Equipment and Furnishings - ATA 25 (Self Study) Year 2022 /2023 CONTENTS 1. Overview on equipment and furnishing items and arrangements. 1.1 Flight Compartment Door/bulkhead construction Seats Amenities 1.2 Passenger compartment Cabin items - Seats (First class, business class, premium, and economy) - Cabin Attendant seats. - Lining and Furnishings / Overhead stowage. - Passenger Service Chanel. - Curtains / partitions / Class dividers. - Ancillary equipment. - Floor Covering. - Buffet and Galleys - Galley equipment. - Lavatories. - Lavatory equipment. - Evolution in lavatories. CONTENTS Cabin arrangement Lay Out of Passenger Accommodation (LOPA) Parameters used for cabin definitions Regulations used for cabin definitions Arrangement of cabin items 1.3 Cargo compartment - Cargo Compartment Constructions and certification. - Cargo Loading Systems - Cargo Lining and furnishings - Cargo containers 2. Aircraft Cabin Definition based on Airline Business models. 2.1 Supplier Furnishing Equipment 2.2 Buyer Furnishing Equipment 2.3 Custom products CONTENTS 3. Aircraft Cabin modification and certification. 3.1 Cabin modification thru Aircraft manufacturer modification. 3.2 Minor Modification. 3.3 Major modification thru Supplement type certificate (STC). 3.4 Overview on certification rules. Certification principles Minor VS Major modification TSO certification and CS 25 rules related to cabin 9G and 16G Dynamic testing for seats Seat Modifications Fireworthiness criteria's Fireworthiness rules. Dilemma of toxicity rule. Dilemma of exemption. CONTENTS 4. Cabin interior lifecycle 4.1 Cabin refresher programs. 4.2 Cabin refurbishments. 4.3 Cabin reconfigurations. 4.4 Integration of In-flight entertainment / Live satellite TV. 4.5 Integration of mobile telephony and internet Connectivity. 4.6 Integration of other technologies related to maintenance. 5. Cabin maintenance definition and Cost reduction challenges: 5.1 Peculiarity of Equipment and furnishing Maintenance VS Aircraft maintenance (Systems, Avionics, Propulsion and Structure) concepts. 5.2 Cabin Appearance standards. 5.3 Aircraft Cabin Cleaning Challenges. 5.4 Cost reduction thru alternate products (ie; PMA parts, DOA-POA modification) 5.5 Part repair outside OEM tolerable limits. 5.6 Warranty negotiations. 5.7 Reliability investigations. CONTENTS 6. Emergency equipment: 6.1 Overview of variable emergency equipment used on aircraft 6.2 Evacuation systems (door cert, slide, slide raft, escape rope, ditching rope) 6.3 Dr. Helen Muir study case on cabin evacuation in Cranfield University. 6.4 Regulatory requirements for emergency equipment. Certification regulations (CS 25 rules) Operation regulations (EASA CAT OPS rules). 6.5 Emergency Equipment Operational rules comparison (JAA Ops 1 , EU Ops, EASA CAT OPS and FAA FAR 121 rules.) 7. Future of cabin interiors. 7.1 Overview of potential future product innovation 7.2 relationship between IMA/Communication and cabin 1. Overview Of Equipment and furnishing items and arrangement. ATA 25 - Equipment and furnishing are found in these three main compartments: - Flight Compartment (Cockpit) - Passenger compartments (Cabin) - Cargo compartments Based on aircraft design and features ATA 25 could cover more compartments that can be located in cargo or above the cabin. Here are some examples: - Boeing 777 and 787 and Airbus A350 have the options of overhead crew compartments - A330 and A340 have the option of lower deck mobile crew rest compartments - A340-600 have the option of lower deck compartment that can contain galleys and lavs 1. Overview Of Equipment and furnishing items and arrangement. Some aircraft like the Boeing 777 and 787 or Airbus A350 have the option of overhead compartments: Below image is for 787 shows location of - Overhead Flight Crew Rest (OFCR) located above the cabin in forward area and is used by pilots to rest during long flights. The compartment has a range of comfort equipment. - Overhead Flight Attendant Rest (OFAR) located above the cabin in aft area and is used by crew to sleep during long flights. The compartment has a limited range of comfort These compartments are supposed to be accessible to cabin crew only, and are generally referred as “Secret Chambers”. 1. Overview Of Equipment and furnishing items and arrangement. Airbus adopted on A330 /A340 a different design approach by using lower deck mobile crew rest (LDMCR) which serve as similar function to BOEING OFAR. Its advantage is being mobile. It is a big container in the cargo compartment which can be removed if not needed. Airbus A330 /340 LDMCR (Lower Deck mobile crew rest) 1. Overview Of Equipment and furnishing items and arrangement. Airbus A340-600 has different possibilities of compartment configurations in cargo location, this can vary from Galleys, Lavatories crew rests and stowage. Airbus A340-600 possible lower deck compartments configuration 1. Overview Of Equipment and furnishing items and arrangement. Almost all wide body aircraft have the options of crew rests in different configurations and features Airbus A380 Lower deck crew rest Can you think of an improper usage of crew rest compartment? “ Mile-High club” issue will be discussed in maintenance and design modification section as a case study. 1.1 Flight compartment A flight compartment is designed to support flight crew: - pilots seats. - Observer seats - Amenities for short- or long-range flights. on large transport commercial aircraft The flight compartment door and bulkhead are intrusion and ballistic characteristic compliant: After 9/11 Attack in New York, FAA mandated on all US operators and foreign operators to reinforce cockpit door and bulkhead to sustain fire arm or even a bomb to prevent terrorist from entering cockpit by force and take control of aircraft. Reference FAA regulations: FAR 25.795, FAR 121.313(j), and FAR 129.28 9/11 attacks has radically changed aviation transport security 1.1 Flight compartment Pilot seat: multiple features are made for comfort and safety that include: vertical travel: to adjust the seat upwards or downwards horizontal travel: to move the seat forwards or backwards adjustable backrest, inboard armrest, side stick armrest and safety harness Sogerma seats used on Airbus fleet. The seat is fully electrical, with manual override option (in case of failure) 1.1 Flight compartment Observer seats: Additional foldable seats are in cockpit with safety features only. These are commonly referred by crew as Jump seats or Dead head seats (dead head is a terminology used to refer for a pilot not on duty but flying on airplane) Observer Seats on A320 1.1 Flight compartment Amenities in Cockpit: Multiple amenities are provided to improve pilot comfort in cockpit, cosmetic appearance is also taken in consideration, usage of proper colors is selected in order not to disturb vision. This is a need to ensure max performance of pilots. Cockpit comfort has dramatically evolved since Douglas DC-3 to even reach luxury on Boeing 787. 1.1 Flight compartment Amenities in Cockpit: Below are some examples on cockpit items with their intent: - - - HEAT AND SOUND INSULATION PANELS: to reduce noise in cockpit and provide pleasant temperature control for a better cockpit environment. LINING AND FURNISHING PANELS: covers the heat and sound insulation blankets, Also these panels provide cockpit decoration. The shapes and colors of the linings are designed to provide a harmonious and sound-insulated cockpit. FLOOR COVERING: The cockpit floor is covered with easy-to-clean and sun-and moisture-resistant carpet. - SUNVISOR: to reduce intensity of sunlight and reduce glare. - BLIND ROLLER: to block sunlight coming thru windows - FOOT WARMER: To improve thermal comfort, a pair of electrically heated panels are installed on the cockpit floor at both the Captain's and the First Officer's stations. 1.1 Flight compartment Amenities in Cockpit: - COAT STOWAGE: For pilots to hang their jackets and coats. - PILOT BAG STOWAGE: to store pilot bag in a convenient accessible location - MISCELLANEOUS STOWAGES: stowage for variety of items that might include emergency equipment - BOTTLE HOLDER: easy access bottle holder near pilot seat - PAPER HOLDER: installed in variable locations for ease of pilot to affix any paper. - FOLDABLE TABLE: to use it as work table or as meal tray table. - WASTE BIN: for waste disposal - SAFE LOCKER: for storing and securing items of values 1.1 Flight compartment A380 Cockpit layout showing seats, Amenities and emergency equipment Rear Center View of A380 Cockpit 1.1 Flight compartment A380 Cockpit layout showing Avionics, Amenities and emergency equipment Forward View of A380 Cockpit 1.1 Flight compartment A380 Cockpit layout showing seats, Amenities and emergency equipment Rear right side View of A380 Cockpit 1.1 Flight compartment A380 Cockpit layout showing seats, Amenities and emergency equipment Rear left side View of A380 Cockpit 1.2 Passenger compartment In passenger compartment of a large transport aircraft, there are much more than just seats, you can basically find everything you expect to find in a luxury house and much more… moving to VVIP the choices are unlimited… you can even have a tennis court or even a swimming pool !!! In this part discussion will be on large transport commercial aircraft only: First an overview on items and product will be highlighted, Second an overview on how items arrangement is made. - 1.2 Passenger compartment Cabin items: The cabin of an aircraft features the following: - Seats (First class, business class, premium, and economy) - Cabin Attendant seats. - Lining and Furnishings. - Overhead stowage. - Passenger Service Chanel - Curtains / partitions / Class dividers - Ancillary equipment. - Floor Covering. - Buffet and Galleys - Galley equipment. - Lavatories. - Lavatory equipment. - Emergency Equipment (to be discussed in separate section) 1.2 Passenger compartment Cabin items: Seats / Economy class Economy (EY)Seats have multiple basic features along with additional selectable features: Basic Features: Armrest, meal tray table, seat pouch, adjustable headrest, recline function Extra Features: Entertainment system (IFE), Power outlet, USB connection, Coat Hook, Cup holder, foot rest, etc… Each feature is customizable based on airline wish, varying from colors to fabric type to monitor size etc… this is based on seat manufacturer catalogue options. Example of some marketed economy seats along with offerable features Manufacturer: Collins (previously know as B/E aerospace), Seat Model: Pinnacle Example of some marketed economy seats along with offerable features Manufacturer: Geven, Seat Model: Piuma Example of some marketed economy seats along with offerable features Manufacturer: Recaro, Seat Model: SL3510 1.2 Passenger compartment Cabin items: Seats / Business class Business Seats are of bigger size (in width and pitch) and have more features when compared to economy. These features could be: Multiple articulation with possibility of electric control, Lie flat or full flat bed, massage function, bigger IFE screens, control of dimmable window from seat, call button from seats. Full privacy area, front ottoman, bigger stowages, amenity stowage, center console, dedicated reading light etc… Example of some marketed Business seats along with offerable features Manufacturer: Collins (previously know as B/E aerospace), Seat Model: Mi Q Example of some marketed Business seats along with offerable features Manufacturer: Recaro, Seat Model: CL 5710 Example of some marketed Business seats along with offerable features Manufacturer: Collins (previously know as B/E aerospace), Seat Model: Diamond Click here for more details on this seat 1.2 Passenger compartment Cabin items: Seats Additionally, other class of seats exists: - Premium seats, which are a class between economy and business. Typically, those seats as similar to economy but have a higher width and bigger pitch and might have more features than economy. - First class seats, which have full privacy even some products come with door and can be transformed to full flat bed and have higher width and pitch and might comes with some exotic features like having a small beverage freezer or can rotate 180 degree to be transformed with side seat to a “restaurant like” dining. Note: these products are not standard like economy and business but rather custom designed based on airline requirement - Premium Business Seats has recently arisen in the market especially with airlines that do not offer first class seating, it is a high-class business that share some features of first-class seating. 1.2 Passenger compartment Cabin items: Seats Premium seats: - Refer to below link for comparison of Premium seats versus Economy / Business on Iberia A350: https://iberia.3dseatmapvr.com/examples/a350next.html - Refer to below link for comparison of Premium seats versus Economy / Business on Air France A350: https://my.matterport.com/show/?m=BGMm8DLQnKe&brand=0 Case study 1: Compare Airfrance / Iberia premium class products and features. Case study2: Compare Airfrance / Iberia Seating selections / Arrangements. In both cases discuss the similarities and differences between both airlines along with factors driving airlines for product selections. 1.2 Passenger compartment Cabin items: Emirates First Class seating (which is much more than a seat) 1.2 Passenger compartment Cabin items: Emirates First Class (which is much more than a seat) Latest first class product of emirates “Old“ first class product of emirates (Designer: Pierre Jean Design Studio - Paris - 2003) 1.2 Passenger compartment Cabin items: Etihad Old first class the seat can be rotated 180 degree and the 23-inch screen can be stowed to have a real dining experience. The seat has a mini fridge for beverage. 1.2 Passenger compartment Cabin items: Luxury Is not new… In early 70’s (prior to the world oil crisis ) airframe manufacturers and airlines were eager to provide extravagant high standard products. Below are some photos of Trans World Airlines (TWA) and Gulf Air on its Lockheed Martin L1011 Tri-Star). Similarly, other airframe manufacturers like Boeing and Douglas provided luxury options TWA first class cabin (Lockheed Martin L1011 tristar) Swivel seats / collapsible table design where passenger can transform their seating to a real dining experience (L1011) 1.2 Passenger compartment Cabin items: Luxury Is not new… 1970’s L1011 Tri-Star: Gulf Air was the national carrier of four wealthy oil countries (Bahrain, UAE, Oman and Qatar) - Luxury in its cabin is rare to find even on todays standards 1.2 Passenger compartment Cabin items: Luxury Is not new… and American Airlines first class cabin 1.2 Passenger compartment Cabin items: Cabin Attendant seats (CAS) Seats used by cabin crew (during take off and landing and for resting during flight are different from passenger seats. CAS are designed with some features to support crew duties these features include: - - - Seat belts with four attachment points to enable proper restraint during turbulence where cabin crew might need to perform duty. Built in communication handset to be able to communicate with other cabin crew or pilots. Built in accessible stowage for stowing emergency equipment that cabin crew might need to use. 1.2 Passenger compartment Cabin items: Cabin Attendant seats (CAS) Standard Cabin attendant seat: Featuring basic seat, with 4 points seat belt and a lower stowage compartment accessible while seated seat belt A380 offerable product (MFG: Goodrich) 1.2 Passenger compartment Cabin items: Cabin Attendant seats (CAS) A380 offerable product (MFG: Goodrich) 1.2 Passenger compartment Cabin items: Cabin Attendant seats (CAS) High comfort Cabin attendant seat: Featuring same options of a standard seat with the following additions: - Wider in dimension - Arm rests - Meal tray table - Foot rest This product is not popular, however airlines that fly long destinations and do not have onboard crew rest might select this option. 787 offerable product (MFG Ipeco) 1.2 Passenger compartment Cabin items: Cabin Attendant seats (CAS) High comfort Cabin attendant seat: A380 offerable product 1.2 Passenger compartment Cabin items: Cabin Attendant seats (CAS) Cabin attendant seats might feature communication / control tools Cabin attendant seats designated as “crew station” feature communication / control tools in order for cabin crew to perform their duties while seated. Note: Some cabin attendant seats might not feature any communication tool as not all cabin crew seats are designated as crew station. M as ter Standard 4-switch Standard 5-switch Dual lights only Light switch only Blank panel 1.2 Passenger compartment Cabin items: Cabin Attendant seats (CAS) Cabin attendant seats might be of different designs (floor mounted, wall mounted, double seats, high comfort or swivel type) based on aircraft design features and or regulatory Authority (EASA, FAA, CAA…) requirements. Airlines have the option of color customization only for plastic, fabric and seat belt color A320 offerable product (MFG: Goodrich or SICMA) 1.2 Passenger compartment Cabin items: Cabin attendant seats (Mini Case study, to be discussed during online course) If you have to define a configuration for a low-cost carrier (Vietjet Air), or legacy carrier (Viet Nam Airlines) for operation on short or medium range flight, what would you select? standard cabin attendant seat or high comfort? Justify? If you have to define a configuration for a low-cost carrier (Vietjet Air), or legacy carrier (Viet Nam Airlines) for operation of Long-haul flight, what would you select? standard cabin attendant seat or high comfort? Justify? How existence of cabin crew rest could impact your choice? Back to cabin crew rest, would you select to have crew rest option for vietjet (Low-cost carrier) on its long-haul flight? Why? Similarly, for Viet Nam Airlines would you select to have crew rest option on its longhaul flight? Why? 1.2 Passenger compartment Lining and Furnishings: are decorative items that cover the inside upper half fuselage of aircraft The aircraft fuselage is covered from inside with insulation blankets to improve sound insulation thermal insulation and prevent humidity accumulation. From cabin side to have an aesthetic appearance lining and furnishing items are installed. Those items are: dado panels sidewall panels cove light panels OHSC, including handrail ceiling panels exit ceiling panels door and door frame linings. Airlines can select and customize the colors as per their needs, additional customization (shape or material or trim is also possible but involve additional cost) 1.2 Passenger compartment Lining and Furnishings: Beside mentioned customization, these products comes in different standard sizes, the selection is more related to cabin arrangement A320 sizes of Ceiling, DADO and sidewall panels 1.2 Passenger compartment Lining and Furnishings: Cove lights comes in different standard shapes based on light type to be installed A320 variable cove light shapes 1.2 Passenger compartment Lining and Furnishings: Overhead Stowage compartment (OHSC) Those are the stowage bins above seats used by passengers to store their hand luggages. The most common type OHSC are of fixed type (you open the door to get access) Another type is movable ( the whole bin move downward for ease of access) Different configurations are possible (in length size and in location) Fixed OHSC on A380 1.2 Passenger compartment Lining and Furnishings: Overhead Stowage compartment (OHSC) Movable OHSC on A380 1.2 Passenger compartment Lining and Furnishings: Overhead Stowage compartment (OHSC) A380 with OHSC on sides only 1.2 Passenger compartment Lining and Furnishings: Overhead Stowage compartment (OHSC) Why different configurations are possible? And which one is better? It is a matter of choice and it is up to airline to determine their needs for example: - Fixed OHSC are simpler than movable, so maintenance cost less. However movable OHSC are handier to passengers. - Number of OHSC needed is based on number of seats, if an aircraft is with low density, airline might decide not to have center bins to give more space impression for passengers and also save weight. - Some airlines adopt movable OHSC in business class without center bin as number of passengers is low, while they adopt fixed bin in economy class. Those bin are installed in center and sides to have max storage. Other airlines might not choose this config as they prefer to have one OHSC product rather than 2 which means less spares and lower maintenance cost. If you have to define a configuration for a low-cost carrier (Vietjet Air), or legacy carrier (Viet Nam Airlines) what would you select for each? and how can you justify your choice? 1.2 Passenger compartment Lining and Furnishings: Overhead Stowage compartment (OHSC) (Mini case study) If you have to define a configuration for a low-cost carrier (Vietjet Air), or legacy carrier (Viet Nam Airlines) what would you select for each? and how can you justify your choice? 1.2 Passenger compartment Lining and Furnishings: Overhead Stowage compartment (OHSC) 787 Door 1 area: Different OHSC installation layout (Overhead Flight Crew Rest (OFCR) can be seen protruding from ceiling when selected) 1.2 Passenger compartment Passenger Service Chanel Passenger Service Chanel are sometimes referred as Passenger Service/Information Unit (PSIU), or Passenger Supply Channels (PSC) or Passenger Service Unit (PSU). The PSC arrangement is derived from the seating arrangement. The PSC is installed below the OHSC at every seat row and contain: - Attendant call switches individual reading lights individual reading light switches. individual air outlets emergency oxygen container Loudspeaker "No Smoking / Fasten Seat Belt" sign. Infill panels are used to cover the remaining space. 1.2 Passenger compartment Passenger Service Chanel A320 typical Passenger Service/Information Unit (PSIU) 1.2 Passenger compartment Passenger Service Chanel A350 typical Passenger Supply Channels (PSC) 1.2 Passenger compartment Passenger Service Chanel A380 typical Passenger Service Unit (PSU) 1.2 Passenger compartment: Passenger Service Chanel 787 typical Passenger Service Unit (PSU) 1.2 Passenger compartment: Evolution of cabin design on specific project: A320 Example 1.2 Passenger compartment: Evolution of cabin design on specific project: A320 Example 1.2 Passenger compartment: Evolution of cabin design on specific project: A320 Example Airspace design was developed by Airbus on A350, the same design concept is derived for A320/321 NEO and A330 NEO to have a better consistency in their fleets. Additionally, Airbus adopted this new improvement from the previous enhanced product to respond to Boeing Skyline interior of 787 where similar adaptation was taken on 737 sky interior for cabin Aesthetic improvement. Refer to Airbus Airspace folder for details of this project. Refer to below video for comparison between Airbus Airspace and Boeing Skyline on: Narrow Body: A320 VS 737 Wide Body: A330 Neo VS 787 Extra wide Body: A350 VS 777X 1.2 Passenger compartment: Curtains and partitions: Curtains and partitions with other furnishings, provide privacy to dedicated areas including galleys, passenger doors, cabin attendant areas and the cockpit aisle. A variety of colorful curtain textiles can be used to enhance the appearance of passenger compartments. The following details can be customized: color, material, pleating Example of an A330 Layout of curtains and partitions installation 1.2 Passenger compartment: Curtains and partitions: Curtains The curtain is folded into approximately 70 mm wide pleats however, Different dimensions are possible in agreement with the customer/vendor Two types of pleating are possible: sewn pleated : these pleats are machine sewn. The seams alternate from front to back. steam pleated : the material is folded, and steam pleated. If interested more refer to A330/A340 Curtain-brochure Sewn pleated VS steam pleated curtain 1.2 Passenger compartment: Curtains and partitions: Partitions Partitions can be combined with ancillary equipment e.g. literature pockets, magazine racks and baby bassinets, etc. and In-flight Entertainment (IFE) items such as LCD monitors. Partitions are made of a honeycomb sandwich panel covered with a decorative film. the most common types of partitions are: • full-height straight partitions • full-height cranked partitions • below OHSC straight partitions • below OHSC cranked partitions below OHSC cranked partitions (A320 program) Straight partitions (A350 program) 1.2 Passenger compartment: Ancillary equipment: Baby bassinet Doghouse Stowage 1.2 Passenger compartment: Ancillary equipment: A choice of ancillary equipment is installed throughout the cabin. These items are used for passenger and crew convenience and to maximize benefit of cabin space, the most common ancillary items are: - Stowage Doghouses Baby bassinets Child restraint system Folding tables Literature pockets Magazine racks Postcard racks Picture frames Floor Heating system 1.2 Passenger compartment: Ancillary equipment: Stowage. Stowage can be used for the storage of emergency and electronic equipment, passenger service items), trolleys, standard units and/or passenger and crew belongings. Different types of doors are available including roller-shutter, single door or sliding door. these equipment care selectable with different widths; door types latches etc... Colors, or covering tedlar film can be customized along with stowage accessories (shelves, drawer coat rods etc...) 1.2 Passenger compartment: Ancillary equipment: Stowage. Stowage are available in two main types: 'Full-height stowage' or 'Below OHSC height’ - Full-height stowage installation is limited to certain cabin locations. and requires removal of the OHSC at that particular section. - Height below OHSC can be installed throughout the cabin. Full-height stowage Height below OHSC 1.2 Passenger compartment: Ancillary equipment: Doghouses To optimize space behind the last row of the passenger seats, doghouses can be installed for the storage of emergency equipment and cabin service items. Doghouse are available with door or with sliding drawer to provide better access to contents. They are available in different widths and can be customized in color or locking provisions Doghouses available with doors or sliding drawers or panels 1.2 Passenger compartment: Ancillary equipment: Baby bassinets Baby bassinets combine comfort and safety for babies on longer flights. They are wall-mounted by means of pip-pins . When not in use the bassinet can be folded to a minimum size and stored. It consists of a foldable aluminum tube frame and fabric bassinet with foam mattress. Baby bassinet installed on partition can be stowed in OHS when not in use 1.2 Passenger compartment: Ancillary equipment: Child restraint system Child restraint system are mounted on passenger seats to provide proper restraint. In accordance with general transport regulations babies weighting up to 10 kg must be secured facing against the flight direction. Children up to 25 kg are secured facing the flight direction. Fastening is similar to that found in a car by means of a 5-point-harness. Child restraint system can be installed FWD or aft facing, when not in use it could be folded to be stored onboard 1.2 Passenger compartment: Ancillary equipment: Folding table Folding tables of different widths can be installed at certain cabin attendant stations. They can be used as working tables or worktops. They are secured in a folded stowage position. Folding table installation (A320 program) 1.2 Passenger compartment: Ancillary equipment: Literature Pockets Literature Pockets are generally installed in front of the first passenger rows or on door frame linings They are used for storage of safety cards and airline advertising material. Literature pockets 1.2 Passenger compartment: Ancillary equipment: Magazine racks, Postcard racks. Magazine racks are installed on upper side of wall for storing magazines and newspapers Single, double and triple slot magazine racks can be added to any suitable rigid wall such as a partition, stowage, galley or lavatory. Postcard racks are similar to magazine rack but of smaller size used to store postcards and sometimes used to store immigration cards Magazine racks and postcards racks offerable on Airbus A350 program 1.2 Passenger compartment: Ancillary equipment: Cranked partition featuring ancillary equipment: Magazine rack (top right) baby bassinet (center) and three literature pouches (bottom) 1.2 Passenger compartment: Ancillary equipment: Picture frame picture frame are installed on lateral cabin surface to feature artwork or advertisement. Variable sizes can be selected. Picture frame of variable sizes (A350 program) Picture frame installation (787 program) 1.2 Passenger compartment: Ancillary equipment: Floor Heating System (FHS) The FHS is used to provide thermal comfort to passengers / cabin crew in the cabin areas, that are likely to get very cold during long flight missions and on ground during cold weather operations. Therefore, electrically heated floor panels are used in the door zones. The heated floor panels are part of the automatically operating floor area heating system Heated floor panels are distributed per door zone in accordance with the cabin layout and are invisible to passengers. Heated floor panel construction (2nd Gen) on A330/A340 program FHS on A330 located near door and aft galley 1.2 Passenger compartment: Floor covering: Floor covering (Left: Textile carpet. Right: Mat carpet) 1.2 Passenger compartment: Floor covering: There are two types of floor coverings used on aircraft. 1- textile carpets: this is a fabric carpet similar to the "moquette“. 2- Non textile carpet known as NTF (Non Textile Flooring). it is a mat type. Airlines have the choice of selecting Non Textile Floor Covering: For installation in entrance / exit areas, galleys, and in lavatories. Textile floor Covering: For installation in cabin area. These products are offered thru airframe makers, or directly from the suppliers. Airlines might select to customize the products in terms of colors, patterns or texture. For NTF, behind the appearance aspects, there is a range of different selection related to the engineering of the product itself. 1.2 Passenger compartment: Floor covering: Based on airline business model, selection is made: A budgeted airline might select one NTF products for wet area (entrance / exit areas, galleys, and in lavatories) and one textile product for cabin. Preferred design of flooring will be without pattern or with a non directional random pattern as this would save material waste in cuts. Indigo (low cost carrier based in India): A320 Aircraft featuring one simple carpet in cabin and one simple NTF in wet areas and entrances. 1.2 Passenger compartment: Floor covering: Premium airlines might go in much more customization... Carpets in each zone (first, business and economy) might be of different design. even in one zone (ie first class) carpet in aisle area could differ from other areas. Etihad Airways (wealthy airline based in Arabian gulf, branding itself as seven star airline): A380 Aircraft featuring 6 different carpet design with orientation pattern 1.2 Passenger compartment: Floor covering: selection of lav NTF could differ between first business and economy lavs. Similarly, NTF in each galley area (first class, business class, economy class) could be selected differently. Etihad Airways A380 Aircraft featuring 5 different NTF design in cabin with orientation pattern. 1.2 Passenger compartment: Floor covering: Some wealthy airlines might decide to have textile carpet in entrance as this is a first impression of a passenger entering the aircraft. Textile carpet is subject to high wear if installed in entrance and would require more frequent replacement and thus a higher cost. In spite that luxury generally goes against cost savings, innovation and creativity could prove this wrong… beside is the photo of first class of emirates where NTF is installed in first class cabin… Pattern selected is wooden “parquet” style. Some other airlines use similar pattern for entrances or wet areas but this is never seen in cabin area… not even with low cost carrier… NTF used in first class in an innovative way 1.2 Passenger compartment: Floor covering: Additionally premium airlines would not only go thru customization in color, but might select a big patterns for high cosmetic appearance… (in such case a small damage would require a full flooring replacement as partial replacement is impossible in order to conserve the continuity and consistency in the pattern). Standard texture (round dots) versus custom texture to simulate a carpet pattern Also texture of NTF could be customized to an embossing pattern. Furthermore NTF could have a light sensitive pigmentation where based on lighting color or intensity a new pattern design or wording or logo could appear on the floor (such products are custom made). If interested more, refer to enclosed Airbus standard NTF selection Brochure. 1.2 Passenger compartment: Floor covering: From engineering perspectives NTF is made of variable layers whether fused in production or during installation, there are different product design concepts of NTF related to NTF construction and material. each concepts has its pro and cons in terms of: - Maintainability Weight saving Stability in terms of waving and bubbling Appearance in terms of telegraphing this will be discussed further in online course along with highlight why Airbus and Boeing has different requirements, and how this is related to the aircraft structural design concept!!! If interested on maintenance aspects of NTF refer to enclosed sample video for: - NTF installation on aircraft. - NTF large damage repair. - NTF medium damage repair. 1.2 Passenger compartment: Floor covering: Mini study case: If you have to select floor covering for Vietjet or for Viet Nam Airlines, or for presidential aircraft of Vietnam (VIP), what would be your choices of: 1. Carpet / NTF locations. 2. Carpet / NTF patterns and texture. 3. Would you select different designs for each zone (ie business/economy class, for VIP would you select same design for bedroom, or meeting room or staff work areas...) 4. Coming to maintenance, what type of repair carpet would you allow on NTF ? 5. What is your maintenance constraints for carpet replacement (routine replacement regardless of condition?, On condition replacement of worn out carpets, schedule replacement of aisle carpet only etc... ) Carpets and NTF can be offered with self adhesive pre installed or without self adhesive. Flooring coming with adhesive are easy to install and require less time, however they have a shelf life expiry date... flooring without adhesive require more time as adhesive has to be added prior installation but has no shelf life expiry... Based on your identified maintenance plan (item 5) would you select product with self adhesive or without self adhesive? could you consider using both products? and under which circumstances, could this depend on your fleet size? 1.2 Passenger compartment Galleys: Example of A330 NEO Rear Galley: Innovative Cabin Enabler (ICE) possible arrangement 1.2 Passenger compartment Galleys: Definition Galleys could be found in multiple location in a commercial aircraft. Galleys are the “kitchenettes” or “kitchens” where catering (food, beverages, kitchenware's, chinaware etc…) is stored and prepared. Galleys could be: - Dry Galleys (no water supply/drain available) - Wet Galleys (water supply/drain is available) - Powered / non powered galley (electric power is available or no) an airline can select wet-powered galley, dry-unpowered galley etc.... Customization is possible based on airline will ((ie: number of carts, or galley equipment to be installed, finish and trim, other selectable options etc...) 1.2 Passenger compartment Galley options and features : Galleys are offered in different sizes with possibility of installation in multiple areas in an aircraft based on structural, electrical and water/waste provisions in an aircraft. Possible galley installation locations on A350 1.2 Passenger compartment Galley options and features : Galleys have many features which fall under the following categories: - Regulatory and safety requirements like double latching of carts… Maintenance handiness, like access door and shutoff valves… Operational handiness like pull out table and grip handles… Convenience / optional items like mirror, paper clips ... If interested more refer to: Jamco galley options offered on Boeing 787 program (Photos). Jamco galley options offered on Boeing 787 program (Drawing). 1.2 Passenger compartment Galleys: Construction Galley construction is complex in terms of structure, electric, and plumbing. In details: Structures: Galley structures are of very light weight with extensive use of honeycomb and other composite materials. a small galley weighing 150 Kg would carry a load of 10 times its weight and expected to sustain heavy landings that could exceed repetitively 5G thus totaling an equivalent weight of above 50 times its weight. All this should be sustained repetitively throughout the aircraft life... Electric: the smallest powered galley on A320 has a 20KVA power... to have a flavor what does that means look at main galley feeder cable.. it is around 2 inches in diameter!!!! Water supply and drain: Along the tight space of galley pressurized water is supplied... 1.2 Passenger compartment Galleys: Certification in summary galleys are light weight structures carrying extensive loads with tremendous electric power with presence of pressurized water. All this is in a very tight place... how can this be designed in a safe way? As galleys are directly interfacing on aircraft (Structural attachments and loading, electrical interfacing, water waste interface) Aircraft manufacturer define the requirements, safety standard and provide guidelines for development, design and production of galleys. If interested more refer to enclosed sample document of: - Airbus A320 galley frame spec 2520 M1F00 02 00 Iss 13 1.2 Passenger compartment Galleys: History in early Commercial transport days, no galleys or galley equipment existed on aircraft. Later airlines used to manage catering and food serving in a primitive way using dedicated areas. It was till the 1960's at the time of wide body aircraft appearance and increased number of passenger, catering needed to be well organized and airlines wanted to have such facility, The main question that everyone was asking, what size these equipment should be? Photos on the right shows galleys on DC-3 in the 40’s which were nothing more than work bench and few storages Douglas DC-3 Galley 1.2 Passenger compartment Galleys: History (Evolution of Galley/Galley equipment standard) Some airlines defined their own equipment in term of sizing other airlines selected to work together: the most famous standard is the ATLAS standard defined by 5 airlines: Alitalia, TAP, Lufthansa, Air France, and Sabena. nowadays this is by far the most common standard. the second less famous standard is KSSU defined by KLM, Swissair, SAS Scandinavian Airlines, and UTA. the naming of ATLAS and KSSU refer to the first letters of airlines who defined this standard. this standard specify all galley equipment's sizes (carts, Oven, freezers, etc…) KSSU standard is narrower in size when compared to ATLAS standard. Other standards much less famous became obsolete over the years. 1.2 Passenger compartment Galleys: History (Evolution of Galley/Galley equipment standard) ATLAS sizing varies in different categories the most famous ones are Size 1, 2 , 3 and 4 below are some examples of equipment based on size: Size 1: Generally, coffee makers and espresso makers comes in this standard size Size 2: Generally, Ovens, wine chillers comes in this standard size Size 3: Carts, waste trolley, trash compactors comes in this standard size. Size 4: standard containers and Bun warmers comes in this standard size. Illustration of different Atlas Compartment sizes 1.2 Passenger compartment Galleys: History (Evolution of Galley/Galley equipment standard) As ATLAS standard becomes the norm nowadays, another issue arise along commonality of powered Galley inserts (GAIN) These equipment's have electric connection and in many cases water connections. As Atlas is about size of equipment only, the connections could be of different size, location and shapes... This means interchangeability is not possible in many cases… toward mid to end of 2000, ARINC 810 standard was developed, this standard adopt the ATLAS standards in term of size and standardize the electrical connections and power consumption along with potable water connection and water drain connection... virtually an ARINC 810 galley insert can be swapped with another ARINC 810 equipment of same size... Arinc 810 is the norm on new airplanes like 787 and A350 and optional on aircraft like A320 NEO. If interested more refer to enclosed ARINC 810 standard 1.2 Passenger compartment Galleys: History (Evolution of Galley/Galley equipment standard) ARINC 810 connector. Port B for power, Port A for data ( ARINC 812) Variable connectors of different standards used on non ARINC 810 equipment 1.2 Passenger compartment Galleys: History (Evolution of Galley/Galley equipment standard) Another interesting standard related to Galley equipment, Galley and aircraft is the ARINC 812... In case the galley equipment is qualified along with galley and aircraft to this standard, a mechanic can troubleshoot and monitor the equipment from aircraft side without the need to take off the equipment to shop for troubleshooting. Currently there is a range of products meeting this standard offered by Collins aerospace (Ex B/E aerospace) and Safran (Ex Zodiac), however the only aircraft meeting ARINC 812 as of today is the Airbus A350. 1.2 Passenger compartment Galley Inserts (GAIN): A range of offerable galley equipment can be offered to airlines these equipment can be powered or unpowered Non powered Galley insert (GAINs) - Full size trolley - Half size trolley - Full size waste cart - Half size waste cart - Foldable serving trolley - Duty free trolley. - Standard container - Standard ice container The airline have the option to customize each of these items. If interested more refer to: - Non powered GAIN selection offered on 787 by Diethelm Keller Aviation - Non powered GAIN selection offered on A350 program These equipment are generally certified and Qualified thru a Technical Standard Order (REF TSO 175) and meet SAE Standard no AS8056 If interested more refer to: - SAE AS8056 Minimum Design and Performance of Airplane Galley In-Flight Carts, Containers, and Associated Components 1.2 Passenger compartment Galley Inserts (GAIN): Non powered GAIN Half size trolley Full size waste cart Standard container Non powered galley equipped with carts and standard units 1.2 Passenger compartment Galley Inserts (GAIN): Powered Galley insert (GAINs) Electrical insert can vary from common type to luxury type to uncommon types Common types can be found on majority of airlines: - OVEN (induction, convection, steam type) - Beverage MAKER - Water boiler - HOT CUP these equipment are made for heating food stored by catering and to provide standard beverages (coffee and tea mainly). Beverage maker (B/E) Water Boiler (B/E) Oven (IPECO) 1.2 Passenger compartment Galley Inserts (GAIN): Powered Galley insert (GAINs) Luxury type of electrical insert are made to feature high end catering: - MACHINE-ESPRESSO - Nespresso maker - Bun Warmer - Freezer, fridge, wine chiller Airlines might select these types of GAIN for serving business and first class B/E Essence line of powered Galley Inserts Note: nowadays cosmetic appearance of inserts (which is rarely visible to passenger) is given increased attention 1.2 Passenger compartment Galley Inserts (GAIN): Powered Galley insert (GAINs) Uncommon type of electrical galley inserts: On some prestigious airlines we can find Additional type of equipment designed for cooking: - Microwave - Rice cooker - Toaster - Skillet Why do airlines need to cook onboard if food is already pre-prepared by catering??? Aerolux Custom made skillet Aerolux Custom made toaster Ipeco Microwave 1.2 Passenger compartment Galley Inserts (GAIN): Powered Galley insert (GAINs) Why do airlines need to cook onboard if food is already pre-prepared by catering??? For business and first class, some airline have Sky chef... a real chef to cook your food!!! These chefs are trained to work onboard as preparing aircraft food in the air differ from on ground.... why is it different to cook in air? - Humidity issue... - Space issue... - Taste in low pressure environment… 1.2 Passenger compartment Galley Inserts (GAIN): Powered Galley insert (GAINs) Other type of electrical galley inserts: can be found not for luxury or food serving but for efficiency in service: - Trash compactor: they are waste carts that compact the trash. As space is limited on aircraft some airlines use trash compactors to save space. One trash compactor save the space of three waste carts. - Air chiller: As cart contain food, these carts need to be cooled otherwise it will spoil and the worst airline nightmare is to have passenger food poisoned... Note: on some aircraft the air chiller is an insert on galley (ie: A320) while on others it is a remote chilling system that is part of the aircraft cooling system (ie: 787) (Think about it like a split Air condition (Air chiller) and a central Air condition (Remote chilling system)) Safran (Monogram) Trash Compactor 1.2 Passenger compartment Galley Inserts (GAIN): Powered Galley insert (GAINs) Each Galley insert type could be customizable in type, function or appearance: bbelow are some examples: Type: An oven for instance could be convection or induction or steam type Function: A beverage maker can be for brewing coffee only, or coffee and tea, or with additional spout for hot water. Appearance: Color, door opening direction, transparent door are some appearance options that can be selected on some equipment. These equipment are generally certified and Qualified thru a Technical Standard Order (REF TSO 184 and meet SAE Standard no AS8057 If interested more, Refer to: - Airbus A350 Offerable Electric Galley inserts - SAE AS 8057,Minimum Design and Performance of Airplane Galley Insert Equipment, Electrical Pressurized 1.2 Passenger compartment: Lavatories: Custom first class lavatory design for Gulf Air A330 in 2005 (Courtesy of Simon Lunn and Associate) 1.2 Passenger compartment: Lavatories: Lavatories could be found in multiple location in a commercial aircraft. An airline have the options of installing lavs in multiple location in the aircraft based on aircraft provision (for water, waste, electric and structure). A350 possible lav installation location 1.2 Passenger compartment: Lavatories: Lavatories installation depend on standard provisions available on aircraft. Below photo explains the water and waste lines versus an installed lav. It is very uncommon to have an airline asking for a lav to be in a place outside the standard provisions, however this could often happens. (ie: Etihad Airways has Lav 12 on its A340-600 in a custom location.) In such cases provisions has to be created in the non standard location Lavatory can be installed where water and waste lines provisions are available 1.2 Passenger compartment: Lavatories: An airline can select different Lav types and sizes to be installed in aircraft in multiple defined location provisions. A350 Offerable lavs (note: some lavs are peculiar to specific locations due to geometry limitation 1.2 Passenger compartment: Lavatory: The airline have the option of customizing the lav colors based on the company brand color to reflect their identity. Example of an airline color definition for an A330 Lav 1.2 Passenger compartment: Lavatory equipment: The lavatory comes with multiple standard equipment, additionally the airline can select alternate options or additional equipment. Example of standard lav equipment on Airbus A350 1.2 Passenger compartment: Lavatory equipment: automatic seat and lid close for the toilet unit multifunctional stowage variant soap bottle holder variant additional mirror variant amenities shelf variant foot pedal actuated waste flap water faucet with touchless activation liquid soap dispenser (manual) flower vase dispensers for toilet seat cover, tissues, wet wipe sanitizers and water cups syringe disposal box provisions water filter for Lavatory Water Supply Assembly (LWSA) trash compactor razor/power outlet and/or individual air outlet on/or close to the information strip hold down padded support nursing table and a padding feature toilet flush with a touchless / touch combo antimicrobial coated interior (toilet shroud, seat and lid) wash table and a ceiling light with RGBW lighting device different lighting options like a mirror light (white), RGB lighting devices for an Amenity shelf illumination Example of optional lav equipment on Airbus A350 1.2 Passenger compartment: Lavatory equipment: Automated Faucet Clothes Hook Composite Countertop / Sink Door Handle and Lock Emergency Equipment Stowage Facial Tissues Personal Air Outlet Interior Assist Handles LED Lighting Manual Toilet Seat Covers Non-glass Mirror Paper Towels Passenger Information Sign Shelf Above Sink (Separate Dry Shelf) Sink Drain Screen Soap Bottle Dispenser Holder Speaker Toilet Lid/Seat Handle Toilet Paper Holder Touchless/Touch Combo Toilet Flush Example of standard lav equipment on Boeing 787 1.2 Passenger compartment: Lavatory equipment: Example of optional lav equipment on Boeing 787 1.2 Passenger compartment: Evolution in Lavatories Post COVID19, touchless features seems to become more attractive for airlines in response to passenger preferences and demand. (Door opening, water faucet, waste chute, Lid cover, flush function) Luxury in lavs that used to be achieved by custom expensive design, and thus proving not common among airlines, seems to be substituted by light effects benefiting from the booming technology of LED. Innovation does not stay here, it goes also for gray water reuse for water saving / reduced weight (sink water is recirculated to be used for flushing the toilets) Refer to enclosed Diehl brochures for further details 1.2 Passenger compartment: Evolution in Lavatories: Touchless features Toilet lid, seat and flush touchless function 1.2 Passenger compartment: Evolution in Lavatories: Touchless features Touchless Soap dispenser Touchless Faucet Touchless Chute Soap dispenser, Water faucet, waste chute touchless function 1.2 Passenger compartment: Evolution in Lavatories: Touchless features Hands free door handle and other touchless functions 1.2 Passenger compartment: Evolution in Lavatories: Luxury Customization option Lav appearance enhancement thru lighting 1.2 Passenger compartment: Evolution in Lavatories: Gray water solution 1- Hand wash water will be used for toilet flush 2- Grey water will be stored in a small tank 3- and transferred via a pump 4- to the spray ring or nozzles. 5- An overflow protection is part of the tank. If the maximum level is reached and no toilet flush was activated, the water will be drained automatically into the waste system. 1.2 Passenger compartment Cabin Arrangement knowing what are all cabin items... the question is how to arrange them to define the Cabin Lay out known also as LOPA (Lay Out of Passenger Accommodation)... Simple LOPA of a narrow body aircraft (A321) in details: - How many class (Economy, premium economy, business, premium business, first class). - How many seats in each class? - How many cabin attendant seats? - How many toilets? - How many closets, stowage, overhead bin, partitions, class dividers… etc…? - How many galleys, and how many carts etc…? - Where to put each item (i.e. shall all economy lavs be at rear or evenly distributed in cabin? similarly where shall galleys be put? 1.2 Passenger compartment: Cabin Arrangement Complex LOPA of A380 1.2 Passenger compartment Cabin Arrangement In the online course we will explore in details how cabin definition is made and we will be tackling this on multiple requirement levels: - Regulatory requirements. Airlines / Industry standards. Airline business model. Engineering limitation If interested more on products offered by manufacturer and possible arrangements refer to: Boeing 787 configuration guide (chapter 25). Airbus A350 configuration guide (part 1) Airbus A350 configuration guide (part 2) 2. Aircraft Cabin Definition based on Airline Business models. Cabin products are not made by airframe manufacturers (ie: Boeing, Airbus, Embaraer etc...) but by a varietie of small manufacturers Specialized in specific products (aerolux, jamco, iaccobucci etc...) or agglomeration of manufacturers consisting of variable entities (Safran Group (Ex-Zodiac), Collins (Ex B/E aerospace)). These suppliers are known as OEM (Original Equipment Manufacturer) Airlines and Operators, differentiate themselves in brand and services thru different cabin items selections in the designs of furnishings. Those products are offered or accepted by the airframe manufacturer thru three different ways at time of aircraft definition / production: - SFE products. - BFE products. - Custom products. 2.1 SFE products. SFE products are Supplier Furnishing Equipment: - - - These equipment are manufactured by companies in accordance to exact specifications and requirements of the airframe maker (ie: Airbus, Boeing etc...) the selection of these equipment does not involve additional cost to the price of aircraft negotiated with airlines / owner. The manufacturer (Airbus or Boeing) hold responsibility on the performance and reliability of the equipment, and held responsibility on warranty. Note: Equipment and furnishings in Cockpit and Cargo are mainly SFE, with some selection choices. 2.2 BFE products. BFE products are Buyer Furnishing Equipment: - - - - - These equipment meets minimal requirements of airframe maker (ie: Airbus, Boeing etc...), and are accepted to be fitted in production. Purchase terms (cost, warranty, delivery time etc...) are solely between the airlines and the OEM. The airline or owner has to purchase the equipment and give it to airframe manufacturer (Airbus, Boeing…) to fit it during production. The manufacturer is only responsible on fitting these equipment if provided on a specific time during production. The manufacturer might get involved in reliability and performance of a BFE or even share warranty cost, when failure is due to an issue from aircraft side. However it is the airline who should challenge the airframe manufacturer… In case the airline/OEM fails to provide these equipment, the aircraft will be delivered without these equipment, it will be later the responsibility of the airline to sort out this issue thru different possible ways. 2.3 Custom products. Airlines tend to have custom products reflecting their identity unique for them. to Achieve this, airlines works with design houses (JPA, Saffron, Landor...) to come up with specific design concepts this could involve full cabin or specific products (ie: seat design, Lav design, Carpets, Layout arrangement, cabin color, Placard font , Full rebranding, livery change etc...) After a concept is made and agreed with the airline, tenders will be made to OEM to develop products based on their needs. For example: when a Seat design concept is made, tender listing the airline needs will be made and all seat manufacturers are invited to bid for developing the design. sometimes designs are too expensive that cost is higher than an airline capability or too complex that no manufacturer dare to take the project. Even when realized, the end product might not be as initially provisioned… Such projects involve tremendous costs (ie: Etihad Airways full Brand at launch of the airline cost over 1 billion USD). 2.3 Custom products. - - - - Airframe maker (ie: Airbus, Boeing etc...), accept such product provided that OEM is able to prove that these designed products meets all standards required. Airframe makers do not get involved in any certification of the product. Airframe maker (ie: Airbus, Boeing etc...) mandate to have all certification and production to be delivered to them on a specific time. In case of failure to do so, aircraft might be pulled out of production and put on hold till delivery of all needed certification and product or aircraft might be delivered “as is” without the custom products. Airframe maker (ie: Airbus, Boeing etc...) do not hold any responsibility of technical support or warranty for these products... it is up to airlines and OEM to agree on after sale terms. 2.3 Custom products. From design, to mockup (prototype) to final product the design will change and might not look as nice as initial concept… Design concepts Final product JPA concept design executed by Zodiac Aerospace (Cirrus seat) and installed on United airlines. (Cirrus is one of the most successful seats that became a BFE product, many airlines selected different variant of it including Viet Nam Airlines) Zodiac Aerospace (Cirrus seat) On Viet Nam Airlines. (Seat color customization is made to reflect Viet Nam Airline identity along with other customization options that include In flight Entertainment system) 2.3 Custom products. Additionally marketed images might differ from reality…. 1- Prototype 2- Marketed product (Qatar Airways) 3- Actual product B/E Super diamond seats. 1- Initial concept seems massive and luxury, 2- marketed images on Qatar Airways where seat is customized with the airline Burgundy identity color. 3- Actual seat seems to be a dwarf miniature of prototype. (Qatar Airways was unhappy with this seat, they decided later to change this product on future aircraft and retrofit the existing affected fleets) 2.3 Custom products. In spite that custom products are mostly First class seats, airlines sometimes tend to have business class seats custom too… To a lower extend some other products could be custom designed like lavatories... Some wealthy airlines might add new product lines as a brand signatures like Virgin Australia bar or Emirates A380 recreation area or old Etihad Entry lounge… however popularity of such product can vary from high success that drives airlines to further develop the product or to a failure that drives the airlines to eliminate it… Products not with direct passenger contacts or view are rarely made custom… however some wealthy airlines might go far away with some vanity customization like Etihad airways customization of galleys and ceiling… 2.3 Custom products. Simon Lunn and Associate: Custom first class lavatory design for Gulf Air in 2005 2.3 Custom products. Actual product on Gulf Air A330 fleet featuring extensive use of chrome and wood patterns with use of gold and off white color along with sky view window 2.3 Custom products. Virgin Australia bar 2.3 Custom products. The famous Emirates signature recreation area on A380 This product proved to be very popular among Business and first class passengers where emirates developed this product design… Photos shown are for the third generation of bar-recreation area 2.3 Custom products. Evolution of Emirates lounge (Gen 1 VS Gen 3) What really distinguish Emirates is its consistency in their images… while some airlines introduce new product they tend to change the whole design, which means they will run with two different standards over years. Emirates airlines re-create their products with same identity, this can be seen in lounge, First class seating and business class seating… this consistency gives the Emirates brand a market value. 2.3 Custom products. Actual product Marketed product Etihad unsuccessful first class lounge on A330-200 and A340-500. Lounge proved to be unsuccessful as it was hard to maintain with associated rocket price, very heavy construction and waste lot of aircraft space and rarely used by rarely existing first class passengers. Product introduced in 2008.. after few years starting from 2011, Etihad reconfigured its fleet to remove its failed product. 2.3 Custom products. - - - - Custom products are extremely expensive, and has high cost of after sale support (to maintain), with long lead time for spare. Custom products always underperform as they generally do not reach maturity in design. High cost custom developed products has zero or even negative value when airlines decide to sell the aircraft as no on want to have a product which is not reliable and costly to maintain. Furthermore, this product do not reflect the new owner identity. Airlines Worst nightmare… what happens if the OEM is bankrupted… In spite all this, it is very common within airlines to go on this path as brand identity seems to have a high revenue benefit on the aviation business models. 2.3 Custom products. From technical perspective it might be insane to select such complex product with insane development price and huge production cost with extreme high spare cost... HOW CAN AIRLINES MAKES PROFIT BY SELECTING SUCH EXPENSIVE PRODUCTS? IS IT REALLY PROFITABLE? AND HOW? WHY AIRLINES MAKING LOSSES STILL SELECT CUSTOM PRODUCTS? Many successful business models for airlines is not necessarily profitable from selling tickets or flying aircraft... Example Case study: - EMIRATES airlines Business model. Air Canada Business Model. Government subsidized airlines. 2.3 Custom products. Example Case study: Emirates airlines. The airline have a successful profitable business model however it is not profitable in terms of selling tickets (or at least, ticket sales do not explain the huge profits and quick growth of the airline), The airline sales thru their duty free, has exceeded a yearly profit of 1 billion USD in 2007. Additionally when emirates made a huge order of over 100 A380, and delivery was delayed, they got over 1.25 billion dollars cashback penalty from airbus. Airbus sold the huge A380 order at discounted price to emirates in order to finance the project, this gave emirates huge assets value that was translated in profits for upcoming years. Emirates thru its DNATA Group for hotels and tourism have a positive income sources. 2.3 Custom products. Example Case study: Air Canada Business Model: In early 2000 Air Canada was suffering major hits staring with 9-11 where their business was in bad shape, then hit by SARS where Canadian airports were literally empty of passengers for months, the airlines was privatized and stuck with lot of penalizing contracts while American rival airlines were supported by the US government. - The airline seems out of hope. However, a change in the business model focusing on Airlines reward miles was major savior as this entity within Air Canada valued more than 2 Billion of the airline itself. If interested more, refer to Study case of Yale University entitled "Air Canada Selling the Company by the Slice" Can you name a business model (other than airlines) where Branding is important and has high cost, and profit is not made from direct sales? If interested watch “ the founder” movie… 2.3 Custom products. Example Case study: Subsidized models: - - Some airlines around the world are government owned or obtain government support. Countries justify the benefit of this aid by boosting the economy of the country especially the tourism sector... The example of Dubai / Abu Dhabi with Emirates / Etihad is very illustrative. Some airlines in GCC (ie: Qatar, Etihad etc... ) obtain government support on what is accused by “Open Cheques" to grow fast... some of these airlines do not even pay for fuel, they even tanker their fuel... this has led to some court cases from airlines and governments due to this unfair trade principles: Lufthansa filed a case in the EU against Etihad for the unfair trade. Canada and UAE went into political tension due to this unfair trade where it reached withdrawal of ON arrival visas for Canadians... USA congress warned emirates, Etihad and Qatar on restricting their flight to USA if transparency is not shown in their business models. A common say in Aviation sector is "No one makes profit from flying aircraft" which is true to a certain extent. 2.3 Custom products. Many could think that the custom products and investment in branding is specific to premium airlines only, is that true? Can you think of casual (low cost) restaurant who have a strong branding when compared to a fine dining (expensive) restaurant? a typical example could be McDonalds... low cost carrier might invest in branding and products to distinguish themselves if this proved to be profitable, however the purpose tend to be more for money savings. Example Case study: - Lakers Airways (1966 intercontinental low cost carrier) - Ryan Air (custom product development) 2.3 Custom products. Example case study: Lakers Airways (1966 intercontinental low cost carrier) Laker Airways was the first low cost international carrier in the world, that threatened many legacy airlines with its strategy that went against the flow… While Airlines strive to provide the max comfort and luxury and use this in their advertisement, Sir Freddie Lakers shook the aviation world in the 60th by cheap flights with no luxury. Fuel and money savings was achieved by multiple means… one of them was to have basic cabin equipment with reduced seat pitching, minimal facilities from lavs to galleys along with minimal equipment… Lakers model is not limited to cabin, but extend to aircraft operation. In spite of its later failure, it became a standard even for legacy airlines… 2.3 Custom products. Example Case study: Ryan Air Ryanair is a profitable Irish Low-cost airline that operates more than 300 Boeing 737 aircraft. it is strong enough to threatens legacy airlines around Europe and has insanely squeezed cost savings to increase profits. Part of cost savings are many "Smart to Crazy" custom products, below are some of them: - - - Investing in custom seat design (focus is on light weight, no articulation mechanism) to reduce weight on the expenses of passenger comfort in order to meet their business model. Investing in customization of cabin to use all possible areas for advertisement: back seat as a billboard, OHSC doors, walls and partitions. Investing on custom “payable” lavatories where you need to put coins in order to use it... This is possible since there is no rule mandating to have lav on aircraft*… (fortunately they decided to cancel this project). * Existing CS 25 regulations mandate requirements of certifications in case there is a lav but does not mandate to have lavs. 2.3 Custom products. (Mini case study) For cabin products (Seats, Lavs, Galleys, Carpets etc…) What types of products (BFE, SFE, Custom) would you select for Viet Nam Airlines? and why? For cabin products (Seats, Lavs, Galleys, Carpets etc…) What types of products (BFE, SFE, Custom) would you select for VietJet Air? and why? Discuss the common choices selected for Viet Nam and Viet Jet. Discuss the difference in choices selected for Viet Nam and Viet Jet. 4. Cabin interior lifecycle The world fleet age of large commercial transport is estimated of around 12 years… The number of aircraft exceeding 20 years of age is increasing with time… An aircraft can remain in operation for a period that can exceed 30 years. Iran’s Mahan Air is still operating a 747-400 of over 31 years old on a routine flight schedule!!! 4. Cabin interior lifecycle During aircraft life, the cabin get renewed or totally changed multiple times especially when aircraft move from an operator to another. On average an aircraft cabin life cycle is 4 to 8 years. But could occur on even shorter intervals or the opposite could happens Wealthy airlines tend to change the cabin at short duration while airlines in financial trouble tries to stretch the period of change. In between a change some airlines elect to restore their cabin to initial mint conditions. Picture on the right shows an example of how frequent Gulf Air re-configured its fleet. Interval vary from yearly to 5 years 4. Cabin interior lifecycle Cabin renovation programs could be made in order to meet one of the following: - Integrate new products that follows the latest trends and technologies. - Change the layout to accommodate more or less seating to match the airline business model. - Put old fleet in line with current fleet (in term of color and soft furnishings). - Give the cabin its initial brand new look Such projects are: - Cabin refresher programs. Cabin refurbishments. Cabin reconfigurations. Integration of In flight entertainment / Live satellite TV. Integration of mobile telephony and internet Connectivity. Integration of other technologies related to maintenance. 4. Cabin interior lifecycle 4.1 Cabin refresher programs. After few years of operation, cabin would look dull due to environment effects (even if it is well maintained). colors will fade, fabric repetitively washed loose its original appearance etc... Some, airlines elect to refresh their cabin by replacing all upholstery (carpet, curtains, seat covers...) and repaint the cabin and replace tedlar films etc... to restore a fresh look. this is not only made for appearance but also for comfort. For example airlines could elect to change all seat cushions that became flattened and hard with years . Such programs do not involve any change of the original products. All work is in accordance with existing manuals and data. 4. Cabin interior lifecycle 4.2 Cabin refurbishments. A refurbishment is a change in appearance that involve soft furnishings material changes. This would involve a change in upholstery (carpet, curtains, seat covers...) and cabin colors thru painting, and tedlar films replacement. the main common reason of such project, is to put old fleet in line with new fleets. Such project involve changes of the original soft furnishing products. The aircraft layout (LOPA) remains unchanged. As material is changed, a modification and certification is needed. Generally these mods are classified as minor thru an EASA Part 21J modification. Etihad Cabin refurbishment (of initial owned aircraft by Singapore Airlines) to be in line with Etihad Cabin definition 4. Cabin interior lifecycle 4.3 Cabin reconfigurations. A reconfiguration could vary from a complete replacement of the aircraft cabin that include everything, or it can be limited to a specific zone (ie: business class seat replacement) or seat re-pitching... this can be also accompanied a refurbishment program or a refresher program. Airlines elect to have a reconfiguration program to integrate new products, and /or to readjust seat pitching to meet demands based on its business model. Such project involve removal and addition of new equipment along with a change in the LOPA . A modification and certification are needed. Generally these mods are classified as major and require an STC (Supplement type certificate) if done by companies other than airframe manufacturer (or major mod from airframe manufacturer). 4.3 Cabin reconfigurations: Example of reconfiguration project In 2005 Gulf air went thru a full rebranding thru consultants (Landor and Simon Lunn). Its whole fleet was reconfigured and refurbished to reflect the new brand… the next slides shows the work carried by its maintenance facility Work consisted of integration of new products and seating along with refurbishment. The aircraft pre and post modification looks totally different 4.3 Cabin reconfigurations: Example of reconfiguration project Pre modification LOPA and post modification LOPA showing new first class seating, and new business class with zone area increased over the economy seating 4. Cabin interior lifecycle 4.4 Integration of In flight entertainment / Live satellite TV*. In Flight Entertainment (IFE) systems are integrated on seats. Thus, a seat change during reconfiguration generally involve an IFE change too (unless removed seat and new seat have same IFE)... Generally airlines tend to change the IFE system to introduce new systems which might features bigger screens, higher resolution, better systems streaming, additional features like Duty free, gaming etc... Airlines might even introduce new technologies like live satellite TV where an antenna is installed on top of the aircraft.. this would drive to a big structural modification... Generally airframe manufacturer do not offer such modifications. These mods are generally major mods as they involve structural and systems changes and require an STC (Supplement type certificate). *IFE and connectivity are avionics trade and not cabin, however configuration projects are generally handled by cabin engineers. 4.5 Integration of mobile telephony and internet Connectivity*. Similarly airlines might select to introduce internet connectivity /(if not existing), or upgrade it is existing system for a faster internet connection (KU to improved KU band technologies, or to KA band) along introduction of mobile telephony that enables passengers to use their mobile phones during flight. This can be part of IFE system or a separate system. Similar to IFE, airframe manufacturer rarely offer such modifications as retrofit. These mods are generally major mods as they involve structural and systems changes and require an STC (Supplement type certificate). *IFE and connectivity are avionics trade and not cabin, however configuration projects are generally handled by cabin engineers Evolution of connectivity onboard aircraft 5. Cabin maintenance definition and cost reduction challenge: So far, we have explored how some airlines spend money generously on cabin. Unfortunately, when it comes to maintenance, cabin engineers, like any other trade (systems, structures, avionics or propulsion) operate under maintenance tight budget. At the same time cabin appearance is the image of the airline. This means that Interior engineers have to maintain cabin in the best possible way with the least possible spending. Cabin Definition budget Cabin Maintenance budget In the industry it is known that "Cabin engineers have to bake a cake from the shit" 5. Cabin maintenance definition and cost reduction challenge: 5.1 Peculiarity of Equipment and furnishing Maintenance VS Aircraft maintenance (Systems, Avionics, Propulsion and Structure) concepts. In order to understand how can this be realized, first we need to understand what is peculiar about cabin versus other trades (systems, structures, avionics or propulsion) in the following areas: - Maintenance program. - Standard to meet. - In service issues. - Manual quality. - Out of Manual support. - Logistics. - Reliability. - Performance. - Warranty. - OEM out of business. - Customer abuse. 5. Cabin maintenance definition and cost reduction challenge: Maintenance program: The maintenance program Document (MPD) provided by the airframe manufacturer covers all requirement to ensure efficient operation of aircraft in terms of safety and cost saving. For interior trade the maintenance program is not customized as each airline have different cabin and products. And its requirements is limited to emergency equipment expiry dates and very few other requirement. Unlike other trades (systems, structures, avionics or propulsion) Cabin interior engineers have to create and define their routine maintenance programs. Interior development engineer have to define and create the routine maintenance for cabin Other development engineers (Systems, avionics, structures…) have the maintenance program developed by airframe maker. 5. Cabin maintenance definition and cost reduction challenge: Standard to meet. In all trades, meeting airworthiness standard is satisfactory (carry mandatory mods mandated by AD's or AOT’s). Some airlines select to have a slightly higher standard to increase fleet readiness (ie: for summer operation system engineer might elect to replace cooling pack filter to ensure cooling is optimal) these customization are very limited and minimal. For Interiors, meeting the same standard is totally unsatisfactory... A higher standard is needed to ensure a nice cabin look. No airline Spend generous money on cabin to look out of shape during operation… 5. Cabin maintenance definition and cost reduction challenge: Standard to meet. to explain better, here are some cases that do not constitute an airworthiness issue or even a defect but are generally not acceptable for airlines: - Faded color on variable items. Delaminated mirror. Pen mark on wall. Scratched surface. Permanent coffee stain on meal tray Lightly worn out carpet etc... A standard far higher than airworthiness is needed for cabin interiors. Cabin standard Operational readiness Airworthiness Standard level requirements for Cabin interior 5. Cabin maintenance definition and cost reduction challenge: In service issues. During aircraft life, issues and damages are faced in all trades. In all trades other than interiors, the service engineer will refer to the aircraft manual or component manual to rectify the defect thru repair or replacement. In case repair is outside the limits, OEM is contacted to provide solution. In case OEM was unable to provide support, airframe maker has the responsibility to assist. For interior engineer, similar approach is used with the following differences especially for BFE products and custom products: - Manual quality - Out of Manual support - Logistics 5. Cabin maintenance definition and cost reduction challenge: In service issues. Manual quality especially for BFE products and custom products lack the following: - CMM's have very limited repair options as OEM's tend to sell you spares rather than repairing. - CMM's content is incomplete, with lot of missing data. - Manual quality and format standard could be far from any professional documentation with many OEM's Manuals for custom products are generally incomplete with missing data and with limited repair instructions 5. Cabin maintenance definition and cost reduction challenge: In service issues. Out of Manual support Some OEM's do not hold design approval, thus when they provide the airline with a repair (if they provide), it will be the airline responsibility to get approval from local authority or an EASA Part 21J design organization. Some OEM ask to pay an advance cost to look into the airline request.(the silly part is when you pay and OEM comes back to tell you it is unrepairable, replace the component) Similarly if the airframe manufacturer is approached on BFE or custom products, whether for repair or approval the answer is in general negative. However for SFE products things could be much easier 5. Cabin maintenance definition and cost reduction challenge: In service issues. Logistics - Lead time of spares is very high as these products are custom to the airline and manufacturer don't held spare but rather fabricate it on demand. - In case the airline approach the OEM’s for better support in spares they answer by providing a Recommended Spare part list (RSPL) with rocket price to purchase as backup plan... Such approach is neither economical nor feasible. 5. Cabin maintenance definition and cost reduction challenge: Reliability - Aircraft reliability is monitored by Airframe manufacturer and suppliers (ie; an engine issue is tracked by engine manufacturer and airframe maker, investigated, and solution is provided to all affected operator) - For interiors similar principles applies on SFE products but not for BFE and custom products. - For BFE and Custom products, Airframe maker is not concerned at all, OEM tries to “escape from his responsibilities”. At best the OEM wait the airline to justify for him that reliability of product is less than initially agreed. Thus, it is the interior engineer responsibility to monitor and deep investigate reliability to justify his claim to the OEM. 5. Cabin maintenance definition and cost reduction challenge: Performance. Performance of any component on aircraft (other than interior BFE and custom products) is known as hundreds of operators with thousands of aircraft use the same products during aircraft life that could reach decades... In interior, BFE and SFE are limited to specific operator with limited quantity and during cabin life cycle that might be limited to few years. Custom product virtually never reach maturity and their performance remain unspecified. The only sure fact is that they underperform. Custom products virtually never reach maturity since the life span of cabin product is less than maturity time. Additionally, the number of developed products is limited in quantity 5. Cabin maintenance definition and cost reduction challenge: Warranty. In all trades other than interiors, all parts have clear warranty conditions from airframe makers and OEM with general terms of agreements... To a high extent any warranty claim is paid… In interiors especially BFE and custom product warranty terms are more like a personal insurance, where there is always a clause which you are unaware of... Consequently, warranty claim is many times revoked… Even warranty on SFE products get rejected if related to abuse. Interior warranty claim versus other trades (Systems, avionics, structures and propulsions) warranty claims 5. Cabin maintenance definition and cost reduction challenge: OEM out of business: In case an OEM is out of business (ie: bankruptcy or approval suspended etc…) the airframe manufacturer has the obligation to support the product. Unfortunately, this does not always apply in interiors. Additionally, other companies generally fight to take over the out of market company, as after sale support for widely spread products has a value of multi million of USD… In Interiors, especially custom and BFE products Airframe maker has no obligation to support, and no other companies is interested to take over after sale support as it not economically viable. The airlines then has to find at their expenses a solution: Example to be discussed as study case: - Koito Seats (Japan), - Avio Interiors(Italy), - Aabe Fabrics (Netherlands) 5. Cabin maintenance definition and cost reduction challenge: OEM out of business: Unfaithful case of Koito Koito Seats - Japan is a well-established seat supplier in the market for decades... the company has gained over the years considerable market share of aviation seats. in 2010 the aviation industry was shocked when The Japan Civil Aviation Bureau (JCAB) announced that many of Koito seats are not airworthy. More than 150,000 seats used on over 1000 aircraft varying from Airbus A300, A310, A318, A319, A320, A321, A330 and A340 Boeing 717, 737, 747, 757, 767, 777 and McDonnell Douglas MD-11, DC-9, MD-88 and MD-90 are affected. 5. Cabin maintenance definition and cost reduction challenge: OEM out of business: : Unfaithful case of Koito The investigation with EASA revealed: - Falsification of static, dynamic and flammability testing. - Fictitious dynamic test. - Plots inserted into test reports following failure to meet required certification requirements. - Flammability test coupons not representative of production parts. - Fictitious deformation values entered in test reports when values exceeded the maximum allowed. - Length of time over which the falsification occurred extend for decades. - Lack of retained records within Koito increase the suspects. JCAB and EASA have concluded that all data (both design and manufacturing) generated by Koito must be treated as suspect. 5. Cabin maintenance definition and cost reduction challenge: OEM out of business: Unfaithful case of Koito EASA issued AD 2011-0098 requesting airlines to replace seats in 2 years or justify thru re-testing seat airworthiness. Airbus and Boeing unified their efforts to support airlines by validating the certification thru retesting. This was limited to specific models offered as SFE or BFE when applicable. All Airlines who selected those as Custom products and many others who selected seats as BFE, or retrofitted their cabin with those seats were stuck in a disastrous situation especially that procurement of any seat from market would take at least 2 years... Similarly, many airlines who selected koito seats for future aircraft were obliged to delay their deliveries. EASA AD 2011-0098 5. Cabin maintenance definition and cost reduction challenge: Customer abuse. In addition to all listed challenges, Customer abuse is very peculiar to cabin... A passenger onboard a flight with plenty of dead time will try to explore each and every part around him, some might even pick some stuff to take it home... This can vary from small common things like blanket or magazine or knife fork... To other items like life vests... Or even strange things like passengers detaching monitor from seats to take it!!! Needless to mention a bored kid with a permanent marker using his art skills on cabin items or even parents helping their kids to draw… https://viewfromthewing.com/shocking-video-showsparent-helping-child-draw-on-airline-seat-back-trays/ Customer abuse comes as the cherry on the top of the cake of interior issues… A mother helping her kid to draw on the seat back 5. Cabin maintenance definition and cost reduction challenge: With all the listed above, work of interior engineer is far harder than any other engineer whether on mechanic level, shop level, service engineer level, design engineer level etc... Is it possible to overcome all these issue? and ensure low maintenance cost? In the online course you will learn how interior engineers can successfully solve these challenges. BUT DOES IT REALLY WORTH TO WORK AS CABIN ENGINEER? In spite of the tough stressful work in cabin trade, Interior engineers are generally paid higher than other engineers, there are rare to find and there is a high demand on them... In case you become an interior engineer, you will not only have a well paid secure job, but you will also benefit from a wide industry exposure along with lot of duty travels... and benefits with endless invitations and presents from OEM’s... (be careful of bribes…) 7.Future of cabin interiors. 7.1 Overview of potential future product innovation What to expect in near future on new aircraft clean sheet design? Refer to below video explaining Airbus vision… 7.2 relationship between IMA/Communication and cabin Can you identify the solid future bond between Aircraft IMA/AFDX/Network and cabin? Would it make the Interior engineering Job easier or thougher?