LAST FU*KING EXAM, WE MADE IT
MRO BUSINESS
SUMMARY
YEAR 2 | BLOCK 6 | JUNE
,Table of Contents
Engine planning – week 1 ................................................................................................................ 3
Gas Turbine Management – week 2 .............................................................................................. 12
Direct mx cost and mx reserves – week 4 ..................................................................................... 21
Airline fleet management & phase in/out – week 5 ..................................................................... 34
Aircraft Asset Management – week 6 ........................................................................................... 44
LEAN – week 7................................................................................................................................ 51
Airframe material inspection – week 9 ........................................................................................ 66
MRO IT – week 8........................................................................................................................... 69
Questions....................................................................................................................................... 72
Open question ............................................................................. Error! Bookmark not defined.
Workshop 1 ....................................................................................................................................... 1
Workshop 2 ..................................................................................................................................... 2
Workshop 4 ..................................................................................................................................... 5
Workshop 5 ..................................................................................................................................... 7
Workshop 6 ..................................................................................................................................... 8
Workshop 8 ................................................................................. Error! Bookmark not defined.
PAGE | 2
, Engine planning – week 1
ENGINE PLANNING
Effects for the airline
Air turn back.
Aircraft out of service for 72 hours.
Heavy repairs, costs up to $ 3.500.000,- or when engine is scrapped $ 11.000.000,-
Temporary lease engine.
Unforeseen costs… Or is this covered?
Engine Planning necessity
An Engine Planning is necessary for:
- Lease contract and return conditions; Engine needs to be delivered with a certain
remaining life;
- Operational costs; High fuel burns due to inefficiency; FOD ingestion
- Life Limits; Full performance restoration, LLPs module replacement, you can’t go
any further.
Engines are next to the airframe the most expensive assets. The value of a new CFM567B
engine is $11.000.000,-. Overhaul costs vary between $1.500.000,- and $4.500.000,-.
Low-Thrust Rating Engine High-Thrust Rating Engine
LLP Scheduled end of life limited parts
Performance EGTm, fuel flow and other performance improvements
Hot Parts Damages found on parts during inspections
Others Any other occurrence
PAGE | 3
, Major Elements off the Long-Term Engine Planning
1. Life Limited Parts (LLP)
2. EGT Margin based on:
Theoretical input manufacturer;
Corrected actual results during operation of the aircraft;
3. Known risks for repairs after inspections:
J-hook;
Dilution holes around spray nozzles
EGTm
– Higher reduction of EGTm are caused by:
Environment (China, India…)
NOTE: Only EGTm effects on FC’s are related to certain regions; By performing to less Engine
Washes;
– A low EGTm will cause a high EGT, where the engine will have EGT exceedances
when operating on high power settings.
– A Full Performance restoration will enhance the performance and EGTm of an
engine.
– When in the planning EGTm due is better compared to Full Performance,
savings are made!
– Performing an Engine Wash does not mean you can advance the EGTm to the
limits for a redelivery of an engine / aircraft.
– Lessors use a mean of the past year, not the latest exact figure!
High rating vs low rating engine & shop visit
PAGE | 4
MRO BUSINESS
SUMMARY
YEAR 2 | BLOCK 6 | JUNE
,Table of Contents
Engine planning – week 1 ................................................................................................................ 3
Gas Turbine Management – week 2 .............................................................................................. 12
Direct mx cost and mx reserves – week 4 ..................................................................................... 21
Airline fleet management & phase in/out – week 5 ..................................................................... 34
Aircraft Asset Management – week 6 ........................................................................................... 44
LEAN – week 7................................................................................................................................ 51
Airframe material inspection – week 9 ........................................................................................ 66
MRO IT – week 8........................................................................................................................... 69
Questions....................................................................................................................................... 72
Open question ............................................................................. Error! Bookmark not defined.
Workshop 1 ....................................................................................................................................... 1
Workshop 2 ..................................................................................................................................... 2
Workshop 4 ..................................................................................................................................... 5
Workshop 5 ..................................................................................................................................... 7
Workshop 6 ..................................................................................................................................... 8
Workshop 8 ................................................................................. Error! Bookmark not defined.
PAGE | 2
, Engine planning – week 1
ENGINE PLANNING
Effects for the airline
Air turn back.
Aircraft out of service for 72 hours.
Heavy repairs, costs up to $ 3.500.000,- or when engine is scrapped $ 11.000.000,-
Temporary lease engine.
Unforeseen costs… Or is this covered?
Engine Planning necessity
An Engine Planning is necessary for:
- Lease contract and return conditions; Engine needs to be delivered with a certain
remaining life;
- Operational costs; High fuel burns due to inefficiency; FOD ingestion
- Life Limits; Full performance restoration, LLPs module replacement, you can’t go
any further.
Engines are next to the airframe the most expensive assets. The value of a new CFM567B
engine is $11.000.000,-. Overhaul costs vary between $1.500.000,- and $4.500.000,-.
Low-Thrust Rating Engine High-Thrust Rating Engine
LLP Scheduled end of life limited parts
Performance EGTm, fuel flow and other performance improvements
Hot Parts Damages found on parts during inspections
Others Any other occurrence
PAGE | 3
, Major Elements off the Long-Term Engine Planning
1. Life Limited Parts (LLP)
2. EGT Margin based on:
Theoretical input manufacturer;
Corrected actual results during operation of the aircraft;
3. Known risks for repairs after inspections:
J-hook;
Dilution holes around spray nozzles
EGTm
– Higher reduction of EGTm are caused by:
Environment (China, India…)
NOTE: Only EGTm effects on FC’s are related to certain regions; By performing to less Engine
Washes;
– A low EGTm will cause a high EGT, where the engine will have EGT exceedances
when operating on high power settings.
– A Full Performance restoration will enhance the performance and EGTm of an
engine.
– When in the planning EGTm due is better compared to Full Performance,
savings are made!
– Performing an Engine Wash does not mean you can advance the EGTm to the
limits for a redelivery of an engine / aircraft.
– Lessors use a mean of the past year, not the latest exact figure!
High rating vs low rating engine & shop visit
PAGE | 4
