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. 

LTM invested several million euros to prepare its site located at Malta精东影业 Luqa International Airport (MLA) in preparing for the technical support of the Boeing 787. This included the training of its engineering teams as well as the procurement of the necessary tooling and equipment needed to perform maintenance on the type.  

According to a Lufthansa Technik statement, the completion of the overhaul of the LOT 787 means that 鈥淟TM can now further strengthen and expand its role as the European competence center for base maintenance of widebody aircraft鈥�.聽聽

A standard C-Check on a commercial aircraft comprises extensive checks of the various systems of the aircraft and its structure, which in the case of the Boeing 787 consists to a large extent of composite materials. According to LTM, the company was able to build on its own extensive experience in dealing with these modern materials, which the company has gained over many years of supporting the Airbus A350, for example. The work also drew on LTM精东影业 previous experience of carrying out such specialist engineering work as NDT (non-destructive testing) procedures for composite materials.聽

鈥淲e are very pleased with the completion of the first base maintenance check on our Boeing 787-9 by Lufthansa Technik Malta,鈥� said Krzysztof Krolak, Vice President of Technical Operations at LOT Polish Airlines. 鈥淭his significant milestone, which comes only months after LTM精东影业 announcement to expand its product portfolio to include Boeing精东影业 popular long-haul widebody, underscores the robust capabilities and technical expertise within the Lufthansa Technik network.鈥� 

鈥淎fter years of servicing only Airbus models here in Malta, it feels special that we now once again actively service a Boeing aircraft type. And with LOT精东影业 unique special livery, what better way could there have been to introduce the Dreamliner in our facility,鈥� said Maria Cilia, LTM精东影业 Chief Executive Officer. 鈥淭his is an important milestone for us and stands as further testament to how much this company has grown and evolved into a wide-body center of excellence.鈥� 

鈥淚 would like to thank our customers for their great trust in our services. Special thanks go to my team for their dedication, passion, and continued commitment to our customers and our company.鈥� 

鈥淭he recent layover not only marked the first 787 check for our team in Malta, but it also marked our first ever base maintenance services for our valued Polish customer,鈥� added Andreas van de Kuil, Vice President of Central Sales Europe and CIS.  

鈥淚 also thank LOT Polish Airlines for their trust in this cooperation, which we hopefully can deepen even further in the time to come,鈥� he added.聽

About Lufthansa Technik Malta 

Lufthansa Technik Malta was founded in 2002 as a joint venture between Lufthansa Technik and Air Malta (since rebranded as KM Malta Airlines). Based at Malta International Airport, the company offers a wide range of line and base maintenance services for short-haul Airbus A320, A320neo, and long-haul Airbus A330, A340, A350, and Boeing 787 aircraft.  

The company employs around 600 aviation engineering staff and serves a wide range of international airline customers. 

The aircraft involved in this first C-Check at LTM first flew in June 2018 and entered service with LOT Polish Airlines later that same month. It carries 294 passengers in a three-class layout and sports a special external color scheme marking Polish independence. It entered the LTM hangar in Malta on April 7, 2024, following a two-hour and 25-minute ferry flight from Warsaw Airport (WAW).聽 聽

Lufthansa Boeing 747-8 makes heavy landing in Los Angeles: video聽

• Aircraft
• Airlines

byLuke Peters

2024-04-29

The Lufthansa A380, registered D-AIMC, flew out to Manila Ninoy Aquino International Airport (MNL) in October 2023, but finally made its way back to Frankfurt Airport (FRA) on February 17, 2024, after undergoing extensive work.聽

It was the first time that LTP had carried out a 12-year check on an A380, having previously completed both three- and six-year checks on the Airbus type previously.聽聽

At times, over 100 aircraft mechanics were on hand to complete the work, including the removal of more than 500 passenger seats and all other monuments just to enable access.  

As part of the work the A380 landing gear, which consists of five individual gear assemblies and a total of 22 wheels, was completely replaced.  

A team at (LTLGS) in London are now working on the four main landing gear components removed from the aircraft to make them almost as good as new, while the nose landing gear is overhauled by its manufacturer.聽

All four Rolls-Royce Trent 900 engines were also removed from the wings for more detailed structural inspections. 

The team at LTP also ensure that any airworthiness directives (ADs) modification requests issued while D-AIMC was out-of-action were implemented. 

Lufthansa精东影业 next A380, registered D-AIMH, is now set to undergo the 12-year check after arriving in Manilla on February 11, 2024.聽聽

The A380 is enjoying a second lease of life as demand for air travel continues to surge following the COVID-19 pandemic.  

With its huge passenger capacity, airlines are once again seeing the value in operating the superjumbo, which is also extremely popular with passengers.  

In addition to Lufthansa Airlines, LTP currently counts four other A380 operators among its customer base. 

Despite the opening of a third overhaul line for the type last year, the company’s capacities will be almost fully utilized well into the coming years. 

鈥淭he return of the A380 to the fleets of many airlines has also boosted demand for maintenance services enormously. We are benefiting quite well from this with our A380 expertise here in Manila, that we recently even expanded with the third overhaul line,鈥� explains Elmar Lutter, Chief Executive Officer of Lufthansa Technik Philippines. 鈥淚n view of the delays in the delivery of numerous new wide-body aircraft, I am certain that services for the A380 will remain an integral part of our portfolio for years to come.鈥澛�

Lufthansa hunting for 13,000 new recruits with four areas most in need of staff

• Airlines

byIan Molyneaux

2024-01-15

The agreement announced on January 22, 2024, will see Lufthansa Technik provide the Air India subsidiary with Engine Maintenance Services (EMS).聽

The contract includes overhauling a minimum of three CFM56-7B engines for Air India Express鈥� Boeing 737-800 fleet. 

The agreement between the two parties was signed at in Hyderabad, which was held between January 18 and 21, 2024.聽聽

鈥淲e are extremely pleased to announce this cooperation with Lufthansa Technik. Thereby, Air India Express now has access to Lufthansa Technik精东影业 industry-leading experience and years of knowledge that will further assist us in our growth and operational reliability,鈥� Anil Jain, Head of Engineering at Air India Express, said.   

Lufthansa Technik already supports a part of Air India Express鈥� 737 fleet with ad hoc repair and exchange of components as well as Aircraft on Ground (AOG) Services. 

鈥淲e extend our gratitude to Air India Express for entrusting us with their vital maintenance needs. Lufthansa Technik holds this collaboration in high regard and eagerly anticipates the development of this new and mutually beneficial partnership,鈥� Johanna Koch, Vice President Corporate Sales Southeast Asia & Indian Subcontinent at Lufthansa Technik, said.聽

Air India精东影业 first Airbus A350 commercial flight touches down in Mumbai聽聽

• Airlines

byIan Molyneaux

2024-01-22

The airline said that its subsidiary, Lufthansa Technik, will develop and implement the first class cabins as part of the company精东影业 鈥淎mbition 2030鈥� program. 

Though the German flag carrier unveiled the comprehensive product revamp Allegris in February 2023 that included first class suites called 鈥淪uite Plus鈥�, it has not provided further details about the B747-8 first class product.

In early November 2023, Lufthansa shared that market demand for both short-haul and long-haul flights remains high, particularly among leisure travelers.

The airline continues to see a trend in booking towards business and first class, so developing its premium products remains a priority.

Maintaining a strong position in MRO

Lufthansa also said that it expects a long-term increase in demand for repair and overhaul services, particularly in the engine sector, so the 鈥淎mbition 2030鈥� program will further expand its global position in the technical support of aircraft fleets.

鈥淚n view of the ongoing manufacturer problems – especially with engines – the strategic value of our Lufthansa Technik as an integral part of the Lufthansa Group has again increased significantly in recent months,鈥� Dr. Detlef Kayser, Chairman of the Supervisory Board of Lufthansa Technik said in a press statement. 鈥淲e see this as a great opportunity to further develop our MRO division strategically with an ambitious growth program and to further increase its profitability.鈥�

No more plans to sell shares in Lufthansa Technik

Overall, Lufthansa Group and Lufthansa Technik maintain an optimistic view on things, saying the company is 鈥渃onvinced鈥� that it is able to achieve its 2030 goals without a third party shareholder. Plans to acquire a further shareholder in Lufthansa Technik, therefore, are dropped.

“Lufthansa Technik should continue to be the determining factor in our very dynamic industry in the future,鈥� S枚ren Stark, CEO Lufthansa Technik said. 鈥淲e have very ambitious goals for the coming years: We will invest in the expansion of our services as well as in the digitalization of our business and the expansion of our international presence. This will benefit our customers and our employees around the world.鈥�

Lufthansa unveils new Allegris long-haul cabin product

• Civil Aviation

byMiquel Ros

2023-02-28

The design has been crafted with world leaders and the globe精东影业 richest people in mind with spaces onboard the jet that easily outsize most people精东影业 homes.

The interior covers more than 340 square meters in total and has been named CelestialSTAR by Lufthansa Technik‘s design team.

It was styled to 鈥渆mphasize both the contemporary purity and the typical Middle Eastern geometric design patterns as well as the vastness and openness of the sky: a reminiscence not only of the widest cabin among all newly available VVIP aircraft types, but also of the diversity in the Middle Eastern philosophy鈥�.

For the head of state or VVIP onboard their multifunctional private suite is created to act as a cocoon where the 鈥渂athroom and sleeping quarters can merge into a self-contained retreat鈥�.

They can wash themselves under the largest rain and massage shower ever designed for a private jet and then jump into a generous king-size bed.

鈥淚f there is less need for seclusion, rotating and sliding lamellae can open the cocoon to the rest of the cabin to provide access to the exercise or dressing rooms on the side, or simply to allow more daylight into the VVIP area. In this way, the feeling of space is maximized by the enormous cabin width of the BBJ 777-9,鈥� Lufthansa Technik said in a statement on November 8, 2023.

Adjacent to the private suite is the Celestial Lounge, through which passengers enter the aircraft like a lobby.

When the corridors are open, the Celestial Lounge merges almost seamlessly into the adjoining conference and dining area.

The 11 individual seats can also be easily rotated from a dining or conference position at the large center table toward the surrounding divans and moved outward for conversations on the side.

鈥淭he thoughtful design of the BBJ 777-9 interior created by Lufthansa Technik illustrates the key features of our newest, largest and most capable BBJ on the market,鈥� Alexis Fecteau, Managing Director of Marketing at BBJ, said. 鈥淭he elegant interior elements maximize personal comfort for passengers onboard the BBJ 777-9, which is capable of flying over 22 hours and connecting any two cities in the world, non-stop.鈥�

Guest passenger suites

Since the CelestialSTAR concept primarily targets customers from royal families in the Middle East, who usually fly around the world with large delegations, the second half of the cabin offers generous accommodation.

High-ranking ministers or state guests can be accommodated in the six Deluxe Suites, modern first-class compartments that have been specially adapted to this VVIP cabin design.

For additional passengers, there are also 32 seats in the so-called Executive Area, which corresponds to state-of-the-art business class seating. This is followed at the rear of the cabin by the Entourage Area, a premium economy cabin.

鈥淭he BBJ 777-9 is the largest aircraft type newly available on the market and thus simply predestined for its role as successor to the BBJ 747 as the most popular aircraft for heads of state, many of which are among our loyal customers for decades,鈥� said Hassan Gasim, Sales Director Middle East VIP & Special Aircraft Services at Lufthansa Technik.

Gasim added: 鈥淭hrough our close cooperation with Boeing Business Jets and furthermore Lufthansa’s role as launch customer for the new type, we were able to build up extensive technical expertise at an early stage. Therefore, we are pleased to present our valued customers at the Dubai Airshow this once again groundbreaking interior that makes the most of the BBJ 777-9’s size.鈥�

The CelestialSTAR cabin design is the first of its kind to be derived directly from the BBJ 777-9 design data provided by BBJ.

Lufthansa Technik will present all details of CelestialSTAR at the from November 13 to 17, including a film and a virtual tour through the cabin at booth #1120.

精东影业 is a media partner of the Dubai Airshow 2023. You can reach out to our dedicated journalists Miquel Ros and Ian Molyneaux to share your story or set up a meeting by emailing us at聽editor@aerotime.aero

Airbus ups production targets as firm plans for 40k deliveries in next 20 years聽

• Aircraft

byIan Molyneaux

2023-11-09

The new design is specifically aimed at government and military operators that need greater functionality from the interior and perform various specialized tasks with their aircraft, such as medical evacuations (MedEvac). 

鈥淲ith its cabin dimensions, the ACJ TwoTwenty represents an optimal platform for the most diverse manifestations of future government and special mission aircraft, at the price of significantly smaller and less flexible aircraft types,鈥� said Wieland Timm, the Head of Sales for Special Mission Aircraft at Lufthansa Technik. 鈥淲ith our expertise both in the field of VIP completion but also in the field of special mission modifications, we are able to reflect even the high demands of governments or armed forces in this type of aircraft, and to do so highly individually.鈥�  

Lufthansa Technik said that it could equip the A220-based VIP aircraft with a layout for working (two people), conferencing (seven people), and sleeping areas, which would ensure 鈥渁 high level of comfort and functionality as well as security and privacy鈥�. 

Furthermore, the company精东影业 standard ACJ TwoTwenty configuration includes 12 Premium Economy class and 20 Economy Class seats, with a total of 41 passengers being able to travel onboard the aircraft. That is 鈥渟ignificantly more than on conventional business jets at comparable prices鈥�. 

A MedEvac configuration includes eight stretchers, or two next-generation Patient Transport Units (PTU NG) used for intensive care patients, as well as the option to include mixed stretcher/PTU NG configurations. 

With additional fuel tanks added onto the ACJ TwoTwenty compared to the Airbus A220, the Lufthansa Technik-outfitted VIP aircraft can travel up to 5,650 nautical miles (10,460 kilometers). 

The company will reveal more renderings of the cabin later in 2023, a spokesperson confirmed in an email to 精东影业. 

VIP aircraft: how do presidents, prime ministers and heads of state travel?

• Aircraft

byGabriele Petrauskaite

2023-02-05

The new 2,000 square meter facility increases LTTS’ total capacity for aircraft engine maintenance and repair in the area to 10,000 square meters and allows the company to expand its services to include Engine Manifolds, which distribute air or fluids for optimal engine performance.

The EPAR facility has already generated 25 new jobs, with CEO Michael Malewski citing recruitment as a priority as the company continues to diversify and grow in the post-pandemic recovery period.

“With this new facility we are diversifying our product portfolio and enhancing our manufacturing capabilities to better serve our customers鈥� needs,” Malewski said. “I believe we have some of the best people in the world working for us at each of our three locations, but we need even more as we experience rapid post-pandemic recovery.鈥�

LTTS has been operating in Ireland since 1992, with over 300 employees across its operations in Shannon, Kildare, and Dublin.

The aircraft, registered as D-ALFA, belongs to Lufthansa Cargo. After it was modified, the aircraft re-entered service on February 3, 2023, on a flight LH8410 from Frankfurt to Bengaluru, India, to Chengdu, China, according to a Lufthansa statement issued on the same day.

AeroSHARK modification is jointly developed by Lufthansa Technik and BASF. It is a surface film that mimics the microscopic structure of shark skin. It consists of around 50 micrometers鈥搒ized ribs. Called riblets, these micro ribs allow for optimizing the airflow on an aircraft fuselage and engine nacelles. According to Lufthansa Technik, the technology allows for achieving 1% fuel and emissions savings.

Airbus explores autonomous flight through biomimicry聽

• Aviation Technology and Innovation

byMiquel Ros

2023-01-13

While Lufthansa is now premiering the technology in airfreight, the aircraft is not the first Boeing 777 equipped with AeroSHARK to enter service. SWISS has been transporting passengers with a Boeing 777-300ER modified in this way since October 2022.

Lufthansa Cargo plans to gradually modify its entire 777 freighter fleet with the technology. SWISS is also having its twelve Boeing 777-300ERs modified with AeroSHARK. The airline精东影业 second and third aircraft have already been modified and are being prepared to return to service.

The German airline group expects to generate 50% more revenue in the 2022 financial year and achieve record results in its Lufthansa Cargo and Lufthansa Technik business lines, according to a released by the airline.聽聽

鈥淭he Group therefore expects to be able to generate Adjusted EBIT of around 鈧�1.5 billion ($1.58 billion) in the 2022 financial year (previously: more than 鈧�1 billion ($1.05 billion)),鈥� the airline revealed in the statement. 

Alongside strong demand for air travel, the German carrier highlighted that its average yields in the passenger business remained well above pre-crisis level. 

鈥淭he booking situation for the coming months indicates a continuation of the positive trend in the Group精东影业 passenger business,鈥� Lufthansa added. 

Lufthansa will report its full year 2022 results on March 3, 2023.聽

Transatlantic strength makes Lufthansa confident on travel demand

• Aviation Economics & Finance

byVictoria Bryan

2022-10-27

Lufthansa also recorded good demand on transatlantic routes and pent-up travel demand coming out of a profitable third quarter. In June 2022, the German airline announced that it would bring back the Airbus A380 by the summer of 2023. 

However, staff shortages have caused operational issues for the airline group. 

In November 2022, the airline group announced plans to hire 20,000 new employees to address staff shortages which forced Lufthansa to cut thousands of flights during the peak summer season of 2022.   

Read more: Lufthansa launches drive to hire 20,000 employees to tackle staff shortages 

Lufthansa launches drive to hire 20,000 employees to tackle staff shortages

• Airlines

byGabriele Petrauskaite

2022-11-22