogue status may not be entirely down to the human element but more so that of the issue of piece parts in terms of the quality and robustness of the components utilized during maintenance and repair. Regardless, a good level of approved aircraft maintenance may restore reliability levels, and hopefully elevate these components above rogue status.

 

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RF System Lab welcomed new customers last month in a multitude of industries. RF System Lab’s most recent client list includes companies in power generation, oil and gas, energy, casting, and food processing.
One of RF System Lab’s newest customers in the food processing industry is MillerCoors. MillerCoors is a leading U. S. brewing company that is a joint venture between SABMiller and Molson Coors Brewing Company. They required a high-quality borescope to complete processed piping sanitation inspections and ensure that their pipes were clean and had no leakage. With a reputation of quality products on the line, MillerCoors needed to make sure to invest in a borescope that could help them complete sanitation inspections with confidence.
Husky Energy is another company among RF System Lab’s newest customers. Husky Energy, representing both the oil and gas and energy industries, is one of Canada’s largest integrated energy companies. Husky Energy was looking for a reasonably priced, fully-functioning video borescope to perform asset integrity inspections on pumps and valves. They have provided nothing but positive feedback about their 6.9mm – 5m borescope purchase. The 5 meter length makes the VJ-ADV perfect for a crucial part of their integrity inspections; examining longer pipes.
Another new VJ-Advance video borescope user is National Mechanical Services. National Mechanical Services, a well-known power generation field service company specializing in generators, heavy rotating equipment and outside machinery repairs, purchased the 6.9mm – 3m VJ-Advance video borescope to assist with power generator service and repair. One notable use of the versatile 6.9mm VJ-ADV is complex stator end winding inspections to ensure that they are not melted or damaged.
RF System Lab is proud to have world leader in superalloy, aluminum and titanium investment casting, PCC Structurals, as a new customer. PCC Structurals purchased the 2.8mm VJ-ADV to take advantage of the benefits that a super-slim articulating video borescope provides. Having the ability to easily ensure that holes in casted parts were not blocked and that internal passageways did not contain any foreign object debris (FOD) after removing the casting mold is crucial to any casting business. For this reason, many casting companies struggle with rigid-style borescopes, so investing in a video borescope with 360 degree articulation and a high-resolution camera with video capabilities was an easy decision for PCC Structurals.

Air New Zealand Technical Operations has selected the PinPoint Tool Control System from HABCO to facilitate a wholesale maintenance and operational changeover to RFID technology to manage aircraft tools, improve efficiency and deliver greater safety across the operation.

“Tool control has long been recognized as a vital element in aviation safety. The PinPoint Tool Control System from HABCO minimizes the potential for foreign object damage while allowing us to realize substantial operational benefits. This new technology provides the potential to make a step change in the way we operate, and to improve our efficiency and safety margins,” stated Tech Ops GM of Aircraft Maintenance, Viv de Beus.

Pinpoint Tool Control System from HABCO is a comprehensive tool control product offering that has been designed and developed by aviation professionals for use by airline operators, maintenance depots and aerospace manufacturers to allow for the ultimate 100 percent solution in tracking predictability and accountability of tools, ground support and other devices. The PinPoint tool control system is offered in four fully-customizable configurations for use in aircraft line maintenance, MRO and depot-level maintenance and throughout a multitude of aerospace manufacturing applications. Air New Zealand plans to initially purchase 30 units in the AeroMASTER product configuration.

“Air New Zealand has used bar-coded electronic tool tracking technology for several years. This broad experience was used to develop real-world tests for the extensive testing and evaluation of new generation tool control technologies. While some solutions proved less than desirable, the PinPoint Tool Control System was the clear choice,” stated Auckland Performance improvement manager Murray Courtier.

Pinpoint Tool Control System brings together in close collaboration the talents and capabilities of three aerospace companies to deliver on a product that decreases FOD, increases efficiency and lowers cost. The PinPoint Group – a business unit of Sikorsky Aircraft – developed the product concept in close collaboration with IDZ Technologies, with IDZ providing the technology and HABCO Industries leading the design, manufacturing and integration implementation efforts through the company’s asset management business value stream.

“We’re pleased that Air New Zealand has chosen Pinpoint Tool Control System from HABCO for their maintenance requirements on the B787-9 Dreamliner as it enters into service later this year. It validates the extensive thinking and hard work that has gone into development of the PinPoint Tool Control System over the past two years. It’s a product that is truly right for the aerospace industry,” stated Simon Gharibian, MD of the PinPoint Group.

Pinpoint Tool Control System is the first in a series of products that HABCO Industries is planning to develop and manufacture to help aviation companies – operators and manufacturers alike manage their assets more efficiently and cost effectively. “We see Air New Zealand as being at the forefront of using products like PinPoint Tool Control System to manage their assets throughout their enterprise. HABCO plans to be a leader in the development of cutting edge asset management solutions that are aviation and aerospace relevant,” remarked Brian Montanari, president and CEO, HABCO Industries.

Monarch Aircraft Engineering (MAEL), part of The Monarch Group performs heavy maintenance checks, line maintenance, engineering and technical support to a well-established range of blue chip customers including easyJet, DHL, Flybe, Jet2.com, LOT Polish Airlines, Norwegian, Thomson Airways, Boeing, and Titan Airways.

November 2013 saw the opening of a multi-million pound new maintenance hangar at Birmingham Airport, which the company says has already serviced more than 600 aircraft. With safety a top priority for MAEL and in a move to ensure Birmingham Airport is a world-class facility for aircraft maintenance, a decision was made to replace all of its engineers’ personal tools with a new controlled system, in order to provide complete security and accountability in and around the hangar.

Lee Burgess, GM Maintenance Planning & Strategy at Monarch Aircraft Engineering said: “An established toolkit can take many years to build, so it was common that many of our engineers built theirs over a very long period of time. This meant that far more experienced engineers possess a full range of quality tools, but for those who are relatively new to the industry, they often only had the basics.”

“A solution was needed to not only ensure engineers have access to quality tools from day one, but to also enable complete control and ownership of the tooling inventory to monitor usage and be able to account for tools daily.”

Finding the right partner

Following a grueling selection process, MAEL partnered with global tooling solutions specialist Snap-on Industrial UK to facilitate the replacement of more than 27,000 hand and power tools with its world leading Level 5 tool control system which came at a very competitive price.

As a recognized manufacturer of quality products, Snap-on Industrial was included in the selection process from the start. According to Lee, the team from Snap-on Industrial demonstrated from the early stages that they understood the vision of MAEL.

He said: “Snap-on Industrial understood the need to work with us pre and post implementation to develop the tools held in each cabinet. The hands on involvement in development ensured our team had the right tools in the correct volumes to do the job without holding up production.”

Snap-on’s Level 5 program ‘TCMax Asset Software Management’ was chosen by MAEL as it offered secure storage of assets and the detailed control and traceability required by the business. It works to counter Foreign Object Damage (FOD) and make the workplace safer and more productive through five key measures: tool organisation, tool visibility through engineered coloured foam inserts, tool security, tool tracking and digital tool accountability which provides full audit trail and torque calibration schedules.

Within this, Networkable Tool Control (NTC) provides electronic keyless lockable tool storage units, allowing only authorised personnel to access. All tools in the system are laser etched with an ID number linked to a specific cabinet within the TCMax asset management system, providing comprehensive tool accountability.

When a tool is removed from the cabinet a unique record is generated, providing real-time inventory management including details of who is currently using each tool, on which aircraft, even to a specific area, all linked to a works order. Critical events such as calibration requests and broken or lost tools will trigger an alert sending an automatic email distribution to a list of shift supervisors, ensuring immediate action is taken to locate missing tools or the timely replacement in the case of broken tools.

The results

The MAEL inventory management team now have central visibility and real time reporting for all assets in use within the operation. This allows them to analyse tool usage easily and utilise inventory and future investments with greater clarity. It also has the ability to provide audit information to ensure customers have greater confidence in MAEL’s business controls.
The Snap-on Industrial programme represents a significant investment by MAEL, one of which would have previously been made, albeit at a lesser level, by each engineer.

MAEL made sure that engineers who would become the end users were involved in the development process, ensuring that Snap On fully understood the needs of the business, and ensuring buy in from its team. Not only do the new tool cabinets look better then personal toolboxes scattered around the hangar, but they put great quality tools at the engineer’s fingertips.

Mick Adams, Managing Director at MAEL said the full engagement of staff was one of the most pleasing aspects of the new Snap-on Industrial solution.

He stated: “Many engineers have been operating with their own tools for many years and the positive engagement from staff in changing to a company supplied toolkit is in no small part due to the support we have received from Snap-on Industrial during the initial stages of the program.

“The team at Snap-on Industrial went above and beyond to ensure they obtained a full and proper understanding of not just our processes, but also what is important to us, what makes us tick, our culture, and our DNA.”

The new solution marks a significant step change in safety management as MAEL now has complete visibility of what is being used, on which aircraft and by whom.

Lee commented: “We strive to consistently develop and improve our safety standards across the board. With a full review planned to take place at six and again at twelve months, we will be able to identify if any changes need to be made in order to adhere to our exact needs.”

As a result of the successful implementation of the program at Birmingham Airport, plans are being considered to extend the solution to the hangar facilities in Luton and Manchester.

Ian Brook, Snap-on (UK) Sales Director, concluded: “There is increasing pressure within the aerospace industry to conform to tighter audit processes for tool control. Snap-on’s understanding of these demands and constant drive to deliver innovative bespoke solutions that solve customers’ problems, have resulted in the solution we see here. The synergy between our two businesses is clear, sharing the same objectives for the delivery of a quality product and service excellence. We are very pleased to have been selected and continue to enjoy the business partnership we have with Monarch Aircraft Engineering.”

If you are an IA or AP technician in the aviation industry, a good-performing, high-quality borescope is essential to your job. Whether your specialty is turbines, recips, airframes or avionics, you need a quality borescope in your toolkit that you can rely on.
Borescopes are used in all facets of the aviation industry, from helicopters to military fighter jets. There’s a reason for that: borescopes are able to inspect confined areas where you cannot easily see to ensure safe and reliable operation of aircraft parts including turbines, airframes, winglets, landing gear, and other confined space areas.
One of the essential uses of articulating borescopes is for turbine engine inspection. Turbine engines have many internal rotating sections, as well as combustion chambers, that can be inspected with an articulating video borescope. Borescopes, which can enter directly through an injector nozzle or access port and require no engine disassembly, are able to internally inspect these blades for corrosion, wear, or imperfections such as cracks, which can occur if the compressor section gets too hot. Utilizing a borescope to inspect and maintain any type of engine helps to ensure that the aircraft is airworthy.
Turbine engines in helicopters, or rotorcrafts, are located near the main rotor blades, so in order to perform any sort of maintenance on them, professionals usually have to climb up scaffolding or a ladder; this is where the features of articulating borescopes, such as RF System Lab’s VJ-Advance (VJ-ADV) video borescope, are extremely beneficial. The VJ-ADV’s compact, portable design and on demand power (the VJ-ADV video borescope simply requires AA batteries – no need to wait for it to charge or make sure there is an electrical outlet nearby), helicopter turbine inspections are completed with ease. In addition, the super-slim 2.8mm VJ-ADV video borescope is a great fit for Main Rotor Gearbox (MRGB) inspections. The thin diameter insertion tube easily allows technicians to check for cracks developed in the welding area between the shaft and bevel gear, ensuring that the MRGB is in working order and no leaks will occur.

In addition to turbine inspections, borescopes have many other aviation-related uses. As quoted by RF System Lab’s General Manager, Sean O’Connor: “Applications include inspecting airframes, flap tracks, wiring harnesses, and landing gear.” Additionally, borescopes are used in corrosion inspections.” In fact, a borescope can be used on just about any piece of aviation equipment. Borescopes range in size, for instance: the VJ-ADV comes in 2.8mm, 3.9mm and 6.9mm diameters, so finding a size to fit an access port is easily managed.

However, just because a borescope is able to inspect many different parts of an aircraft does not mean that some areas should not be approached with caution. “Special care should be taken when using a borescope to inspect fuel tanks, with proper grounding being very important,” notes O’Connor. “Aside from fuel tanks, as long as the scope is liquid proof and resistant to the common fluids found in various aircraft systems, a borescope can safely be used anywhere.” Borescope technicians that are approved to sign off on annual inspections certifying airworthiness will have the proper Inspector Authorization (IA) Certification; but making sure to be properly educated on safety precautions when doing any kind of inspection is extremely important.

Another important reason borescopes are crucial to aircraft inspections: they allow maintenance professionals to complete 100-hour FAA inspections, necessary for a majority of aircrafts, with confidence. 100-hour inspections require photographic evidence of internal aircraft structures, which are easily captured by an articulating video borescope such as the VJ-ADV. Without a high-quality borescope to provide documentation, Maintenance professionals could put their license and reputation on the line.

Remote Visual Inspection (RVI) anywhere within an aircraft maintenance facility, or on a flight line, is not a problem with the VJ-Advance video borescope because it is battery powered, completely portable, and lightweight. For more information on the impressive VJ-Advance line of joystick controlled, fully articulating video borescopes, or to find out how you can demo the VJ-Advance video borescope for free at your own facility, visit the RF System Lab website or call (888) 747-6526 to speak to a borescope expert regarding your exact inspection needs.

The Monarch Group announced that Ian Bartholomew has been appointed as interim managing director of Monarch Aircraft Engineering Limited (MAEL), its aircraft maintenance division. He succeeds Mick Adams, who is leaving the business to take up a post at Etihad Airways as vice president of MRO based in Abu Dhabi.

Ian Bartholomew is currently commercial director of MAEL and has over 25 years’ experience in the aircraft maintenance, repair and overhaul (MRO) industry. He joined Monarch in 2003 from the MRO arm of Air France/KLM.

“Mick expressed his desire to the Board in February to leave Monarch for the MRO business of Etihad Airways and has been working his notice period. In Ian Bartholomew we have an experienced replacement to lead the business and help to develop our future plans,” Andrew Swaffield, CEO of The Monarch Group, said. “On behalf of the Board I would like to thank Mick Adams for his contribution to the business during his 29 years in total with the Monarch Group. This is a life-changing opportunity for Mick and his family and he departs with our best wishes for his future career.”

Mick Adams, managing director of MAEL, commented: “It has been a privilege to lead MAEL and I am very proud of the leading MRO market positioning that we have established, which is built on the credibility of our offer and the trust of our customers. I would like to thank the people in MAEL and across the Group for their loyalty and support over the years and I wish them continued success for the future.”

 

FL Technics Training is expanding the range of its services by launching Online Training, an Internet-based platform providing online EASA-compliant courses. The platform covers a set of specialized continuing and re-current courses, supplemented by the issuance of relevant certificates upon successful completion of the courses.

Online Training is a remote EASA Part-147-compliant training program, based on visually enhanced materials available online. The program is designed specifically for aircraft technical professionals and is aimed at both individuals and employers seeking to receive specialized aviation training in-house thus substantially saving both time and money.

“Moving certain aviation courses online allows us to be closer to our customers than ever before. From now on, MRO professionals are able to access all the required courses from the comfort of their own homes or offices. All they need is an Internet connection as well as a PC or any other device capable of online video playback. All courses can be viewed, re-viewed and stopped at any time to grant all the students added convenience and the opportunity to learn at one’s own individual pace. Moreover, Online Training will help both individuals and organizations to significantly reduce their course-related travel costs and unburden them from the previously unavoidable need to make lengthy trips to the desired training facilities,” says Kestutis Volungevicius, thehead of FL Technics Training.

Online Training starts with several courses, covering initial and continuing Human Factors and Electrical Wiring Interconnection System (Target Group 1-2 and 3-8) areas. According to the 2014 training schedule, new courses will be added to the platform each month thus expanding the program to include training on FTS Phase I and Phase II, FTS (continuation), Aviation Legislation i.a.w Part-66 M10, Aviation Legislation (continuation), Human Factors i.a.w Part-145 Initial, Safety Management Systems, IR Part-145 and IR Part-M areas by the end of the year.

 

Southwest Airlines expanded its OnPoint solution agreement with GE Aviation to cover a total of 196 CFM56-7B engines which power its Boeing 737-800 aircraft, and up to 100 CFM56-7B engines, that power recently acquired Boeing 737-700 aircraft.

“Having our engines maintained by GE Aviation provides Southwest Airlines with the peace of mind that our fleet is receiving the highest-quality maintenance, repair and overhaul services available straight from the manufacturer,” said Mike Van de Ven, executive vice president and COO of Southwest Airlines.

“Southwest Airlines is one of our biggest customers, and we take great pride in ensuring its engines receive the best services and support,” said Kevin McAllister, president and CEO of GE Aviation’s Services organization. “OnPoint solution agreements enable our customers to focus on their operations, while we work to ensure their maintenance needs are met and their engines are ready to fly.”

GE says OnPoint solutions are customized service agreements tailored to the operational and financial needs of each customer for any size fleet and adds the agreements are designed to help lower the customers’ cost of ownership and maximize the use of their assets.

On June 30, 2014, Johann Panier officially took up his duties as chief executive officer of Barfield Inc., a new Air France Industries KLM Engineering & Maintenance subsidiary following its recent acquisition from Sabena Technics.

Barfield is a supplier of MRO services specializing in component support, and providing services ranging from repairs to flight hour solutions including spares support, the design of test equipment, and the distribution of spare parts. The company employs 230 staff at three U. S. facilities in Miami, Phoenix, and Louisville.

An alumnus of the Ecole Nationale des Arts et Métiers, holding an MBA from France’s HEC business school and Six Sigma Green Belt, Johann Panier began his career with Dedienne Aerospace, a company specializing in Ground Support Equipment (GSE), in Toulouse and then in Miami. In 2002, he moved to Air France Industries where he held various positions, such as head of department for equipment and engine purchasing. Subsequently he was appointed head of the External Repairs product line. Since 2012, he was leading major projects for AFI KLM E&M Business Development.

“I am proud of this appointment and delighted to be able to count on staff who are dedicated to their company and to their customers, and enthusiastic at the idea of joining the network of a world-renowned MRO,” Panier said. “I am confident in the company’s growth prospects, and convinced that the impact of synergies within the network will propel the combined Barfield/AMG to the rank of major, competitive player serving the whole Americas market.”

Aviation Technical Services (ATS) formally opened its newly‐ renovated 607,000‐square‐foot MRO complex at Kansas City International Airport (MCI) with a ribbon‐cutting and positive customer news on July 24, 2014.

The private celebration welcomed Missouri Governor Jay Nixon, Airport Director Mark VanLoh, other community leaders, invited guests, employees and their family members and business partners.

Two of those business partners, Hawaiian Airlines and Air Canada, officially committed programs to the ATS‐KC facility. Hawaiian’s agreement for Boeing 767 heavy maintenance was formally signed earlier last week. This contract initially involves two nose‐to‐tail heavy checks beginning in September 2014 and has the opportunity to turn into a longer term, exclusive agreement. ATS recently completed a series of Airbus A330 interior modifications for Hawaiian Airlines at its facility in Everett, Washington, adding to the partnership. ATS was awarded Air Canada’s exclusive agreement for Boeing 787 modifications before the event’s formal program. The four‐year contract solidifies and extends a previous version that had three 787s completed at the ATS facility in Everett, Wash., earlier this year. The remaining 34 events will be inducted into the Kansas City facility starting in September 2014 and extending through 2018.

“Selecting Aviation Technical Services for these 767 heavy checks was a natural fit for our network and fleet given ATS’s extensive knowledge of the 767 as well as our recent success on the A330 modifications,” said Lorrin Sardinha, vice president of Maintenance and Engineering at Hawaiian Airlines. “We look forward to our continued partnership.”

Air Canada’s vice president of Maintenance, Alan Butterfield, added, “Working with ATS on this next generation of technology is reassuring, and we are looking forward to continuing this important partnership.”

`“This is a great day for ATS, our customers and the extended Kansas City community. The ATS team, the Aviation Department and Metropolitan Community College aligned well to get this operation up and running in just a few months—including a complete renovation of this hangar,” said Matt Yerbic, president and CEO of ATS.

“I’d like to sincerely thank Governor Nixon, the State of Missouri, including the Missouri Partnership and the Missouri Department of Economic Development, the City of Kansas City, Missouri, the Kansas City Missouri Economic Development Corporation, Platte County Economic Development Council and the Kansas City Area Development Council and many others for coming together to reignite the tradition of aviation in this area for airline customers and skilled aerospace workers, alike. Since we took the keys to the building, I’m proud to report that over 70 technicians and support folks have joined the ATS‐KC team and we’re continuing to hire. The fact that these flagship carriers [Hawaiian and Air Canada] have confirmed their commitment to this facility today is very exciting,” he added.