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MTU Maintenance Berlin-Brandenburg GmbHDr.-Ernst-Zimmermann-Straße 214974 Ludwigsfelde • GermanyTel. +49 3378 824-00Fax +49 3378 824-300AOG +49 3378 824-888E-mail [email protected]
MTU Aero Engines GmbHDachauer Straße 66580995 Munich • GermanyTel. +49 89 1489-0Fax +49 89 1489-5500E-mail [email protected]
MTU Aero Engines Holding AGDachauer Straße 66580995 Munich • GermanyTel. +49 89 1489-0Fax +49 89 1489-5500www.mtu.de
MTU Maintenance Canada Ltd.6020 Russ Baker WayRichmond, BC V7B 1B4 • CanadaTel. +1 604 233-5700Fax +1 604 233-5701www.mtu-canada.com
MTU Maintenance Zhuhai Co. Ltd.1 Tianke RoadFree Trade ZoneZhuhai, 519030 • PR ChinaTel. +86 756 8687-806Fax +86 756 8687-901AOG +86 138 23039999E-mail [email protected]
Airfoil Services Sdn. Bhd.No 12 Jalan TeknologiTaman Sains Selangor 1Kota Damansara PJU547810 Petaling Jaya • MalaysiaTel. +60 3 6145-3600Fax +60 3 6141-6813
An MTU Aero Engines Company
MTU Maintenance Hannover GmbHMünchner Straße 3130855 Langenhagen • GermanyTel. +49 511 7806-0Fax +49 511 7806-111AOG +49 171 4314333E-mail [email protected]
The one-stop shop for engine services
An MTU Aero Engines Company
Quality, speed and efficiency are the hallmarksof MTU Maintenance. As a unit of MTU AeroEngines, Germany’s leading engine manufac-turer, MTU Maintenance operates globally andis the world’s largest independent provider ofengine maintenance services for commercialengines. Its capabilities run the gamut fromthe maintenance, repair and overhaul (MRO)of commercial aircraft engines and stationarygas turbines to the in-depth repair of pieceparts and engine accessories. Complementingcore business, MTU’s services ensure uninter-rupted revenue operations by providing spareengines on lease.
The maintenance branch of MTU Aero Enginesbenefits greatly from its parent company’svast expertise in the development and produc-tion of aircraft engines, which has been accu-mulated during its almost 100 years of opera-tion. The parent company’s headquarters inMunich, Germany, is also home to the Mainte-nance group’s main office. MTU Maintenancehas over 2,000 highly-qualified employees andprovides engine MRO services to customersaround the globe.
Global leader
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Repair beats replacementTrue to its motto “repair beats replacement”,MTU Maintenance provides its customers withindividually tailored service packages and re-pair solutions. MTU’s MRO specialists pursuethe same goal as their customers—minimizingmaintenance costs per flight hour. Outstandingresults are achieved in all of the group’s facil-ities through the uniformly high quality stan-dards and the continuous development of newtechnologies. The innovative high-tech repairtechniques that emerge set benchmarks in theindustry.
Think globally, act locallyTo be successful long-term, proximity to one’scustomers is vital. With this in mind, MTUMaintenance has built a global service networkunparalleled in the independent MRO commu-nity. Its locations in Germany, Canada, Chinaand Malaysia ensure a strong presence in themost significant aviation markets. Customersbenefit from a regionally based partner who isthoroughly familiar with local market needs.
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Experts for large commercialengines
In the course of its long partnership with theworld’s leading engine manufacturers, some25 years ago, MTU ventured into the businessof maintenance, repair and overhaul. This stephas proved to be highly successful, as todayMTU Maintenance has become the world’slargest independent MRO provider. Over theyears, it has acquired unique systems exper-tise, in particular in the high-thrust sector (en-gines with 20,000 lbf/100 kN and beyond).
Broad range of services and unique in-depth repairsThe MTU Maintenance group’s centerpiece isMTU Maintenance Hannover on the outskirtsof Hannover, Germany, which specializes in thesupport of high-thrust commercial engines. In the early years, it mostly repaired enginesco-developed by MTU. This enabled swift andsmooth transfer of knowledge from designengineering to repair, and vice versa. In the
meantime, the product portfolio has been ex-tended to include such engines as the CFM56.The shop is also responsible for the finalassembly and, on an exclusive basis, the initialrepair of the PW6000, which powers the A318.
MTU Maintenance excels through its long andextensive experience in engine overhaul and itsunique depth of repair. Employees are highlyqualified and take great pride in providing first-class customer service.
Long on-wing timesThe cost-effectiveness of an engine dependslargely on its time on wing, which in turn de-pends on how well the engine has been main-tained. Thanks to its many years of experienceand high standards, MTU has continued toextend engine on-wing times considerably pro-viding a competitive advantage for operators,as the longer an engine remains in service,the lower are its life cycle costs. In addition,many new services are on offer that improveefficiency. Engine Condition Monitoring (ECM),for instance, tracks relevant engine parametersduring engine operation and radios this databack to MTU. The incoming data is analyzedin real time and expose even the smallest ofdeviations, so that malfunctions can be identi-fied and rectified early.
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One-stop maintenance MTU Maintenance provides a comprehensiveline of services with a clear customer focusfor most high-thrust engines, these include a24-hour AOG service, component repairs,logistics and shipping. The maintenance, repairand overhaul (MRO) of the V2500 bears im-pressive witness to the high quality of MTU’sV2500 dedicated support, which dates backto 1989 when the engine first entered service.Today the group leads the market in V2500repairs. Be it high-pressure turbine blades orshrounds: almost 95 percent of componentrepairs are performed in-house as is the casefor repairs on the GE CF6 series engines.
A reliable partnerWhereas many service providers are exitingthe repair market for the CF6-50, MTU Mainte-nance remains a reliable partner. In the over-haul and repair of CFM56 engines, the grouphas also made a name for itself internationally.To meet an ever-increasing demand, MTU Main-tenance provides CFM56 repairs at severallocations worldwide. Moreover, it has carvedout a leading position in the maintenance ofother engine types, such as the PW2000, forwhich MTU Maintenance Hannover is the solefull-service provider outside the U.S.
CF6-80C2 fan stator assembly.
< The CFM56—an very popular engine type—is repairedat three different locations. Here, work is being per-formed on the fan.
Inspection of the V2500 fan during assembly at MTUMaintenance Hannover.
MRO portfolio
IAE:• V2500-A1• V2500-A5• V2500-D5CFMI:• CFM56-3• CFM56-5B• CFM56-7General Electric:• CF6-50• CF6-80C2• GP7000 (in planning)Pratt & Whitney:• PW2000• PW6000
MTU Maintenance’s strengths at a glance:— outstanding customer service— customized MRO solutions— fast turnaround times— long on-wing times— broad repair spectrum and unique in-depth
repairs— excellent quality standards— 24-hour on-call AOG services— 24-hour on-call spare engine services— optimized maintenance costs per flight hour
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MTU Maintenance Berlin-Brandenburg is MTU’scenter of excellence for the repair of low- tomedium-thrust commercial engines. Based inLudwigsfelde, Germany, it repairs and over-hauls all Pratt & Whitney Canada (P&WC) en-gines up to 20,000 lbf (approx. 100 kN) andthe General Electric CF34 series engines. Inthis segment, the company has built a leadingmarket position, which it is continuously ex-panding. Mobile repair teams traveling to thefar corners of the world ensure that the com-pany’s maintenance expertise is availableworldwide.
Authorized CF34™ Service ProviderA shining star in the Ludwigsfelde engineportfolio is the CF34. MTU Maintenance Berlin-Brandenburg holds an “Authorized CF34™Service Provider” license and boasts full en-gine competence for the CF34. The enginepowers 50-seat regional jets and is the solechoice for the new 70- to 100-passenger jetsfrom Bombardier and Embraer and for thenew Chinese regional jet. Rising demand inthis sector is met at MTU Maintenance Berlin-Brandenburg with its ever increasing serviceportfolio. In late 2005, the CF34-8 joined itssister engines, the CF34-1 and CF34-3, forfull service support. Preparations for the latestversion, the CF34-10, are currently in fullswing. Its market launch slated for 2008 willalso mark its inclusion in the MTU portfolio,thus completing the full range of CF34 MROat MTU.
Comprehensive after-sales servicesLudwigsfelde also provides MRO services forPratt & Whitney Canada engines in partner-ship with Pratt & Whitney Canada CustomerService Centre Europe (CSC). MTU experts
have repaired more than 2,000 P&WC enginessince 1992. CSC, also based in Ludwigsfelde,is a joint venture between MTU MaintenanceBerlin-Brandenburg and Pratt & WhitneyCanada. It caters to customers in Europe, theMiddle East and Africa.
Versatile low- to medium-thrust enginecapabilitiesMTU Maintenance Berlin-Brandenburg offersthe entire maintenance spectrum—engineretrofitting, modifications, repairs and over-hauls. It provides innovative technologies andoperates high-tech test beds.
Large focus on small engines
MTU’s strengths at a glance:— short turnaround times and reliable
delivery performance — state-of-the-art repair techniques— globally available mobile repair teams— outstanding quality— high engine performance— strong customer orientation through
committed customer support
The Embraer 190 is powered by two General ElectricCF34s. The CF34 family of engines is the most popularin its class.
MRO portfolio
General Electric:• CF34-1• CF34-3• CF34-8• CF34-10 (in planning)Pratt & Whitney Canada:• PT6A• PW200• PW300• PW500
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For many years now, MTU Maintenance hasapplied its engine expertise to the mainte-nance of industrial gas turbines (IGTs) derivedfrom aircraft engines. Irrespective of whetherthe turbines are operated for power genera-tion, marine propulsion or compression pur-poses in land-based or offshore applications,MTU Maintenance ensures they are maintainedto the entire satisfaction of their operators.
Berlin-Brandenburg center of excellenceMTU Maintenance Berlin-Brandenburg hasbeen providing outstanding maintenance ser-vices as a center of excellence for industrialgas turbines ever since these activities havebeen pooled there in1995. The center pro-vides support services for General ElectricLM2500™, LM5000™ and LM6000™ turbinesand is an authorized service provider for thesemodels.
A step ahead through innovative technologies MTU Maintenance Berlin-Brandenburg pridesitself on having one of the world’s two testcenters that permit testing of industrial gasturbines with an output of up to 55 mega-wattsin true service environments—ideal conditionsfor thoroughly testing the often highly stressedturbine components. Moreover, the facilityperforms some 80 percent of all repairs in-house. Key to sustaining this competitive edgeis the use of advanced repair techniques whichundergo continuous improvement.
Services: on-call worldwide and individually tailoredApart from its technological lead, MTU Main-tenance has service capabilities that areunparalleled in the gas turbine market. Thespecialists in Ludwigsfelde are available totheir customers around the clock 365 days a
year. Bottlenecks are unthinkable, the shopsbeing able to handle as many as 20 turbinesat a time. At the behest of its customers, MTUMaintenance will perform full maintenancemanagement with services ranging from re-moval and reinstallation, on-site repairs, sched-uled inspections, remote monitoring and vi-bration analyses to engineering consultancyand customer training. A separate field serviceteam ensures customers receive the best MTUservices including the provision of spare partsand gas turbines on lease. Their local presencein the Americas, Asia and Australia enablesthe MTU field service to reach any point on themap within 24 hours.
Industrial gas turbine specialists
MTU’s strengths at a glance:— customized contracts including perform-
ance and availability warranties — advanced test cell permitting testing in true
service environments— innovative repair techniques and in-house
repair development— quality at aviation industry level— on-site inspections and repairs by a
globally available mobile team of service technicians
The Ludwigsfelde center of excellence provides fullservice support for industrial gas turbines, such as theLM2500™ shown here.
> MTU Maintenance Berlin-Brandenburg techniciansprovide on-site support—for instance for the repair ofindustrial gas turbines on offshore oil rigs.
MRO portfolio
General Electric:• LM2500™• LM2500+™• LM2500DLE™• LM5000™• LM6000™
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MTU Maintenance’s services set benchmarksworldwide and excel by providing maximumoperational reliability and flexibility. Servicesrange from one-time assistance to tailor-madefull 360-degree support for entire engine fleets.Customers can focus on their core businessand let the maintenance specialists take careof their engine support requirements. EfficientMRO pays off in the long run.
The right partner—anywhere and at any time In the selection of a suitable service partner,availability and flexibility are prime criteria.MTU Maintenance’s specialists are globallyavailable 24/7 throughout the year. Excellentlytrained repair teams at all locations provideround-the-clock AOG services. Within hours,dedicated repair teams–such as the CF34team–reach locations anywhere in the world.
Identifying service needs earlyThe company’s innovative, high-performanceEngine Condition Monitoring (ECM) systemfacilitates customers’ accurate planning ofmaintenance by keeping a continuous checkon engine performance. Important parameters,such as pressure, temperature and vibration,are continuously tracked, even the smallest ofdeviations are recorded and evaluated by MTUspecialists. Engine operators then receive thedata and recommendations on what actionsto take online. What makes this approach sospecial is that MTU has developed its ownECM program, which is suitable for all enginetypes and display systems used by airlines.Customers save time and money.
Customized services
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Total Engine Care (TEC™)MTU’s comprehensive service package has aname, for aircraft engines and industrial gasturbines alike: Total Engine Care (TEC™). MTUMaintenance has developed a totally carefreepackage comprising four different modules:• maintenance, repair and overhaul (MRO)• fleet management and technical consul-
tancy • guaranteed availability of spare engines • logistic services including LRU support at
any location worldwide
The bottom line—TEC™ is a full service pack-age that leaves nothing to be desired.
TEC™—advantages at a glance: — one-stop partner for all services— safer planning through optimized cost and
cash flow management— minimized downtimes through guaranteed
availability of spare engines and industrial gas turbines
— extended on-wing times— all-inclusive full maintenance service
On request, MTU Maintenance will also makeavailable engine types other than those listedabove.
Further services include:• dedicated operating lease• standby agreements• sales and leaseback• pooling agreements
ECM is a sophisticated early detection system thatundergoes continuous optimization at MTU.
The PW2000 powers Boeing’s 757 and other aircraft. MTU is the world’s leading provider of maintenanceservices for the V2500—seen here is work on the fanblades.
< The CF34 from General Electric is one of the key programs at MTU Maintenance Berlin-Brandenburg.
Aircraft engines
General Electric:• CF34• CF6-50• CF6-80C2CFMI:• CFM56-3• CFM56-5B• CFM56-7IAE:• V2500-A1• V2500-A5• V2500-D5Pratt & Whitney:• PW2000
Industrial gas turbines• General Electric LM™ series
Engines on-call To keep aircraft flying, MTU Maintenance pro-vides its customers with spare engines asneeded. The company maintains a pool of themost popular engine types as well as industrialgas turbines.
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Other services include comprehensive engi-neering consultancy, training, individually tailored financing concepts and full logisticsolutions.
Comprehensive componentrepair
“Repair beats replacement” is MTU’s motto.In the repair field, MTU specialists have builtup unique expertise that benefits not onlywhole engine overhaul but also componentrepair. On offer is a unique level of in-depthrepair and individual solutions that producesignificant savings—a competitive advantagemuch appreciated by airlines, industrial gasturbine operators, maintenance bases andparts vendors. With its full range of customer-tailored services, MTU Maintenance covers theentire parts spectrum for all the most popularengine types.
More than 25 years of experienceMTU Maintenance has been engaged in com-ponent repairs for over two decades, usingtop-notch techniques, which have been partlydeveloped in-house and are continuously opti-mized. MTUPlus is the trade name for theseinnovative high-tech repairs. MTU-repairedcomponents stand out by their excellent per-formance and extended on-wing times. Thiscontributes substantially to conserving re-sources which benefits both the environmentand customers’ wallets.
From individual repair to full packageMTU’s line of component repairs ranges fromremedial maintenance on individual compo-nents to an innovative overall service package:TPC™ (Total Part Care) is a totally carefreesolution that leaves nothing to be desired. Itincludes MTU’s high-tech repairs, engineeringsupport, spare parts services, logistic servicesand timely delivery to any location worldwide.
Leading through high-tech processesBe it rotors, stators, airfoils, shafts, combus-tors, casings or gearboxes, the repair methodsused on all components are invariably state-of-the-art. Some of these repairs are:• fluoride cleaning• ultrasonic inspection• removal and application of coatings• high-speed grinding and balancing• laser welding• linear friction welding• high-temperature brazing• atmospheric plasma spraying• flame spraying and high-velocity oxy-fuel
flame spraying • vacuum plasma spraying• laser drilling• surface sealing
Aircraft engines• CF34• CF6-50• CF6-80C2• CFM56-3• CFM56-5B• CFM56-7• PW200• PW300• PW500• PW2000• PW4000 Growth• PT6A• V2500
Industrial gas turbines• LM2500™• LM5000™• LM6000™
Here an employee is masking turbine vanes to preparethem for plasma spraying.
Laser powder cladding of blade tips is one of MTU’sstandard repair processes.
Drilling of cooling air holes following the repair of a high-pressure turbine vane using the laser EDMprocess.
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Maintenance of engineaccessories
Accessories are components which are at-tached externally to the engine and are essen-tial for its operation. These include harnesses,valves, pumps and actuators. MTU Mainte-nance offers not only complete engine over-haul and indepth piece part repair but alsothe maintenance of engine accessories. Previ-ously, most of this work had been contractedout to third parties, now MTU Maintenancehas developed its own one-stop maintenanceservice for accessories.
One-stop systems expertise Customers benefit multiply from MTU’s ex-panded capabilities—MTU Maintenance as-sumes overall system responsibility at theusual high level of quality. A world-class ser-vice that substantially reduces maintenanceturnaround times.
New challenges call for expertise and experi-ence, and MTU Maintenance has both. Acces-sory testing, overhauling and repair benefitgreatly from in-house development know-howand many new repair techniques for acces-sories have been introduced with substantialcost-savings for the operator. MTU’s one-stopmaintenance for all line replaceable units(LRUs) is also of particular interest to a grow-ing number of customers. With these devel-opments, MTU Maintenance now offers a
complete maintenance package (engine plusaccessories) at MTU quality standards. Cus-tomers can rely on a single contact to dealwith all their technical needs, thus reducingtheir administrative load.
Globally present, regionally specialized MTU Maintenance Canada in Vancouver is thespecialist in the field of accessory and LRUservices augmenting general accessory main-tenance which is provided at all locations.Customers can choose from the entire spec-trum of services—maintenance and repair, aswell as LRU solutions.
Besides complete engines, MTU Maintenance alsorepairs engine accessories.
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Global presence
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Expanding maintenance activitiesMTU has established itself as a repair andmaintenance specialist operating five mainte-nance shops worldwide—two in Germany andone each in Canada, Malaysia and China withfurther expansion in the pipeline. Currentorder volumes and a growing air traffic marketwill maintain a healthy workload for all itslocations. In the world’s fastest growing mar-ket, Asia, MTU is excellently positioned withits affiliate, MTU Maintenance Zhuhai.
One of the major drives at all locations is theon-going development of overhaul and repairtechnologies. Unique depths of repair havebeen achieved across the board. All of theseinnovations aim to cut costs and turnaroundtimes while enhancing quality.
In the domain of commercial aviation, MTUMaintenance is the world’s largest independ-ent provider of engine maintenance services.It is engaged predominantly in the high-growthmarkets of the V2500, CF6, CFM56, CF34and PW2000 aero engines, and industrial gasturbines (IGTs).
The Maintenance group provides its customerswith top-class service support 24/7 all yearround. It is driven by service-focused thinkingthat is at home equally at all shops. Each MTUshop is a center of excellence with its ownparticular focus, strengths and service port-folios. All share the same high quality standardsand commitment to customers.
MTU Aero Engines Munich, GermanyMTU Aero Engines’ headquarters is also hometo MTU Maintenance’s main office. A tradition-al aviation site, Munich is inextricably linked tothe history of powered flight, its roots reachingback to the beginning of the last century. It isfrom here that the affiliates and most of MTU’sresearch and development activities are con-trolled.
In Munich, engines are assembled and compo-nents manufactured for shipment to the majorengine manufacturers. Spare parts manu-facturing is also a key activity and innovativerepairs and maintenance techniques are de-veloped for use at the company’s affiliates.Furthermore, the German Air Force entruststhe maintenance of all its engines exclusivelyto MTU, with most activities focused in Munich.
MTU Maintenance HannoverLangenhagen, GermanyThe Langenhagen facility is the centerpiece ofthe MTU Maintenance group. It is responsiblefor the maintenance of medium high-thrustcommercial engines. These include the GeneralElectric CF6-50 and CF6-80C2, Pratt & WhitneyPW2000, International Aero Engines V2500and CFMI CFM56-7. Comprehensive servicescomplement the company’s core business,such as engine leasing, 24-hour AOG service,training and Total Engine Care. The shop isMTU’s center of excellence for high-tech re-pairs and the development of innovative repairtechniques.
MTU Maintenance Hannover is also responsibleon an exclusive basis for the final assembly ofthe PW6000 engine which powers the A318.For this purpose, the company obtained pro-duction organization approval from the LBA,the German Federal Office of Civil Aviation in2006. In the future, all maintenance activitieson this engine will be carried out at this loca-tion.
MTU Aero Engines’ headquarters in Munich is also home to MTU Maintenance’s head office.
The Hannover location was the first repair shop set upby MTU.
MTU Maintenance Berlin-Brandenburg is headquarteredin Ludwigsfelde to the south-west of Berlin.
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MTU Maintenance Berlin-BrandenburgLudwigsfelde, GermanyLudwigsfelde-based MTU Maintenance Berlin-Brandenburg specializes in the maintenanceof engines in the small- to medium-thrust cat-egories, as well as industrial gas turbines. Itprovides service support for Pratt & WhitneyCanada PT6A, PW200, PW300 and PW500and General Electric CF34 series engines. It is MTU’s center of excellence for the mainte-nance of industrial gas turbines, with a specialfocus on the General Electric LM™ series. Thelocation boasts one of the world’s largest andmost advanced IGT test cells and also has teststands for turboshaft and turbojet engines.
Ludwigsfelde is the location selected to per-form the final assembly of the TP400-D6 en-gine to power the emerging A400M militarytransport. Final assembly of all EuropeanTP400-D6 engines as well as their productionacceptance testing will be carried out here.The new test cell at Ludwigsfelde is the onlyEuropean production test facility for theTP400-D6 and is considered one of the mostadvanced in the western hemisphere.
MTU Maintenance Canada Richmond, CanadaMTU Maintenance Canada, a wholly-ownedMTU Aero Engines affiliate, is based nearVancouver. The company provides overhaulservices for CF6-50 and CFM56-3 engines.The Canadian site has a special focus on en-gine accessories. Its customers, mainly V2500,CFM56 and CF6 operators, come from all cor-ners of the globe.
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MTU Maintenance’s marketing and salespartners:
Pratt & Whitney Canada Customer ServiceCentre Europe Ludwigsfelde, GermanyPratt & Whitney Canada Customer ServiceCentre Europe (CSC) is an equal-share jointventure between MTU Maintenance Berlin-Brandenburg and Pratt & Whitney Canada(P&WC). It engages in marketing and salesactivities for P&WC engines providing servicesupport for customers in Europe, Africa andthe Middle East. Incoming repair jobs are per-formed by MTU Maintenance Berlin-Branden-burg or a P&WC shop in Southampton in theUK. CSC also offers lease engine support andhas a number of different contract models tosuit varying customer requirements.
MTU Maintenance Zhuhai Zhuhai, PR ChinaLocated in the Zhuhai Special Economic Zone,this shop is an equal-share joint venture be-tween MTU Aero Engines and China SouthernAirlines, China’s largest carrier. It is equippedwith a high-tech machine shop and a highlymodern test cell accommodating engines upto 150,000 lbf. Zhuhai specializes in the main-tenance, repair and overhaul (MRO) of IAEV2500-A5 and CFMI CFM56-3, -5B and -7engines. In the Chinese market, the shop hasbecome the market leader in V2500 andCFM56 engine repairs.
Airfoil ServicesKota Damansara, MalaysiaMTU operates Airfoil Services in the vicinity of Kuala Lumpur in equal partnership withLufthansa Technik. The joint venture’s corecompetency is the repair of low-pressure turbine blades of CF6-50, -80C2, V2500,CFM56-3, -5B and -7 engines and high-pres-sure compressor blades of V2500, CF6-50, -80C2, CFM56-3, -5B, -7 and CF34 engines.The company recently completed the con-struction of a new shop, which quadruples itsrepair capacities.
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Vericor Power Systems Alpharetta, U.S.A.A wholly-owned MTU affiliate Vericor PowerSystems develops, manufactures and supportsgas turbines for marine, compression andpower generation applications and providescomprehensive customer support services forthese turbines. As an OEM for the TF and ASEseries of marine and industrial gas turbines,the company has customers worldwide includ-ing the navies of several countries.
MTU Maintenance’s supplier:
Ceramic Coating Center Châtellerault, FranceCeramic Coating Center (CCC) is an equal-share joint venture between MTU Aero Enginesand Snecma Services (SAFRAN group) spe-cializing in the deposition of ceramic coatingson engine blades. CCC subcontracts withMTU Maintenance’s locations to coat bladesusing the advanced electron-beam physicalvapor deposition (EB-PVD) technique.
MTU Maintenance Canada is located near VancouverAirport.
MTU Maintenance Zhuhai is the most important mainte-nance location in Asia.
Vericor in the U.S. is MTU Aero Engines’ industrial gasturbine affiliate.
CCC in France applies a highly innovative coatingprocess, the EB-PVD coating.
ASSB has relocated to a new site in the Kuala Lumpurmetropolitan area in Malaysia.
CSC at MTU Maintenance Berlin-Brandenburg supportsPratt & Whitney Canada engines.
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MTU Maintenance HannoverMTU Maintenance CanadaMTU Maintenance ZhuhaiAirfoil Services(ASSB)
Low- to medium-thrust enginesCF34PT6APW200PW300PW500
MTU Maintenance Berlin-Brandenburg
Industrial gas turbinesLM2500™LM2500+™LM2500DLE™ LM5000™LM6000™
High-thrust turbofan enginesCF6-50 CF6-80C2 CFM56-3 CFM56-5B CFM56-7 GP7000 PW2000 PW6000 V2500� � � (in planning) � � �
� �
� � � �
LPT blade LPT blade LPT blade LPT blade LPT blade LPT bladeHPC blade/ HPC blade/ HPC blade/ HPC blade/ HPC blade/ HPC blade/vane vane vane vane vane vane
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MTU Maintenance Canada Ltd.Vericor Power Systems LLC.
Airfoil Services Sdn. Bhd.MTU Maintenance Zhuhai Co. Ltd.
Ceramic Coating Center S.A.S.MTU Maintenance Hannover GmbHMTU Maintenance Berlin-Brandenburg GmbHPratt & Whitney Canada Customer Service CentreEurope GmbHMTU Aero Engines Holding AGMTU Aero Engines GmbH
Taking technology to new heights
Quality and short turnaround times are vital forMTU’s customers and provide a competitiveedge that can be decisive in determining thesuccess or failure of an operation.
With a reputation for quality, MTU Maintenancehas become the world’s largest independentprovider of commercial engine maintenanceservices and has attained a leading positionin the MRO market. Its achievements arebased on a process-oriented organizationalstructure and modern quality management.
A focus on material flow, value-added servicesand specialized optimization methods (Contin-uous Improvement Program, CIP) are just someof the tools the company utilizes to continu-ously improve its processes. The outcome isincreased stability and efficiency which ensurethe company’s high quality standards world-wide.
At all locations work processes are clearlydefined and documented in integrated man-agement systems. Regular audits, optimiza-tions and re-certifications ensure high levelsof transparency and effectiveness.
Certified MTU Maintenance locations• MTU Maintenance Hannover:
ISO 9001, EN 9100 and EN 9110 quality standards
• MTU Maintenance Berlin-Brandenburg: ISO 9001 and EN 9100 quality standards
• MTU Maintenance Zhuhai: ISO 9001 quality standard
• MTU Maintenance Canada: ISO 9001 quality standard
The Hannover and Vancouver locations areactive members of the Coordinating Agencyfor Supplier Evaluation (C.A.S.E.). The agencyhas created an internationally recognized avi-ation quality standard, compliance with whichis regularly audited.
As a global company, MTU Maintenance holdscertifications from the world’s three most sig-nificant aviation authorities: EASA, FAA, andCAAC. Individual locations additionally hold allapplicable approvals issued in their respectivecountries.
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Maintenance based onadvanced technologies
MTU Maintenance performs inspections,repairs, assembly and testing using equip-ment and facilities that embody the lateststate-of-the-art. Some of the equipment ituses includes:• numerically controlled measuring machines• fully automated plating systems• fully automated X-ray facilities • programmable low-pressure plasma spray
systems • highly advanced test facilities
At MTU Maintenance Hannover, use is notonly made of the most advanced technologybut also of a most innovative production lineprinciple—the entire repair cycle has been re-organized into flowline operation. Engines ofany type can immediately be inducted and pro-cessed sequentially. Fully automated systemshave been integrated into the entire processcycle from teardown to repair and build-up.The advantages include appreciably shorterturnaround times without compromising quali-ty, more flexible maintenance teams and repairtimes that can be planned more easily.
Competitive edge through innovative techniquesMTU has built up an international reputationfor providing first-class manufacturing andrepair techniques. True to their motto “repairbeats replacement”, MTU maintenance expertsare continuously developing innovative repairtechniques, which range from automated se-lective stripping of coatings to specializedhigh-temperature resistant brazing and high-precision welding using laser processes de-veloped in-house. These techniques have setstandards throughout the industry.
Innovative high-tech techniques have pavedthe way for repairs that had previously beenunthinkable. In MTU Aero Engines’ new centerof excellence for blisk repairs, for instance,blisks—special components in high-pressurecompressors—can now be repaired rather thanreplaced as was the case in the past. The com-pany’s patching technique endows defectiveblades with an additional life, a unique achieve-ment in the industry.
The Ceramic Coating Center (CCC) also offersoutstanding capabilities as do all the new MTUdevelopments in chemical, thermal, thermo-chemical and mechanical surface treatments.A new thermal barrier coating for high-pressureturbines, for instance, substantially extendstheir life by combining engineering competencewith dedicated repair expertise. Before theprotective coating is deposited, the material isprepared by stripping prior coatings from thebase material using a high-pressure water jet.In the process, highly pressurized caustic pot-ash solution removes contamination from theinterior cavities of rotor blades. Consideredparticularly gentle, the method has beendeveloped in-house at MTU. It reveals existingmicrocracks and allows the shop to eliminatethem by additional flushing with a purifyinggas and permanently sealing, using the propri-etary MTUPlus brazing technique.
The surfaces of blade roots are compacted by shotpeening.
Borescope inspection is a method of examining internalengine areas without their being disassembled.
MTU uses a variety of plasma-spraying processes. The technique used is selected to suit the respectiveapplication.
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Pursuit of a common goal MTU Maintenance’s most valuable resource isits employees. The group employs over 2,000staff globally. This highly qualified, competentand motivated workforce has one sharedgoal—customer satisfaction.
Promote strengths, share knowledgeThose who hope to prevail in the world’s majoraviation league have to foster the skills andabilities of their staff. A company’s potentialmultiplies when the company succeeds inbuilding knowledge—and retaining it. With thisin mind, MTU relies on consistent knowledgemanagement, comprehensive initial trainingand continued education. The company coop-erates closely with schools, universities andcolleges to motivate young talent and recruitthe best for MTU at an early stage.
MTU Maintenance secures its competitiveedge through its apprentice training schemesand on-going further training for the entireworkforce. An employee development programtailored to meet specific company needs pro-motes the acquisition of key qualifications andprovides vocational and business training thatis relevant to the real working environment,forward-looking and internationally oriented.
Globally attractive and flexibleWorldwide, the group provides 24-hour AOGservice in line with industry standards. Trulyexceptional, however, is the uniformly highquality of all company services. Whether inHannover or Zhuhai, personnel are qualified todeliver the same high standard of workman-ship at all locations. This is ensured through atraining program that actively promotes know-ledge transfer with high potentials completingpart of their training abroad. English languagecourses for the entire workforce enable globalcommunication among employees regardlessof position and function. This builds cohesionwithin the company and enhances communi-cation with customers and partners.
MTU Maintenance sets international bench-marks in vocational training—the Zhuhai facilityhas started the training of mechatronic tech-nicians adding yet another apprentice trainingdiscipline to the MTU repertoire. The so-calleddual system apprenticeship, which combinesschool and industrial practice, follows theGerman model. It was developed by the Gesell-schaft für technische Zusammenarbeit (GTZ)and offcials of the Industrial & Technical Schoolof Zhuhai.
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Internationality and flexibility are two key attrib-utes which make the company so attractiveboth to customers and potential employees.Modern working time schemes permit thecompany to respond immediately to fluctu-ations in shop visits, a competitive advantageimmediately benefiting customers.
Faster through short lines of communicationIn internal communication, as in interactionwith customers, MTU Maintenance placesgreat importance on short lines of communi-cation. It encourages flat hierarchies, personalaccountability and international staffing ofteams. Intercultural exchange and a commu-nicative organizational structure generateextensive knowledge of regional markets andfast response times. MTU Maintenance’sinternal information retrieval system enablesa seamless flow of communication. The sys-tem is technically state-of-the-art, accessibleto all staff and globally networked.
Motivation boosts successMTU Maintenance’s strength is in the commit-ment of its personnel to the company. Eachmember in the group is commited to the company and to its customers. Driving thisattitude is the shared awareness of being amarket leader and the desire to remain so.The company makes watershed decisions daily,sets trends and excels in technology devel-opment. That is what motivates customersand employees alike.
The V2500 was the first engine program to be includedin MTU Maintenance Zhuhai’s portfolio.
For the Ludwigsfelde location, the CF34 is expected togrow in importance over the next few years.
Top quality training is a priority at MTU.
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Secure success Assuming responsibility is one of the funda-mental values at MTU Aero Engines and MTUMaintenance—responsibility for products andservices, co-workers, customers, partners andneighbors. Responsibility for the environmen-tal has also become a vital concern. At almostall of its locations, MTU has established anenvironmental management system that pro-vides cradle-to-grave control and continuousimprovement of all engine work affecting theenvironment.
Sustainability requires personal accountabilityUnderlying all MTU’s products and workprocesses are the company’s environmentalprotection criteria. These are doggedly ob-served as every individual on the company’sstaff is involved in and personally accountablefor their contribution to protecting the environ-ment. The company fosters environmentalawareness through training and workshops.
The overall concept includes the developmentof environmentally friendly engines and lowenvironmental-impact maintenance, whichinvolves restoring engines to a more efficient,environmentally benign condition. Environmen-tal protection measures at MTU and undergocontinuous improvement. Waste materials arerecycled wherever practicable, legacy damageis cleaned up, power and water consumption,as well as noise and contaminant emissionsare continuously being reduced.
Certified achievementsMTU Maintenance’s activities are embedded inthe company’s integrated management system,which ensures that environmental protectionresponsibilities are met and monitored, as isthe case for all quality control and occupation-al health and safety measures. The Munich,Hannover, Berlin-Brandenburg and Zhuhailocations all meet international environmentalstandards and are certified to ISO 14001.Additionally, the German affiliates are validatedin accordance with the European EMAS Eco-Management and Audit Scheme. Companyactivities in connection with these standardsand schemes are published in environmentaldeclarations regularly issued by the companyfor the various locations.
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