Contacts - Lufthansa Technik Logistik Services

The Lufthansa Technik Logistik Magazine
Lufthansa Technik Logistik GmbH
Director Business Development & Sales
Martin Schamberg
Weg beim Jäger 193
22335 Hamburg
[email protected]
Lufthansa Technik Logistik of America, LLC
Managing Director
Stephen Fondell
1640 Hempstead Turnpike
East Meadow, NY 11554
[email protected]
News & Contracts
Logistics for Germanwings
Development of airworthy RFID tag
Logistics made in America
Customer Relations
Airfoil Services Malaysia
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Ms. Manuela Siewert
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Lufthansa Technik Logistik GmbH
Stefanie Lübcke
Marketing & Sales
Weg beim Jäger 193
22335 Hamburg, Germany
[email protected]
Lufthansa Technik Logistik GmbH
Stefanie Lübcke
Flightlines Hamburg
Photographs: Lufthansa Technik Logistik
N3 Engine Overhaul Services GmbH/o.KG
Thai Airways · Rolls-Royce plc
Germanwings GmbH & Co. KG
Airfoil Services Sdn. Bhd.
Sylvia Jasmin Kraft
News & Contracts
News & Contracts 3
Consumables & Expendables
C&E logistics for SunExpress
Lufthansa Technik Logistik has taken
over the supply of consumables and
expendables for the charter carrier
SunExpress. This service covers not only
standard consumable and expendable
materials including engine oils, lubricants
and chemicals as well as cabin supplies
and special materials for maintenance
operations, up to and including A-checks.
The selection of materials is based on
a detailed initial provisioning study that
profited from Lufthansa Technik Logistik’s
extensive experience of provisioning
entire fleets. The study produced a detailed part number list containing up to
2,400 part numbers that aim to cover 90%
of all of SunExpress’s consumables and
expendable material requests. The remaining parts can be supplied by LTL on
demand of the customer.
Materials will be supplied to a consignment warehouse at SunExpress’s homebase in Antalya (AYT). This warehouse
enables SunExpress to reduce its capital
Dear Readers,
Being the logistics specialist in the
MRO-industry, LTL has continually
enhanced its understanding of its
customer’s special demands over the
last years – the exceedingly diverse
logistical requirements of aircraft
maintenance and overhaul are just
as familiar to us as the challenge of
provisioning parts on time.
The intimate knowledge of the multifaceted business of our customers
has consequently been used by us to
further develop in many fields: information technology, that is precisely
tailored to the market requirements,
the expansion of our international
presence as well as continually optimized supply and transport networks
are just a few examples for
our market-oriented approach. This
development is reflected in our new
corporate slogan: “Smart moves.”
It is a clear, memorable way of saying that we offer intelligent, modern
logistics concepts which ensure that
you always get the best solution. Not
an off-the-shelf solution, but one that’s
a perfect fit for your business model.
For you, “Smart moves.” means
above all else: mobility. We help you
identify your requirements – your
exact position – so that you can make
smart decisions and put in place the
ideal logistics set-up. A long-term
solution that will help you execute
your plans and follow the course your
company has set.
We very much hope you will discover this side of our company while
reading this new issue of LOGbook.
Kind regards,
Martin Schamberg
Director of Marketing & Sales
SunExpress recently had one of its Boeing 737-800s painted by Lufthansa Technik with a special design to celebrate
its 20th anniversary. The “Paint Book” livery is dedicated to the Turkish capital, Istanbul. This aircraft is unique:
the design is the joint product of Turkish and German artists and underscores the importance of collaboration
between different cultures.
Logistics for Germanwings
The power behind
successful flight ops
Behind any successful flight operator
there is always an expert organization for the
materials logistics. Logistics and transport services for the airline Germanwings are provided at its home airport Cologne/Bonn and at
the Stuttgart hub by Lufthansa Technik Logistik.
The two companies have now sealed their
successful cooperation with a formal contract.
Germanwings operates a fleet of 27 Airbus
A319’s that connect to more than 70 destinations all over Europe. But flight operations
can’t function smoothly unless all the necessary spare parts are in the right place at the
right time. Lufthansa Technik Logistik is the
com-pany responsible for Germanwings’
logistic processes at the German airports
Cologne/ Bonn and Stuttgart. Among these
services are incoming goods handling, including initial checks on materials received from
other stations or suppliers; materials warehousing, up to and including entire auxiliary
power units (APUs) and engines; checking
materials out and – where appropriate – back
in; and packaging and shipping, which includes handling hazardous goods. LTL’s warehouse is staffed and ready around the clock
for Germanwings.
When aircraft components are removed for
repairs, the on-site staff at Lufthansa Technik
Logistik coordinates, according to the specifications of the material department of Germanwings, the shipping of components to the
appropriate repair workshops. Components
may also be sent from Cologne and Stuttgart
to other Germanwings stations as needed.
Yet that’s not all: at Cologne/Bonn, Germanwings now relies on the support and experience of LTL’s logistics experts for the maintenance tool handling, too. Under the new contract they will set up and operate a tool crib
for issuing tools and checking them back in.
LTL will also coordinate the shipment of tools
Lufthansa Technik Logistik LOGbook 1. 2010
for repair or calibration and deal with
incoming deliveries of new tools.
In addition to providing direct support at
Germanwings’ locations, LTL also carries
out national and international time definite
transports (TDT) and Aircraft on Ground
(AOG) shipments. The two companies plan
to intensify their cooperation in these areas
and in the area of engine transports –
where LTL’s employees are already handling the loading of incoming and outgoing
Germanwings benefits from numerous
synergetic effects resulting from the storage
of its materials in LTL warehouses. At
Cologne/Bonn, for example, the available
resources and capacities are optimally
utilized because LTL handles the logistics
for a number of customers, including
Lufthansa CityLine and Lufthansa Technik
Maintenance Services in addition to
Germanwings. At Stuttgart, LTL looks after
Lufthansa Technik as well as Germanwings.
But whatever the synergies, LTL always provides a customer-specific set-up and a
logistics solution tailored to each individual
customer, including the usage of the customers‘ IT system.
Lufthansa Technik Logistik LOGbook 1. 2010
tie-up since the airline only pays for material when it is actually consumed. Furthermore, Lufthansa Technik Logistik will provide recommendations for material to be
stored at the stations in Izmir (ADB) and
Istanbul (SAW).
Lufthansa Technik Logistik’s services
also include a help desk available on a
24/7 basis, 365 days per year to source
and provide non-routine C&E material
that is not covered by the consignment.
SunExpress was founded in October
1989 as a subsidiary company of
Lufthansa and Turkish Airlines. Today the
joint venture airline is the market leader in
charter flights between Germany and
Turkey as well as one of the largest
scheduled carriers between Europe and
southern Turkey. SunExpress launched
regular daily connections between Frankfurt and Antalya in 2001, thus becoming
the first private Turkish airline to offer
international scheduled flights.
4 News & Contracts
Innovations 5
Radio Frequency
Identification (RFID)
Transport Services
Small device –
big potential
LOI with Thai Airways
Thai Airways has signed a Letter of Intent (LOI) with
Lufthansa Technik Logistik (LTL) covering the supply of
extensive transport services to the airline’s Technical
Department. Within the scope of the LOI, LTL will organize
the transportation of aircraft spares from European suppliers and repair locations to Thai Airways’ facility in
Under the agreed service package, LTL will be responsible for the transport, covering the entire import and export
handling, as well as the coordination and control of the
material flows of aircraft spares for Thai to and from
Europe. The LTL transport concept in Europe is dovetailed
to Thai Cargo’s “own services concept” under which the
airline itself ensures the transport of the parts. In this connection transport spans the entire process chain from
receipt of the parts at the relevant airport in Europe from
Thai Cargo to handover to the recipient at the appropriate
destination. In the other direction, LTL collects the shipment
from the forwarder and delivers it to Thai Cargo. .
LTL will oversee the flow management for Thai. This
includes the proactive control, monitoring and management of the shipment flows. Furthermore, LTL will deliver
daily status updates concerning the entire turnaround of
the parts from “ready for carriage” up to delivery. In addition, LTL provides material support for the carrier by defining, measuring and controlling lead times. To ensure a
perfect communication, a customer service desk at the airline’s location in Bangkok will be established.
With support by Lufthansa Technik Logistik, Thai Airways
expects firstly to reduce its turnaround times – amongst
other things, due to shorter transport times in Europe – and
secondly to achieve much better visibility of the shipment
flow and proactive transport management.
According to the LOI, the arrangements will initially be
evaluated in a three-month test phase covering material
flows from and to Germany. Subsequently, the service will
be extended to transportation throughout the entire Europe
Lufthansa Technik Logistik (LTL) has
developed a unique RFID tag which fulfills the
airworthiness requirements of the aviation
industry. The particularly small and light transponder makes it possible to permanently tag
components inside and outside the aircraft
cabin – a field of application that is increasingly in demand in this industry.
The use of RFID tags in logistics simplifies and
speeds up processes and improves data quality.
The RFID transponder is permanently attached to
components, which can then be recognized and
their details read by a reading device. LTL’s new
RFID transponder was specifically developed to
meet the needs of the aviation industry. The tag is
only 11 x 41 x 5 millimeters in size with a weight
of 3.2 grammes. It can store up to 512 bits of useful data and is compatible with the relevant RFID
standards EPCglobal UHF Class 1 Gen 2 and
ISO/IEC 18000-6C.
The tag is extremely rugged and thus well suited for use under the extreme mechanical, chemical and thermal conditions encountered during
flight and maintenance operations. It can withstand temperatures ranging from -65°C to +160°C
and altitudes of up to 15,200 meters (50,000 feet).
The newly developed RFID tag complies with regulations in being flame-resistant and insensitive
to humidity, water pressure, dust, X-ray radiation
and magnetic fields.
Another special feature of the RFID transponder
is the long range over which contactless remote
transmission is possible – more than a meter
(U.S.) and up to three meters (EU), depending on
the frequency used.
Components tagged in this way can be identified in logistics processes without direct contact,
avoiding the time-consuming opening and
unpacking of transport boxes. When a component
is fitted with the device, its data can be read,
amended and new data can even be written on
the tag. If RFID gates are used, it is possible to
read and gather data on over 100 transponders
simultaneously. This facilitates tracking & tracing
processes and improves data quality.
The use of RFID technology is becoming
steadily more important in the aircraft industry.
The RFID tag can be used throughout the service
life of an aircraft component, progressing from
production at the OEM‘s to the aircraft manufacturer’s production logistics, to maintenance
processes in MRO organizations. Airbus and
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Lufthansa Technik Logistik LOGbook 1. 2010
Lufthansa Technik Logistik LOGbook 1. 2010
6 Innovations
Boeing are planning to use RFID tags in
their future aircraft types which will be
delivered with components that are fitted
with RFID tags before leaving the factory.
Thus, for example, Airbus is planning to
fit several thousand A350 XWB components with passive RFID transponders:
seats, entertainment systems, screens, life
vests and oxygen bottles, also components in aircraft engines and wings. To
this end Airbus has published a design
specification for their manufacturers
(OEMs) which summarizes the requirements and recommendations regarding
the use of RFID tags on aircraft components. As the first manufacturer, Lufthansa
Technik AG will use the tag on devices of
its cabin management and in-flight entertainment system nice®.
As the growing need for airworthy tags
become apparent, Lufthansa Technik
became involved in the development of
these components early on, under the
leadership of LTL. Development work on
the tag began in September 2008 and it
Customers Relations 7
is currently in the qualification and certification phase. LTL was supported in the
development by project partners Lufthansa Systems, the Center of Intelligent
Objects (ZIO) at the Fraunhofer Institute
for Integrated Circuits (IIS) in Erlangen
and Harting Mitronics AG of Biel in
Switzerland. Tests conducted on the prototype in the laboratories of Lufthansa
Technik and in independent laboratories
have demonstrated its excellent qualities.
Lufthansa Technik chaired the Steering
Committee for the standardization of
RFID tags for aviation. In the qualification
process now under way Lufthansa
Technik Logistik’s RFID tag will be certified to SAE Aerospace Standard 5678,
RTCA Standard DO-160 and protection
class IP 69K. Series production is due to
commence at the end of July 2010. It will
then be possible to acquire the transponder with an Authorized Release Certificate issued by the European Aviation
Safety Agency (EASA Form 1).
Airfoil Services Malaysia
The tag underwent different tests to prove its
ability to withstand extreme external influences.
Quality on time
Jointly owned by Lufthansa Technik
and engine manufacturer MTU Aero
Engines (50/50), Airfoil Services Sdn.
Bhd. (ASSB) in Malaysia specializes in
the repair of engine blades and vanes.
Since 2006, Lufthansa Technik Logistik
is responsible for handling the transport
of these valuable parts from locations
all over the world to ASSB and back to
the customer.
Initially a subsidiary of MTU Aero
Engines, Airfoil Services Sdn.Bhd. (ASSB)
has been an equal-share joint venture of
Lufthansa Technik and MTU since 2003. At
the company’s new factory in Kota Damansara in Malaysia’s State of Selangor, engine airfoils from major aircraft engine
manufacturers are repaired in an innovative and efficient process.
ASSB is what happens when two worldclass engine MRO providers combine their
cutting-edge expertise: the company embodies the best of its “parents” with regard
to processes, technologies and tools,
including a strong focus on quality and
efficiency. In addition, the Airfoil Services
factory features the most modern equipment available, with several state-of-the-art
machines and processes in place.
The RFID tag can be used on various aircraft components.
Lufthansa Technik Logistik LOGbook 1. 2010
Logistics guaranteed
The goal of ASSB is clear: to redeliver
engine parts to the customer within short
turnaround times and with a technical
Lufthansa Technik Logistik LOGbook 1.2010
quality equal to or higher than the standard embodied by the two German joint
venture partners. A quality logistics system
that mirrors the innovative approach of
ASSB in every aspect was needed to
ensure that the blades reach their destination at the right time.
Here Lufthansa Technik Logistik came
into play: after all, “achieving quality on
time” is one of the company ’s goals. LTL
was contracted in 2006 to manage and
handle the transport of reparable and
repaired blades to and from ASSB, connecting Singapore, New York, Frankfurt
and, of course, Hamburg with the
Malaysian facility on both a routine and
ad-hoc basis. Performance parameters are
guaranteed for critical elements of the supply chain. Among other measures, an LTL
assigned implant at ASSB oversees the
entire logistics process, being also responsible for performance reporting.
A bright perspective
The highly skilled workforce, the state-ofthe-art repair methods and the innovative
flow line principle coupled with leading
logistics support make Airfoil Services one
of the world’s foremost centers of excellence in engine blade repair. At the same
time, a variety of measures has been
incorporated to make Airfoil Services a
cost-effective facility over the long term. As
part of MTU’s worldwide network of maintenance facilities and Lufthansa Technik’s
EPAR (Engine Parts & Accessories Repair)
product portfolio, this competence center
will provide excellent services to both joint
venture companies and other customers
worldwide. Airfoil Services will continue to
receive technical support from both MTU
and Lufthansa Technik to maintain these
and implement further high-technology
processes at the top level of quality and
ASSB certificates:
8 Services
Services 9
Lufthansa Technik Logistik America
Logistics made in America
Looking back at ten years of business, Lufthansa Technik Logistik
America (LTLA) confirms its position
as the specialist for aviation logistics
in the North American market. An
extensive range of services and the
continuous development of a network
of strategically located branch offices
at major U.S. airports are visible signs
of this success. Maintaining close ties
to its parent company, LTLA offers
customers in America the highest
quality standards and the support of a
highly qualified and dedicated staff.
When Lufthansa Technik Logistik America
(LTLA) began operating in January 2000,
the premise was more than just creating
a spin-off of LTL Germany. The US logistics arm of the Lufthansa Technik Group
was formed with the clear objective to
become a competitive Lead Logistics
Provider in the American Market while at
the same time keeping one foot firmly
planted in handling activities for Luft-
hansa Technik and the Lufthansa Technik
Logistik family.
After one decade of experience, LTLA
can affirm its success in achieving and
maintaining both goals. “LTLA continues
to serve as the lead logistics provider for
Lufthansa Technik and group companies
in North America,” emphasizes LTLA’s
Managing Director Stephen Fondell.
“At the same time, we are proud of our
strong third-party customer portfolio and
will continue to develop in both areas.”
Complete portfolio in the U.S.
Comparable to LTL as a whole, LTLA
provides more than standard physical
transport on a regional level. Its diverse
portfolio of services has been developed
to fulfill the specific requirements of its
customers and the demands of the
American market. It covers fast and reliable transport management, material
sourcing, customs brokerage, organization and optimization of repair cycles,
warehouse and distribution centers, and
worldwide 24-hour service. LTLA’ s
expertise in the MRO business enables
the company to manage the supply
chain of aircraft components through its
entire life cycle, from production to teardown and scrapping.
Today, the headquarter in East
Meadow, New York, houses several of
LTLA’s administrative functions including
accounting and IT. Also operating from
there is LTLA’s material sourcing department which serves as the purchasing
arm of LHT in North America & supports
the consumable/expendable product of
LTL by dealing with customers and suppliers in the North American Market.
The company’s range of services regarding transport management includes
both routine and specialized transports.
AOG consignments, cargo air charter
and worldwide transport of aircraft spares
– transports from a minute electrical
switch to the largest of engines are just
part of the day’s work. If necessary, a
member of LTLA’s staff will personally
accompany the necessary spare part to
wherever it’s needed by serving as an onboard-courier and carrying the item personally.
LTLA’s international network helps ensure
efficient, economical materials management
and spare parts provision that meets the
highest standards of quality. This saves customers time and money, enabling them to
concentrate entirely on their core competence, namely flight operations. Yet customer involvement in all the relevant
processes guarantees that optimal solutions
are developed from the outset through
New York – the gateway to the U.S.
LTLA has been extending its network of
branches in the USA continually in order to
maximize proximity and availability to its
customers and ensure that it can meet their
demands. The first of today’s five airport
branches was founded in 2000 at John F.
Kennedy Airport in New York (JFK).
All customs brokerage for the USA is
handled at the JFK office; LTLA’s brokers
specialize in aviation classifications. In addition, the JFK office is the major shipping
and receiving hub for Lufthansa Technik’s
customer material in and out of the USA. In
the last decade, most of the company’s
special transports have been handled from
JFK, including 187 engine transports in
2009 alone.
The warehouse at JFK, which was opened in 2005, is primarily used to hold parts
and handle materials management 24/7
for Lufthansa Technik’s nearby customers,
including Virgin America, Kalitta and Air
Dallas/Fort Worth and Seattle – where
the heartbeat is
The Dallas/Fort Worth (DFW) location
was jointly established in 2000 between
LTLA and Lufthansa Technik Component
Services (LTCS) as a storefront for LTCS’s
U.S.-based customers. These customers
send material for repair to DFW, where LTLA
manages the repair cycle by consolidating
shipments, sending them to Germany for
repair, clearing them through U.S. customs
once they re-enter the U.S., and returning
them to customers. LTCS remains the
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Lufthansa Technik Logistik LOGbook 1. 2010
Lufthansa Technik Logistik LOGbook 1. 2010
Services 11
10 Services
Florida to provide warehousing and distribution services and the supply of expendables to support Lufthansa Technik’s
customer Spirit Airlines. Lufthansa
Technik’s business in South Florida has
since expanded to include several customers for its integrated Total Component
Support (TCS®).
The establishment of the San
Francisco International Airport (SFO)
branch was driven by Lufthansa Technik
customer Virgin America, which relies to
an even greater degree on the fully integrated material services of Total Material
Operations (TMO®). LTLA began operations in SFO in July of 2007, providing
the full scope of logistics services to
Lufthansa Technik for its TMO® customers. In October 2009, LTLA expanded
its line station support at another West
Coast location, namely Los Angeles
largest customer of LTLA’s Dallas facility,
but warehousing and distribution services are also provided for other customers,
and in 2009, LTLA signed a transport
management contract with composite
repairs specialist Lufthansa Technik Tulsa
to manage the shipping and customs
brokerage of thrust reversers to and from
In 2002, LTLA established its first presence on the West Coast in close proximity to Seattle-Tacoma International Airport
(SEA). As a focal point for the aerospace
industry, the Seattle region is an ideal
location, offering LTLA the ability to improve service to its customers in Europe
and especially in Asia.
Fort Lauderdale and San Francisco –
close to the customer
LTLA’s two locations in Fort Lauderdale
and San Francisco are a good example
of its successful involvement in the product and customer structure – and therefore the regional development – of
the Lufthansa Technik Group in North
America. In the fall of 2004, LTLA opened
the Fort Lauderdale (FLL) branch office in
Tulsa – steering the future
Last but not least, the sales and
administrative office of LTLA is located in
the heart of the USA at Tulsa, Oklahoma.
This enables it to stand shoulder to
shoulder with Lufthansa Technik and
support its efforts in the North American
LTLA’s strategic branch distribution and
close connections to the Lufthansa
Technik Group help the company ensure
its competitiveness for both its American
and its European and Asian customers.
Its continually growing commitment is
evidenced by the number of employees,
which has steadily increased over recent
years to the present total of nearly 70
highly qualified people. Together with its
very high standards of quality and
service, this enables LTLA to hold its own
in the North American market.
The introduction of the Airbus A380
to the Lufthansa fleet represents a special challenge for Lufthansa Technik
Logistik: the exceptional size of the
A380 engines means that extensive
preparations are necessary to ensure
that the logistics function smoothly.
The Trent 900 engines used in the
Airbus A380 are remarkable not only for
their excellent in-flight performance, but
also for their literally up to now unknown
dimensions: when they are propped up
on the All Purpose Stand (APS), a special
stand for air transports, each one is 5.1
meters long, 3.43 meters wide and 3.11
meters high and weighs almost 12 tons
(26,200 lbs). Prior to the engines’ introduction, LTL developed appropriate Aircraft on
Ground (AOG) transport plans to ensure
that these giants can be moved as quickly
as possible to any of the A380’s flight destinations for the eventuality that an A380 is
grounded and a spare engine is needed.
Replacement engines from the manufacturer, Rolls-Royce, will be located at selected destinations in the Lufthansa route network around the world so that they can be
made available immediately in the event of
an AOG. To plan the air transport to
Lufthansa’s destinations, LTL first identified
the existing aircraft designs that are suitable for this load, and then contacted the
air freight carriers who operate these aircraft to ask about the possibility of transporting Trent 900 engines. To ensure maximum flexibility, LTL considered not only
Lufthansa flights but also those of other
providers in its global transport network,
since speed is the main priority for AOG
transports once safety is ensured. As only
two types of aircraft turned out to be suitable for the task, the flight schedules of airlines operating those types needed to be
analyzed to set up an air freight network for
the new engines.
A380 engine transport
Prepared to move
For maximum flexibility, LTL also investigated the possibility of AOG engine transport flights from locations other than
Lufthansa’s Frankfurt hub which involved
fulfilling the necessary conditions for road
transport. These transport set-ups are
required for the transport within Germany
to the overhaul workshop at Arnstadt in
Thuringia as well as for the option of a
multimodal transport via air and road. The
requirements are considerable: for example, loads wider than 3 meters need special permits for excess width, and only specialized transport service providers have
the necessary equipment. Even so, since
the end of 2009, after auditing an additional provider for road transport of the Trent
900, LTL has a list with a number of qualified partners.
Special processes for handling the giant
engines were developed and coordinated
with those responsible, and special equipment was acquired. A powerful crane is
needed for loading – an ordinary forklift
would not be able to handle the 12-ton
load. Other technology needed for this task
includes a heavy-duty dolly and extended
forks for the 16-ton forklift truck.
When a Trent 900 engine needs to be
transported to a Lufthansa destination, it is
also necessary to consider the handling
options available once it arrives. The destinations that are currently under consideration for AOG services for the A380 are
being investigated ahead of time to establish, for instance, whether mobile cranes
would be available on the apron. Lufthansa
Technik’s international maintenance teams
are assisting LTL with their knowledge of
the local infrastructure at relevant locations.
With these measures in place, Lufthansa
Technik Logistik is optimally prepared to
transport a Trent 900 engine as fast as
required to anywhere in the world at any
New York
San Francisco
Los Angeles
Fort Lauderdale
Whether overhaul shop or manufacturer – when it comes to transporting
engines, LTLA’s customers rely on its high quality standards. With its leadingedge equipment and processes the company is optimally prepared for the
diverse requirements of various engine types.
The exceptional size of the A380 engines represent a challenge for the
logistics processes.
Lufthansa Technik Logistik LOGbook 1. 2010
Lufthansa Technik Logistik LOGbook 1. 2010