MTU Maintenance ZhuhaiPassion for perfection

MTU Maintenance ZhuhaiAn MTU Aero Engines Company

Center of excellence in Asia Germany’s largest engine manufacturer, MTU Aero Engines and its predecessor companies have been a driving force in aviation for almost 80 years. MTU designs, develops, manufac-tures, markets and supports commercial and military aircraft engines and industrial gas turbines. It has content on engines in all power and thrust categories and across all major engine components and subsystems, such as compressors, combustors, turbines and engine controls. The company cooperates with the world’s major engine makers. MTU employs some 8,500 people and has affiliates in major regions and markets worldwide.

As part of MTU Aero Engines, MTU Mainte-nance has been dedicated to providing excel-lent engine maintenance services for more than 30 years. Today, the company has be-come the largest independent maintenance provider for commercial aircraft engines and industrial gas turbines worldwide and is a pre-ferred partner for airlines and other operators around the globe. From its headquarters in

Munich, MTU operates engine MRO affiliates in Germany (Hannover and Berlin-Branden-burg), Canada (Vancouver), the USA (Dallas), China (Zhuhai), Malaysia (Kuala Lumpur) and Poland (Rzeszów) that provide individually tailored service packages at the customers’ door-step.

To complement its core engine competencies, MTU Maintenance offers additional services such as spare engine support, on-site and on-wing services Engine Trend Monitoring as well as LRU and 24h AOG support. The company focuses on repairing rather than replacing. When it comes to repair development, the com-pany is a global leader that offers unrivaled and cutting-edge technologies.

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Only recently, MTU Maintenance Zhuhai has extended its facility, allowing a 50 percent increase in shop visits per year.

A V2500 engine is being prepared for final testing.

MTU Maintenance Zhuhai is a 50-50 joint venture between parent company MTU Aero Engines and China Southern Air Holding Com-pany which owns China’s largest air carrier, China Southern Airlines. With more than 500 aircraft, China Southern Airlines currently operates the technologically most advanced fleet in China. The carrier maintains an ex-tensive network serving more than 1,000 domestic and international destinations in 187 countries from its Guangzhou and Beijing hubs. In 2012, it carried more than 86 million passengers.

MTU Maintenance Zhuhai is located in Zhuhai’s free trade zone in southern China, in close proximity to Hong Kong and Macao. Covering a land area of 156,000 square meters, the shop represents MTU’s access to the boomingChinese market. For China Southern and other airlines in Asia, it in turn provides access to a highly flexible provider of high-quality com-mercial engine services, helping the airlines reduce costs and shorten turnaround times.

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A V2500 engine is being prepared for final testing.

MTU Maintenance Zhuhai is a 50:50 joint venture with China Southern Air Holding Company.

Since 2003, MTU Maintenance Zhuhai has successfully overhauled more than 1,350 V2500 and CFM56 engines from customers worldwide. Today, the location is the leading provider of aircraft engine maintenance, repair and overhaul services in China. To cater for the future growth, the company has extended its facility in 2012, increasing the annual capa-city to 300 shop visits per year—up 50% from its initial number of 200 engines per year.

With the start of operation in 2003, the shop was certified and approved by the most impor-tant aviation authorities, the CAAC (Civil Avi-ation Administration of China), the European EASA and the US-based FAA (Federal Aviation Authority). In 2010, it received approval from the JCAB (Japanese Civil Aviation Bureau). In total MTU Maintenance Zhuhai holds roughly 20 approvals from all over the world.

The V2500 was the first engine program in Zhuhai’s portfolio.

With a total of $189 million invested in con-struction, advanced equipment and inventory,MTU Maintenance Zhuhai is one of the most advanced engine maintenance, repair and overhaul shops in Asia and the second-largest location within the MTU Maintenance network. Due to comprehensive technology transfer programs throughout its locations, MTU Main-tenance Zhuhai is able to deliver an uncom-promising quality and a range of innovative services—the common hallmark of all MTU maintenance shops.

The new state-of-the-art facility is equipped to perform all necessary processes, such as component and parts cleaning, high-pressure water stripping, non-destructive testing, sur-face treatment, welding, machining, plasma spraying and heat treatment, up to plating, stripping and high-speed grinding, all of which give the shop full repair capabilities according to the highest industry standards, all under one roof.

The test cell is one of the largest and most advanced in the world. It is 100 meters long, 13 by 13 meters in cross-section and has in-take and exhaust ducts 30 meters high. It can accommodate all commercial engine types up to a thrust of 150,000 pounds and is capable of testing 500 engines annually.

Engine maintenance services at its best

Commercial engine portfolio• V2500• CFM56-3• CFM56-5B• CFM56-7, including -7BE

The company’s service offering include: • Modification, upgrade, repair and overhaul of the V2500 and the CFM56 series• Warranty processing vis-a-vis the OEM (1st run warranty)• State-of-the-art repair service for engine components and parts• On-site services by the mobile repair team• Engineering support• AOG hotline with 24/365 service availability• Provision of lease engines through MTU‘s e.pool services• Spare parts deliveries in AOG cases• Individually tailored maintenance programs• On-wing time and shop visit rate• EGT margin, fixed price/shop visit• Fixed price/engine flight hour

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An employee during the inspection of a V2500 diffusor casing.

MTU Maintenance has a global reputation for its unique repair techniques.

Measuring the fan disc of a CFM56 engine.

> Precision and detailed know-how are needed for the assembly of this V2500 engine.

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Across all of MTU’s maintenance shops, great effort is made to repair components before reverting to replacement as a last resort. However, to provide customers with the cost benefits of a repair without diluting the high quality level they expect, innovative repair technologies are needed. MTU Maintenance offers a comprehensive range of repair capabi-lities for complete overhaul, engine teardown, single piece part and accessory repairs.

MTU Maintenance has carved out a leading position in this field worldwide. Such novel repairs can, for example, extend the service life of engine blades by up to four times. This may save the customer two thirds of the cost of new blades. To keep it that way in the future, repair specialists are continuously developing new high-tech repairs and are improving ex-isting techniques. These proprietary EASA/FAA approved repairs are marketed as MTUPlus repairs.

Like all the other MTU locations, MTU Mainte-nance Zhuhai is committed to this approach. It offers its customers the option of having their parts repaired using the company’s high-tech methods. Apart from advanced and highly efficient standard processes, such as high-speed grinding, MTU Maintenance also uses special processes:

• Laser cutting and laser welding in one setup• Welding high-alloy materials using inductive preheating• Adaptive milling• Various thermal spraying processes• Various robot-based inspection and manu- facturing processes

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Leading-edge technology

Ultra-violet light helps discover possible cracks.

High-speed grinding is one of MTU Maintenance’s repair specialties.

A fan is being prepared for balancing.

An extensive exchange of experience and know-how throughout the MTU locations makes the refinement of the company’s repair techniques an ongoing effort. In this process, the shops can draw on the capabilities of various centers of excellence. Customers thus benefit from both MTU’s OEM knowledge and its customer-oriented service approach.

• Engine component and parts cleaning• Non-destructive testing• Machining• Sheet metal working and welding• Vacuum heat treatment• Peening• Plasma and flame spraying, including HVOF• Painting• Plating and stripping• High-speed grinding of rotor blade tips• High-pressure water stripping• Brazing• Tungsten inert gas welding

MTU Maintenance Zhuhai stands for quality and safety, reliable and individually tailored services as well as cost-efficient solutions that provide us with a competitive position in the global MRO market. It is our goal to become Asia’s leading aero engine maintenance pro-vider, and the driving force behind this goal is a highly motivated team of more than 650 professionals. Our employees are our most valuable resource, and we therefore consider it our first priority to fulfill our social respon-sibilities. We offer a broad range of excellent training programs to ensure that the standard of workmanship provided is world class.

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Competent personnel

• Technical on-the-job training: Under an extensive technology transfer pro- gram, MTU Maintenance Zhuhai had some 100 technicians cross-trained at MTU’s facilities in Germany for more than six months, allowing the Zhuhai facility to pro- vide the same high-quality work as the other MTU locations around the world. MTU Main- tenance Zhuhai’s technicians were also trained at MTU Maintenance Canada, where the CFM56-3 is overhauled. This Overseas Training Program is continued on a regular basis. • Basic engine training• Training on production and project manage- ment applications and maintenance software• Computer literacy training• English-language training• Management training• Teamwork training• Initial training for new staff

Excellent training programs, a regular cross training between the other MTU Maintenance facilities and a highly motivated team guarantee world-class maintenance work.

In addition to these offers, MTU Maintenance Zhuhai invests largely in other trainings which ensure that we are able to recruit the best qualified employees.

• Training of future employees: Apprenticeship in cooperation with a local technology school that has adopted the German dual system (a combination of theoretical and practical studies). • Cooperation with top aviation universities in China: The close cooperation with high-class uni- versities allows MTU Maintenance Zhuhai to provide on-the-job trainings for students and to build up a network with potential candidates.

An MTU Aero Engines Company

MTU Maintenance Zhuhai Co. Ltd.1 Tianke RoadFree Trade ZoneZhuhai, 519030 • PR ChinaTel. +86 756 8687-806Fax +86 756 8687-901www.mtu-zhuhai.com C

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