Moderated by James Pozzi, MRO Editor EMEA at Aviation Week Network, the panel provided insights into how MRO organizations are handling challenges posed by new and aging aircraft engines. They explored questions like the impact of engine OEMs’ framework on recent engine problems and the increase in engine MRO shops in the region. 

Post-COVID recovery and increasing demand 

Fulya Turkoz from Lufthansa Technik (LHT) highlighted the rapid post-COVID recovery, noting that the current challenge has shifted from material shortages to workforce needs. With rising air traffic, demand for maintenance services is increasing, necessitating quick turns and more flexible support.  

Olivier Boina from Air France Industries KLM Engineering & Maintenance (AFI KLM E&M) echoed this observation, pointing out that recovery has been strong but has led to significant labor and parts shortages, extending MRO turnaround times by 15-30%.  

Supply chain challenges 

The panelists agreed that the supply chain remains a critical bottleneck. Boina attributed this to the lag in manufacturing recovery and global events like the war in Ukraine, which have increased raw material demand. He estimated that two or three additional years would be needed to fix the supply chain. 

Arne Luxa from MTU Maintenance emphasized that while the company has managed to diversify its portfolio and locations, distributing available parts at the necessary production rate remains a challenge.  

Julius Bogusevicius of FL Technics predicted that supply chain issues might last even longer than anticipated, affecting overall efficiency. 

Adapting maintenance strategies 

In response to these challenges, MROs are adapting their strategies. LHT is combining shop visits with mobile engine services to meet immediate support needs. MTU Maintenance has focused on diversifying its portfolio to manage the high demand for both old and new engines. FL Technics has adopted more creative solutions for second shop visits, such as modular work, reflecting a shift in engine investment philosophy post-COVID. 

Long-term projections and engine lifecycle 

Panelists also discussed the long-term projections for engine maintenance. Luxa mentioned that, despite new programs, legacy engines will remain in service longer than expected, with continued investment in shop visits being necessary. Boina discussed the challenges with newer engines like the LEAP and GTF, indicating that significant fixes might not be fully available until 2026. This means that engines currently in operation will require substantial maintenance in the interim. 

Regional impact and emerging trends 

The increase in engine MRO shops in the region indicates its emergence as a center for engine maintenance. Bogusevicius noted the importance of quick-turn shops and the need for a test cell, suggesting that while performance restoration isn’t always necessary locally, there is a business case for expanding regional capabilities. 

The panel concluded that while the MRO industry faces significant challenges, there are also opportunities for growth and innovation. By adapting strategies and investing in new technologies and capabilities, MROs can better support the evolving needs of the aviation industry. 

By undergoing a rigorous evaluation process and achieving maintenance approval with L5 in its GCAA CAR 145 certification, FL Technics UAE now extends its capabilities to encompass a broader scope of services. This includes authorization to perform aircraft modifications, ensuring that the company is well-equipped to address the evolving needs of airlines operating in the region.

In conjunction with the recent announcement of FL Technics being the first independent aircraft maintenance provider in the new Abu Dhabi Airport Terminal A, the extension of the GCAA CAR 145 certification positions FL Technics as a key player in offering more comprehensive and specialized maintenance solutions at the forefront of the market. This strategic move allows the company to provide tailored services that go beyond routine maintenance, meeting the diverse and evolving requirements of its clients in the United Arab Emirates and the broader Middle East.

Operating from Abu Dhabi Terminal A, FL Technics strategically positions itself as a hub for MRO services focused on narrow-body commercial aircraft in the region. The terminal’s central location and FL Technics’ expertise create a synergistic relationship, enhancing operational efficiency and contributing to the growth of the local aviation ecosystem.

Arif Alameri, Accountable Manager of FL Technics LLC UAE, comments: “In extending our GCAA CAR 145 certification with L5 maintenance solutions, FL Technics reaffirms its commitment to providing unparalleled maintenance solutions. This strategic move enables us to offer a broader spectrum of services, catering to the evolving needs of our clients. We are dedicated to upholding the highest standards of safety, quality, and regulatory compliance.”

Zilvinas Lapinskas, CEO of FL Technics Group, emphasizes the broader global vision regarding GCAA CAR 145 L5: “The achievement of L5 certification by FL Technics LLC UAE represents a significant milestone not only for our UAE operations but for the entire FL Technics Group. It reflects our constant growth and commitment to serve the needs of our clients worldwide. With L5 certification, we are poised to elevate our standards and expand our reach, delivering top-tier solutions to airlines globally and reinforcing our position as a trusted industry leader.”

FL Technics LLC UAE’s enhancement of the GCAA CAR 145 certification with L5 maintenance solutions marks a significant step forward in the company’s pursuit of excellence in aviation maintenance. This strategic move positions FL Technics UAE as a leading provider of comprehensive MRO services, further solidifying its commitment to delivering top-tier solutions to airlines operating in the United Arab Emirates and the broader Middle East.

Once the first stage of the development is finished, facilities will include five bays for base maintenance operations including a complex of full-fledged supporting shops. 

Including the hangar and bays facility of 20,000 sq. m, the total area of the new infrastructure will be 52,000 sq. m.  

It is estimated the construction process will take up to two years and marks FL Technics鈥� commitment to developing the existing global independent MRO network. 

already operates maintenance hangars at Vilnius Airport (VNO) and Kaunas Airport (KUN) in Lithuania, Stansted Airport (STN) and Prestwick Airport (PIK) in the United Kingdom, and Soekarno-Hatta Airport (CGK) in Jakarta, Indonesia.聽聽

With the new facility in the Dominican Republic included, FL Technics owned MRO hangar space will be totaling 86,000 sq. m.聽

With a physical MRO hub in the region FL Technics is aiming to support the growing fleet of narrow-body aircraft operated in the Americas, as the company will leverage its global expertise and Part-145 capabilities certified by the Federal Aviation Administration (FAA) and the European Aviation Safety Agency (EASA).  

The company plans to provide both base and line maintenance services in the new hub. 

鈥淭his expansion is our first physical base maintenance foothold in the region, following the existing FL Technics operations in the Americas, including line maintenance network in Canada. It is a decisive investment as we aim to provide comprehensive MRO solutions to create long-term partnerships and a base for other future developments in the continent,鈥� Zilvinas Lapinskas, CEO of FL Technics, commented on the development. 

With further investments across the Americas in mind, the Punta Cana project itself is also set for future development.  

The infrastructure includes plans for an additional seven bays in the second phase totaling a hub of 12 bays, as a result 鈥� providing crucial addition to the capacity of base maintenance slots in the growing region. 

鈥淲e are pleased to announce our strategic alliance with FL Technics to offer world-class MRO services at Punta Cana International Airport and Punta Cana Free Trade Zone. With this strategic alliance, airport customers will have access to a wide range of aircraft maintenance and repair services, including scheduled inspections, component repairs, cabin modifications, and painting, among others,鈥� Giovanni Rainieri, airside operations director at Punta Cana Airport (PUJ), said. 

Saulius Bajarunas, COO of FL Technics, further commented on the project, as he emphasized the enormous potential the teams bring to the Americas: 鈥淪trategic and operational business development requires meticulous planning and evaluation, especially when it comes to complex projects in new markets. I trust this new infrastructure will become the foundation for future expansion of the new MRO hub, as the FL Technics team will apply best practices already proven successful in other continents.鈥� 

Such strategic developments are backed by Avia Solutions Group, parent company of FL Technics, which is one of the world精东影业 largest ACMI (aircraft, crew, maintenance, and insurance) providers with more than 180 aircraft in its fleet, operating in all continents in the world.聽聽

Outside the MRO and ACMI solutions, the group also provides various aviation services such as pilot and crew training, ground handling and other interconnected services.  

However, ACMI and MRO synergy is one of the key aspects driving growth and prospects in the Americas, as both businesses support each other by offering a range of flexible services for the partners inside and outside the region, with tailored solutions to meet the demands impacted and defined by diverse seasonality of cargo and commercial flight.聽

Chapman Freeborn announces Aviation Emergency Services

• Air Cargo

byAvia Solutions Group

2023-08-15

For the period of 5 years, the FL Technics engineering team will subcontract continuing airworthiness management tasks (SCATM) for the Wizz Air UK fleet of Airbus A320 FAM aircraft. The airline is currently operating 16 aircraft on the market, with potential future expansion in line with the airline’s growth plans.

鈥淔L Technics engineering team has the capacity and flexibility to provide CAMO services worldwide, and we are thrilled to enter a new market, the UK, with our client and partner Wizz Air,鈥� Oleksandr Kulyk, Deputy CEO for Engineering at FL Technics, commented on the new contract. 鈥淭he milestone once again proves the competencies and trust we gained over the years, to provide the highest quality engineering solutions with exceptional efficiency to the leading airlines and lessors.鈥�

The services will be provided leveraging the AMOS (Aircraft Maintenance and Engineering Operating System) that enables both companies to align and maintain efficient service through each stage of operations. 鈥淔or us and our clients, quality, transparency, and effectiveness are the priorities we focus on,鈥� he adds.

The new contract is an expansion of existing FL Technics solutions provided to Wizz Air, including a similar scope of Subcontracted CAMO support for Wizz Air Abu Dhabi, which the company has been providing since 2020. Additionally, FL Technics has been providing the airline with line and base maintenance services across Europe and the Middle East.

The new approval is a result of rigorous FL Technics development in 2022 focused on industry trends related to efficiency and environment. With next-generation aircraft fleets targeting sustainable operations and environmental footprint reduction, maintaining these new aircraft airborne requires new specific knowledge and capabilities, which takes a lot of effort to acquire.

鈥淥ur company is focused on sustainable, modern and reliable engineering solutions, that is why I consider the new certification extension as a decisive and strategic development of our team,鈥� explained Oleksandr Kulyk, Deputy CEO for Engineering at FL Technics. 鈥淭echnical expertise and diligence have proven our capacity to bring development in line with global trends. We are supporting a wide range of operators and lessors across the globe, and the trend we see demonstrates positive and promising development. We expect more aircraft of Airbus A220, Boeing B737-MAX and B787 types to be added to our supported fleet in the nearest future.鈥�

Since these next-generation aircraft are inevitably to replace the legacy types, after the successful extension of capabilities, next in line for FL Technics is to further develop capabilities to receive approval for Airbus A350, which is expected to be received this year.

About FL Technics 

FL Technics is a global provider of aircraft maintenance, repair, and overhaul (MRO) services. The Company specialises in base and line maintenance, spare parts and component support, engine, APU & LG management, full aircraft engineering, and technical training. FL Technics is an EASA Part-145, Part-M, Part-147, Part-21 as well as FAA-145 certified company with hangars in Lithuania, Indonesia, China, and the United Kingdom, along with line stations around the world.

鈥淥ur investment in Canada starts an exciting new chapter in the history of FL Technics and Avia Solutions Group as well as for Wright International and its founders, who will continue to lead the day-to-day operations,鈥� said Zilvinas Lapinskas, CEO of FL Technics in a statement. 鈥�

鈥淲hile we are joining a larger network, it is important to note that FL Technics, like Wright International, is an independent MRO provider whose primary focus is delivering impeccable results for its clients,鈥� commented Mario Sturino, President of Wright International. 鈥淭oday精东影业 agreement is a very positive development for both organizations as well as for the North American aviation market.鈥�

FL Technics is a global provider of aircraft maintenance, repair and overhaul (MRO) services. The company provides line maintenance services at over 70 airports and base maintenance services 鈥� at 5 locations around the world. Line maintenance services are also provided by two other FL Technics subsidiaries, namely Storm Aviation and Flash Line Maintenance.

Wright International provides aircraft line maintenance services up to ‘A’ level checks, A.O.G. support and training for airlines at Canada精东影业 major international airports. Headquartered at Toronto Pearson International Airport, the company is a Transport Canada and EASA Approved Maintenance Organization (AMO) licensed to service most commercial aircraft types.

Quick-turn activity engine shops help maintain engines, preserve their values and ensure that the high-value asset is properly stored in a condition that will allow it to return it to operation immediately.

Consistency of narrow-body aircraft and engines

While wide-body passenger aircraft were parked due to low demand of trans-continental flights, both passenger and cargo narrow-body single-aisle jets have remained quite active throughout the year. In particular, the Airbus A320 and the Boeing 737 families, including the Current Engine Option (ceo) and the NextGeneration (NG) families. The Boeing 737 Classic generation (B737-300/400) was one of the most utilized narrow-body freighters in its niche. It had very active operations during Q2 and Q3 2020 season, in addition to supporting regular charter operations and special COVID-19-related missions. Starting from Q3 2020, the Boeing 737-300 and -500 have resumed active operations in a Business jet segment as a so-called Sportjet, supporting major European sports league events.

The International Civil Aviation Organization indicates that in April 2020, the usage rate for single-aisle jets dropped by 82.1%, while for twin-aisle jets, the number plummeted by 85.9% compared to the same month in 2019. However, while narrow-body aircraft recovered to 47.5% in September 2020, wide-body aircraft only recovered to 32.5% of the previous year精东影业 levels.

FL Technics actively monitored the situation regarding how many aircraft were parked or placed into long-term storage, Andrey Baydarov, the Chief Analyst of FL Technics, told 精东影业 News. 鈥淲e were particularly interested in the engine usage situation, namely the CFM International CFM56 family,鈥� commented the analyst.

A similar tendency holds true when it comes to engines powering the in-demand narrow-bodies. The CFM56 family of engines, namely the CFM56-5B, the CFM56-3 and the CFM567B, power narrow-body aircraft like the Airbus A320ceo, the Boeing 737 Classic and the 737 NextGeneration, respectively. The CFM56-5B and the CFM56-7B generations remained popular even during the peak of the crisis.

While at the peak of the COVID-19 pandemic in April 2020, 35% of the CFM56-5B and the CFM56-7B engine fleet remained in service, the number rose to 75% in September 2020. The CFM56-3 while to a lesser extent has also remained active, especially facilitating cargo movement.

Changes in Engine MRO practices

The current environment in the aviation industry has definitely shifted the whole landscape, from top to bottom. 鈥淥f course, the crisis has changed the engine repair market. Engine owners and operators prefer to avoid extra costs to keep engines in standby mode in the context of the current crisis,鈥� explained Baydarov.

Thus, demand for such services as 鈥渆ngine lease re-delivery, storage and preservation, engine conversions and quick-turn activities are on high demand locally while the classic long-build standard performance restorations are postponed or skipped,鈥� he added. Even when the Boeing 737 MAX returns to service, the ever-rising cargo conversions of the Boeing 737 NG and the Airbus A321 will keep the market for engine hospital repair services and green-time engines hot.

Green-time engines are ideal as a cheaper and still safe option for ACMI, cargo operators or engine lessors who would like to utilize current engine green-life as fully as possible.

The wish to optimize Time on Wing (ToW) can arise from a variety of reasons, among which cash and cost savings is not the least one. A quick-turn solution focuses on repairing certain parts of an engine, rather than overhauling it completely.

The so-called engine hospital shop visit approach not only allows an operator to maximize ToW but to also preserve cash and save time. In such an uncertain environment, time is crucial. If demand suddenly spikes, you want your assets to be able to operate and exploit the opportunity. A quick-turn engine shop is an ideal solution for the task, as an alternative option 鈥� an engine overhaul 鈥� is quite expensive and time-consuming.

鈥淔or example, the CFM56 family has a recurring problem with its High-Pressure Compressor (HPC) Rotor-Stator Contact,鈥� explains FL Technics Engine Services chief executive officer (CEO) Valerij Deveikis. If during an aircraft maintenance a problem is detected, a Top Case repair of the HPC can be quickly conducted by a quick-turn engine shop even at the base maintenance hangar. That allows saving time and realizing the full advantages of one-stop solutions during aircraft maintenance events.

鈥淎ll in all, the demand for quick-turn engine shop services during the current downturn and going forward will be relatively high. Not to mention various aircraft on ground (AOG) events, including such occurrences as bird strikes,鈥� concluded FL Technic精东影业 chief analyst.

In April 2020, Etihad embarked on what it called the most extensive aircraft maintenance program in its 17 years of operations. The Gulf carrier, which had the majority of its 96 passenger aircraft fleet grounded at the time, wanted to use the inactivity time productively, so it would use aircraft grounding for maintenance before commercial passenger services resumed. 

The works on planes ranged from smaller maintenance tasks, such as seat repairs and updates to inflight entertainment systems, to bringing forward scheduled engine changes and modifications on several aircraft. They were carried out by the group精东影业 MRO division Etihad Engineering. 

Etihad operates biggest MRO program in its history

• MRO

by精东影业 Team

2020-04-22

Industry experts, speaking at AIR Convention Digital Week, agree that the COVID-19 crisis and related aircraft groundings provide an opportunity for airlines to send aircraft to maintenance. 鈥淣ow is a really good time to do maintenance,鈥� says Zilvinas Lapinskas, CEO of FL Technics. 

鈥淏efore the coronavirus, customers used to have two main questions. The first question was turnaround times (TAT) and the second question was the price. Now, we have a different situation,鈥� explained Lapinskas. As passenger aircraft fleets were largely grounded, TAT became less important, leaving the price as the most important factor. 

It also allows aircraft operators to save on costs such as buying new components instead of repairing old ones. 鈥淣ow we can remove a component, send it to a specialized shop for repairs, and put back the same component,鈥� explains Lapinskas, as aircraft are going nowhere because of the pandemic.

The timing for MRO repairs is especially useful for European operators that were previously affected by strong seasonality in the continent. 鈥淚n winter, it was impossible to get a slot for base maintenance and in summer hangars stood empty,鈥� explained FL Technics CEO. In summer 2020, operators can still 鈥済et a really attractive man-hour price and you can save money on the components, replacement and so on.鈥�

Firefly Airlines is also using the opportunity to utilize its in-house maintenance team and resources to do scheduled maintenance, says Chor Chee Hoe, Head of Maintenance Support Services at the airline. 鈥淪ince we have in-house MRO capabilities to carry out our base maintenance checks, including C-checks, it is actually a very good opportunity to schedule base maintenance for our grounded aircraft. If the aircraft has less than 30% of remaining flight circles, we consider scheduling earlier base maintenance checks.鈥�

However, currently there are two schools of thought regarding maintenance, noticed Rahul Shah, Senior Vice President of AAR Corp. For airlines that do not have in-house MRO capabilities, a decision to postpone maintenance provides an opportunity to save on cash, rather than spending money on a third-party service, Shah says, adding that 鈥渞ight now cash is the king鈥�.

Watch the full panel discussion here:

AIR Convention Digital Week hosts 30+ global aviation executives discussing how aviation is reshaped by the COVID-19 virus effects and the paths to recovery. Watch the event on aerotime.aero, every day at 2 CET on June 15th 鈥� June 19th, 2020.

Martynas gave 精东影业 an in-depth explanation of the reasons behind the Asian expansion of the company, the obstacles he faced, and his vision for the future of his business.

Martynas Grigalavicius, FL Technics CEO

鈥淭he coming together of MAAS and FL Technics to combine base maintenance and aircraft painting will allow us to offer a true one-stop-shop experience in Kaunas to airlines and leasing companies which combines maintenance with painting and painting with full engineering and maintenance support,鈥� Tim Macdougald, MAAS Aviation Group CEO, explains in a letter to media on October 16, 2019.

MAAS Aviation plans to open a twin bay single aisle paint shop for Airbus A321 in the fourth quarter of 2020. The facility will also be capable of expansion to three bays, according to Macdougald. 

In Kaunas FL Technics has a base maintenance facility. The 8500 square meters hangar and workshop space is capable to serve five narrow-body aircraft at a time, according to the . 

鈥淎ircraft painting is a niche activity offering essential services within the overall MRO sector and there are not many of us doing it,鈥� Macdougald said, also adding that his company is currently the third biggest commercial aircraft painting provider in the world. The newest location bring the total of MAAS Aviation paint bays to eleven. The company also has paint shops in the Netherlands and Alabama (the United States), as well as at Airbus Hamburg (Germany) and Final Assembly Line in Mobile (United States).