Flowline in Engine · PDF fileJ79 F4-Phantom II T64 Sikorsky Tyne CH53-G Transall, ... A319 A320A320--200200 A321A321 MD90 ... LEVEL IILEVEL II WRB PIECE PART HARDWARE HIGHL

DGLR 31.8.2004

MTU Maintenance Hannover

Flowline in Engine Maintenance

Ferdinand ExlerManaging Director

MTU Maintenance Hannover GmbH

31. August / 01. September 2004

Symposium

DGLR 31.8.2004


MTU – The Roots from 1945 to Today

BMW

Siemens & Halske

1957 BMW Triebwerkbau

1958 MAN Turbomotoren

Daimler-Benz

1965MAN Turbo

1969MTU (50% DB/50% MAN)

1965MAN takes overBMW TriebwerkbauBMW withdraws

1985DB takes over a 50% share of MANMANwithdraws

1989MTU becomes a subsidiary of newly established Deutsche Aerospace

1995Deutsche Aerospace renamed Daimler-Benz Aerospace

1998Daimler-Benz Aerospace renamed DaimlerChrysler Aerospace

2000MTU becomesa DaimlerChryslercompany

S/Funk 2003/2

1979Foundation of MTU Maintenance GmbH

2004DaimlerChrysler sells MTU to KKR


DGLR 31.8.2004


JT8DBoeing MD-80-Family V2500

Airbus A319, A320, A321, Boeing MD-90

PW2000

Boeing 757, Boeing C-17, IL-96M/T CF6-80

Airbus A300, A310, A330Boeing 747, B767, MD-11 PW4000G Boeing 777

PW500Cessna BravoCessna Excel PW300

Learjet 60, Do 328JET, IAI GalaxyHawker 1000 C250-C20

Bo105Jet Ranger EJ200

EF2000 EurofighterTyphoon

RB199PanaviaTornado

Larzac Alpha Jet

J79 F4-Phantom II

T64Sikorsky CH53-GTyne

Transall,BreguetAtlantic TP400

Airbus A400M

MTR390Eurocop-ter Tiger

PW6000Airbus A318

GP 7000

Airbus A380

S/Funk 2003/3

The Product Application Range


DGLR 31.8.2004


MTU’s Core CompetenciesGovernment engine

business

Design, development and production

Maintenance

• Low-pressure and high pressure turbines

• High-pressure compressor

• Overall propulsion system integration capability

• Low-pressure and high-pressure compressors

• Engine control and moni-toring unit

• System integration

• Provider of integrated solutions for civil engines and industrial gas turbines

• New repair processes• Integration of new

development, manu-facturing and repair processes

• System integration• Training and logistics

support• New maintenance

concepts

Commercial enginebusiness

S/Funk 2003/4


DGLR 31.8.2004


MTU Aero Engines/MTU Maintenance WorldwiMTU Aero

Engines North America Inc.

Vericor Power Systems Inc.

MTU Maintenance Canada Ltd.

MTU Maintenance do

Brasil Ltda.

MTU Maintenance Hannover GmbH

Ceramic Coating Center SA

(*major joint ventures )

MTU Aero Engines GmbH

ATENA Engineering GmbHEurojet Turbo GmbH*

MTU Turbomeca Rolls-Royce GmbH*

Turbo-Union Ltd.*

MTU Maintenance Berlin-Brandenburg GmbHMTU Aero Engines GmbH, Entwicklungs- und KonstruktionszentrumPratt & Whitney Cananda Customer Service Center Europe GmbH*

Airfoil Services Sdn Bhd*

MTU Maintenance Zhuhai Co.Ltd.

International Aero Engines AG *

DGLR 31.8.2004


MTU Maintenance Hannover 2004

Flow-Line: Tear-Down/Built-Up High-Tech-Repair (Laser Drillingr) Test run

Employees 1308Apprentices 76

MTU Maintenance Hannoverfounded on November 10, 1979

MRO of the engines CF6-50, CF6-80, PW2000, V2500, CFM56

DGLR 31.8.2004


CF6CF6--5050 A300B2/B4A300B2/B4B747B747--200/300200/300 DC10DC10--15/15/--3030

CF6CF6--80C280C2

CFM56CFM56--77

V2500V2500

PW2000* B757B757 CC--1717

A319A319 A320A320--200200 A321A321 MD90MD90

B737B737--600/600/--700/700/--800/800/--900900

B747B747--200/200/--300/300/--400400 MDMD--1111 A300A300--600600A310A310--200/300200/300B767B767--200/300200/300

*) am Oktober 2004 wieder in Hannover gewartet (derzeit in München)

Products 2004 - MTU Maintenance Hannover

PW6000PW6000 A318A318

DGLR 31.8.2004


0

200

400

600

800

1000

1200

1400

1600

Empl

oyee

s

1995 1996 1997 1998 1999 2000 2001 2002 2003

Overall

Apprentices

Employees - MTU Maintenance Hannover

DGLR 31.8.2004


Shop Visits - MTU Maintenance Hannover

0

50

100

150

200

250

300

350

400

Shop

Vis

its

1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003

CF6-50 CF6-80C2

V2500 CFM56-3/ -7

PW2000

DGLR 31.8.2004


19811981

Company Key Driver:Company Key Driver:Company Company --FoundationFoundation

OrderOrder--Portfolio:Portfolio:CF6CF6--50 50 OverhaulOverhaul

19851985Company Key Driver:Company Key Driver:

QualityQuality

MTU Key DriverMTU Key Driver

Qua

lity

Qua

lity

OrderOrder--Portfolio:Portfolio:-- CF6CF6--50 50

OverhaulOverhaul

19901990

Company Key Driver:Company Key Driver:IndividualIndividual WorkscopingWorkscoping

OrderOrder--Portfolio:Portfolio:CF6CF6--80 80 OverhaulOverhaulV2500 V2500 OverhaulOverhaulPW2000 PW2000 OverhaulOverhaul

Indi

vidu

alIn

divi

dual

Wor

ksco

peW

orks

cope

OrderOrder--Portfolio:Portfolio:-- CF6CF6--50 50

OverhaulOverhaul-- PiecePiece PartsParts-- CF6CF6--80 80

OverhaulOverhaul-- V2500 V2500 OverhaulOverhaul-- PW2000 PW2000

OverhaulOverhaul

19951995

Shop

Shop

-- Vis

itVi

sit

Cos

tC

ost

OrderOrder--Portfolio:Portfolio:

-- CF6CF6--50 50 OverhaulOverhaul-- PiecePiece PartsParts-- CF6CF6--80 80 OverhaulOverhaul-- V2500 V2500 OverhaulOverhaul-- PW2000 PW2000

OverhaulOverhaul

On

On --

Tim

eTi

me

Del

.D

el.


-- CF6CF6--50 50 OverhaulOverhaul-- PiecePiece PartsParts-- CF6CF6--80 80 OverhaulOverhaul-- V2500 V2500 OverhaulOverhaul-- PW2000 PW2000 OverhaulOverhaul-- CFM56CFM56--77

Company Key Driver:Company Key Driver:ShopShop--VisitVisit--CostCost 20002000

Company Key Driver:Company Key Driver:OnOn--TimeTime--DeliveryDeliveryRepairRepair DevelopmentDevelopment

OrderOrder--Portfolio:Portfolio:CFM56CFM56--77

Rep

air

Rep

air

Dev

elop

men

tD

evel

opm

ent

Key Driver of MTU Maintenance Hannover1981 to 2000

DGLR 31.8.2004


New Engine and Maintenance Demands

0

5000

10000

15000

20000

25000

30000

35000

1980

1982

1984

1986

1988

1990

1992

1994

1996

1998

2000

2002

2004

2006

2008

2010

2012

2014

2016

2018

2020

2022

Umsa

tz [M

io. U

SD]

New EngineMRO Business

Gulf-War11.09.01

2004

*) Sources: New engines: MTU Market Forecast (2003) 2003-2022; MRO: MTU Maintenance+Aerostrategy (2004, without LLPs) for illustration purposes only, not for company financial/business calculations.

DGLR 31.8.2004


0

5000

10000

15000

20000

25000

30000

35000

1980

1982

1984

1986

1988

1990

1992

1994

1996

1998

2000

2002

2004

2006

2008

2010

2012

2014

2016

2018

2020

2022

Umsa

tz [M

io. U

SD]

NeutriebwerksgeschäftMRO Geschäft

Company-Situation in 2000:

- Shop Overflow

- Bottleneck Space

- Turntime Delays

- Unpredictable Delivery-Dates

- tougher customer requirementin terms of:

* technics* logistics* finance

- Higher degree/ amount of individual customer treatment

DGLR 31.8.2004


MTU Key DriverMTU Key DriverQ

ualit

yQ

ualit

y

Indi

vidu

alIn

divi

dual

Wor

ksco

peW

orks

cope

Shop

Shop

-- Vis

itVi

sit

Cos

tC

ost

On

On --

Tim

eTi

me

Del

.D

el.


-- CF6CF6--50/ 80 50/ 80 OverhaulOverhaul-- PiecePiece PartsParts-- -- V2500 V2500 OverhaulOverhaul-- PW2000 PW2000 OverhaulOverhaul-- CFM56CFM56--3/73/7

Rep

air

Rep

air

Dev

elop

men

tD

evel

opm

ent

Key Driver of MTU Maintenance Hannover

DGLR 31.8.2004


ENGINE DISASSYENGINE DISASSYINTOINTO

SUBSUB--ASSEMBLIESASSEMBLIES

EMU EMU -- DISASSYDISASSYINTO PIECE PARTS INTO PIECE PARTS

(CLEANING AND(CLEANING ANDINSPECTION)INSPECTION)

CUSTOMECUSTOMERR

BENEFITBENEFIT

„„ON LINE“ON LINE“ REGULAR BREGULAR BMTU PRESENTATIONMTU PRESENTATION

BYBYDESIGNATED DESIGNATED

ENGINEERENGINEER•• SUMMARY OF SUMMARY OF ENGINEENGINE

REMOVALSREMOVALS•• SUMMARY OF SUMMARY OF ENGINEENGINE

PERFORMANCEPERFORMANCE•• SUMMARY OF SUMMARY OF FINDINGSFINDINGS•• CORRECTIVE CORRECTIVE ACTIONSACTIONS•• WORKSCOPESWORKSCOPES

CHANGESCHANGES•• SERVICE BULLETINSERVICE BULLETIN

RECOMMAND:RECOMMAND:•• LINE MAINTENANCELINE MAINTENANCE

RECOMMENDATIONRECOMMENDATION

DETAILED TECHNICALDETAILED TECHNICALDISCUSSIONSDISCUSSIONS

(CUSTOMER/OEM/MTU)(CUSTOMER/OEM/MTU)

CustomerCustomer

WRB WRB LEVEL ILEVEL I

QUALITYQUALITYDES. ENGINEERDES. ENGINEERCUST.SERVICECUST.SERVICE

PROD.CONTROLPROD.CONTROLWORKSCOPE CHANGESWORKSCOPE CHANGES

AS REQUIREDAS REQUIREDBSIBSI--FINDINGFINDING

INCOMING INSPECTIONINCOMING INSPECTION

WRBWRBENGINEENGINE

CUST.INFO CUST.INFO (RFR)(RFR)INCOMING INCOMING INSP.INSP.CUST.REQUICUST.REQUIREM:REM:

WRBWRBEMUEMU WORKSCOPE CHANGESWORKSCOPE CHANGES

AS REQUIREDAS REQUIREDEMUEMU--FINDINGSFINDINGS

HDW:HDW:--CONDITIONCONDITION

QUALITYQUALITYDES. ENGINEERDES. ENGINEER

SHOPSHOP WRB WRB LEVEL IILEVEL II

WRBWRBPIECEPIECEPARTPART

HARDWARE HIGHL.HARDWARE HIGHL.SCRAP PART PROGR:SCRAP PART PROGR:

Special Special RepairsRepairsRepairRepair DevelopmentDevelopment

QUALITYQUALITYDES. ENGINEERDES. ENGINEER

INSPECTORINSPECTORREPAIR DEPARTREPAIR DEPART WRB WRB

LEVEL IIILEVEL IIIINDIVIDUALINDIVIDUALTECHNICALTECHNICAL

REQUIREMENTSREQUIREMENTS

ENGINE ASSEMBLYENGINE ASSEMBLYAND AND

MODULE MANAGEM.MODULE MANAGEM.

INDIVIDUALINDIVIDUALREPAIR WORKSCOPEREPAIR WORKSCOPE

INDIVIDUALINDIVIDUALTAT TAT -- REQUIREMENTSREQUIREMENTS

CUST.SERVICECUST.SERVICE

CONTROLLINGCONTROLLING

MANUFAC.MANUFAC.

LOGISTICLOGISTIC

QUALITY QUALITY

InternaInternallCOSTCOST

CONTROLCONTROL

PRODUCTIONPRODUCTIONCONTROLCONTROL

ENGINEERINGENGINEERINGTEAMTEAM

Individual Workscoping

DGLR 31.8.2004


ExampleExample: : OnwingOnwing TimeTime

CF6-50C2ONWING LIFE PRIOR TO MTU SHOPVISIT

0

500

1000

1500

2000

2500

3000

0 5 10 15 20 25 30

NO. OF ENGINES

CSSV AVERAGE

1490 CSSV

CF6-50C2ONWING LIFE OF MTU BUILT ENGINES

0

500

1000

1500

2000

2500

0 5 10 15 20 25 30

NO. OF ENGINESCS

SV

AVERAGE1685 CSSV

DGLR 31.8.2004


0

5000

10000

15000

20000

25000

30000

35000

1980

1982

1984

1986

1988

1990

1992

1994

1996

1998

2000

2002

2004

2006

2008

2010

2012

2014

2016

2018

2020

2022

Umsa

tz [M

io. U

SD]

NeutriebwerksgeschäftMRO Geschäft

PresentPresent

FutureFutureChangeChange--ProcessProcess

•• TransparencyTransparency in in termsterms of of MaterialflowMaterialflow & & ShopShop--StructureStructure

•• visiblevisible customercustomervaluevalue addedadded

•• individualindividual WorkorderWorkorder--MgtMgtwithwith respectrespect to to customercustomerrequirementsrequirements

•• Minimum Minimum TurntimeTurntimeCapabilitiesCapabilities

Linear Linear extrapolationextrapolationof of thethe currentcurrent SystemSystem

oror

SomethingSomething elseelse ????

DGLR 31.8.2004


Something else ?

CIM

TOC

TPS

TQM

Kanban

Lean Production

Coverage of:

DGLR 31.8.2004


Modern MRO System FlowLine TM

Volume basedproduction systems

• Low steeringexpence

• Reliable Standard procedure

• Transparent material flow

• Planed standardroutines

Individual Work Scopingwithin Workstation System

• Optimized customerexpence

• Customized shop visitsolution

• Engineering controlledshop visits

• Individual processesconflic

t

DGLR 31.8.2004


5 days 3 days 2 days 21 days 3 days 5 days 2 days

customer41 internal TAT

MTU-Shop-Structure

Engine TearDown

LPT TearDown

HPT TearDown

HPC TearDown

Combustor

Cleaning

Inspection

Fan TearDown

Coating

Compressor

Blade

Fan Case

Machining

Non Welding

Vane 1

Vane 2

Vane 3

Welding

LPT BuildUp

HPT BuildUp

HPC BuildUp

Fan BuildUp

Engine BuildUp Test Cell

Proz

essb

efun

d

DGLR 31.8.2004


MTU-Network for the Simulation Application (eM-Plant)

5 days 3 days 1 day Linie-Sim 3 days 5 days 2 days

DGLR 31.8.2004


Model of the Combustor Line

DGLR 31.8.2004


ABCDEFGHIKLMN D ' L'K 'I'H 'G 'F'E 'C 'B'

21

20

19

18

17

16

15

14

13a

12

11

10

9

8

7

6

5

4

3

2b

1

0

1'

2'

3 '

4 '

13b

2a

5'

6'

7 '

OPQRSTUVWXYZZ'Y 'X '

8'

H1

Personnel Car-Park

M otor C yclesFactory

Propert y Border

Property Border

Gas Storage

Refuse Disposal

Filte

rSt

atio

n

M 1

Canteen

Test

be n

ch

O ffice building

Social Tract / Rest Room s

Soci

al tr

act

Tes t

ben

ch

SecurityO fficersPersonnel Car-Park Personnel Car-Park

TearDown

BuildUp

Production Area

Airfoils

Repair Lines

Parts

StorageEnergi

e

Eng

ine

Del

iver

y

TestIn

spec

tion

DGLR 31.8.2004

MTU Maintenance HannoverABCDEFGHIKLMN D' L'K'I'H'G'F'E'C'B'

21

20

19

18

17

16

15

14

13a

12

11

10

9

8

7

6

5

4

3

2b

1

0

1'

2'

3'

4'

13b

2a

5'

6'

7'

OPQRSTUVWXYZZ'Y'X'

8'

H1

Personnel Car-Park

Motor CyclesFactory

P rope rty Bo rder

Property Border

Gas Storage

Refuse Disposal

Filte

rSt

atio

n

M1

Canteen

Test

ben

ch

Office building

Social Tract / Rest Rooms

Soci

al tr

act

Test

ben

ch

SecurityOfficersPersonnel Car-Park Personnel Car-Park

Fan CaseEMU

Module

Tear

Down

Plasma

HeatTreatment

Laboratory

Galvanik

FPI

Cleaning

FAN - Module

Insp

ectio

n

Mac

hini

ng

Education[Ground Floor]

ACC[Ground Floor]

Education[Ground Floor]

Composite

FAN

Docks

Eli[Upper Floor]

FAN

Pow

er S

tatio

n]S

uppl

ies]

Eng

ine

Del

iver

y

Energie

Eng

ine

Tear

dow

n

De-Oiling

HPT - LPT Vane Line

Growth

HPT - LPT Blade Line

HPT - FAN Airfoil

Combuster Line

Welding Line

Non Welding Line

Coating Line

Storage

EMU-

Eng

ine

Bui

ldup

EMU

Module

BuildUp

Fan Case

DGLR 31.8.2004


Key Benefits of the modern MRO System FlowLine TM

• Neutral Shop Structure• Minimization of que-days at engine induction

• Visible Customer Value Added in terms of• Material Flow Status• Man power activity (Labour)

• Customized Shop Visit Solutions• Reliable short Turn-Around-Times• Early Predictable Cost Estimation

DGLR 31.8.2004


Thank you for your attention…

DGLR 31.8.2004

MTU Maintenance HannoverThe MTU Flow Line Concept

DGLR 31.8.2004

MTU Maintenance HannoverAdministration BuildingAdministration Building

2

7

6

4

1

8

2 - Induction (20)-Modul-Flowlines

(FAN/Core) (5-6)- Hospitality

Shop

7 - Engine build (19)- Grinding Center (9)- Modul Assembly(11-13)

4 - Main Inspection (1)- Airfoil Inspection (36)

6

- Parts & CombustorRepairline (25-32)

1 - Apprenticeshop

8 - Testcell

Shop Tour

5

5

- Waterjet Stripping(16)- NDT (17+18)- Chemical clean (22)

3 3

Documents

Flowline in Engine · PDF fileJ79 F4-Phantom II T64 Sikorsky Tyne CH53-G Transall, ... A319 A320A320--200200 A321A321 MD90 ... LEVEL IILEVEL II WRB PIECE PART HARDWARE HIGHL