1. COMPANY PRESENTATION & IMPROVEMENTS
November 2013
COMPANY PRESENTATION
&
IMPROVEMENTS
Suat Sağıroğlu

2. Turkish Technic Overwiev
BRIEF HISTORY
1955 : All civil aviation companies are re-organized under Turkish Airlines.
1957 : Maintenance and revisions of three DC-3 aircrafts were made.
2006 : Turkish Technic Inc established with 100% shares belonging to Turkish Airlines with nearly 2400 personnel.
2012 : Turkish Technic has over 4000 personnel with 4 Hangars.

3. Turkish Technic Overwiev
MAIN SERVICES
Line and Base
Maintenance
Engine
APU
Landing Gear
Component
Maintenance – Pool Services
Engineering
Services
: Both Boeing (B737-CL, B737-NG, B /300/300ER) and Airbus (A320, A330 and A340 Series) Aircraft.
: In TEC (partner with P&W) V2500 and CFM56 Engines Family.
: Sundstrand and Honeywell Series.
: B737-CL, B737-NG, A320, A330 and A340 Series.
: Radio&Devices, Hydraulic&Pneumatic&Mechanic Components and Brake Systems.
: Maintenance Management, Structural Damage Evaluation, Relability Services

4. Turkish Technic Overwiev
CUSTOMERS

5. THY Technic Number of aircraft maintenance

6. THY Technic Number of aircraft maintenance
Monthly

7. THY Technic Number of Aircraft maintenance
M/H Summary

8. THY Technic Number of Aircraft maintenance
2013 – M/H monthly

9. THY Maintenance Check Optimization
THY B737-NG FLEET
Has mature and large fleet
Has /800 and 900ERs
High aircraft utilization
Seasonal variation in utilization
( ie. Hadj season)
Flexible manpower available
Has central maintenance base
C check optimization;
Some of the C tasks that do not have the exact C-Check intervals are done in A Checks
By grouping zonal tasks and using access removal/installation cards, labour hours spent on panel removal and installation are reduced.
Maintenance Check Intervals;
A check FH / 600 FH
C check fh/730 day

10. THY Maintenance Check Optimization
PREVIOUS SITUATION
A checks used to be performed at every 150 FH and every 600 FH, there was a 4A, or Big A, check.
THY B737NG fleet can be grouped in 3 categories according to daily utilization.
Group 1 (6,7 FH/Day) 14 A/C , A check at every 22 days
Group 2 (9,7 FH/Day) 38 A/C, A check every 15 days
Group 3 (12,4 FH/Day) 12 A/C, A check every 11 days

11. THY Maintenance Check Optimization
PREVIOUS SITUATION
Workload for each A check is 1 shift ( 0,33 day) and 2 shifts (0,66 day ) for each 4A checks. Annual Total ground time of each group are specified below.
Group 1 (6,7 FH/Day) 14 A/C , 92 days
Group 2 (9,7 FH/Day) 38 A/C, 376 days
Group 3 (12,4 FH/Day) 12 A/C, 163 days
Approximately 24 A checks are performed per A/C for a year A checks performed for 64 A/C fleet and total ground time of fleet is 631 days.

12. THY Maintenance Check Optimization
OPTIMIZATION PROJECT
New A-Check Organization
Stationed in IST (Base) 130 personnel, working in 4 teams, 3 shifts, 24 hours a day.
Each team has 30 mechanics from all technical skills, making it possible to cover all required maintenance (mechanical and avionic) actions. Specialization and only working on A check tasks provide more effective maintance.
The target is 2 A checks a day with an average of 15 checks a week.

13. THY Maintenance Check Optimization
TASK CARDS vs REFERENCE INTERVAL
Task Card Number

14. THY Maintenance Check Optimization
OPTIMIZATION PROJECT
New Intervals: 1000 FH for A checks and 300FH / 30 Days for L checks
A Check interval for each group in days would be approximately,
Group 1(6,7 FH/Day) 14 A/C , A check every 149 days
Group 2 (9,7 FH/Day) 38 A/C, A check every 103 days
Group 3(12,4 FH/Day) 12 A/C, A check every 80 days
L Check interval for each group in days would be approximately,
Group 1 (6,7 FH/Day) 14 A/C ,L check every 30 days
Group 2 (9,7 FH/Day) 38 A/C, L check every 30 days
Group 3(12,4 FH/Day) 12 A/C, L check every 24 days

15. THY Maintenance Check Optimization
EQUALIZED A CHECKS
EQUALIZED L CHECKS
Total M/H
Total M/H

16. THY Maintenance Check Optimization
DETAILS of NEW CHECKS
A checks, which contains all of the tasks that have 1000 FH and above intervals, will be accomplished in 2 shifts (0.66 days) at the main base (IST) and will have an average of 105 manhours.
L checks consist of less complicated tasks that have intervals between 300 FH and 1000 FH. Moreover, they will be accomplished in 1 shift (0.33 days) at 5 different out-stations with an average of 45 manhour workload.
There is going to be 2,85 A and 12 L checks per A/C annually. The total amount for the entire 64 A/C fleet will be 182 A checks and 768 L checks, which corresponds to a total ground time of 328 days.
Total gain in ground time for the B737NG fleet will be 303 days.

17. THY Maintenance Check Optimization
TOTAL GAIN
For Turkish Airlines, as the ground time for planned maintenance will be reduced by a total of 303 days, they will have 303 extra days for the entire 737-NG fleet to operate, which will net them a total of almost 9 million $ a year.
For Turkish Technic, lesser ground time of THY fleet will make maintenance slots available for third party companies, resulting in extra revenue. Moreover, since the maintenance deal with THY was done in PbtH, 303 days will earn Turkish Technic $ a year.

18. THY Maintenance Check Optimization
SUMMARY
150 FH “A Checks” are converted into 300 FH / 30 Days “L Checks” whereas 600 FH, Big A Checks are into 1000 FH A Checks.
New A checks are accomplished by a new A-Check maintenance organization under Turkish Technic, which is specialized in A Checks, making it possible to complete a 1000 FH maintenance at the same amount of time with a 600 FH one.
Ground times caused by scheduled maintenance will be reduced by 303 days for the entire THY 737-NG fleet, from which THY will earn around 9 million $ whereas Turkish Tehcnic will also receive $ through PbtH agreement.

19. Access Panel solution General
THY Tecnich Job cards are prepared to base on the original manufacturer’s document by Maintenance Engineering Dept. Most of the job cards consist of the access panel lists which will be used for to access some maintenance areas.
In previous Situation; job cards are distributed to the technicians who would be work on the aircraft by supervisor. Supervisors also tried to grouping them for preventing to duplication of the opening and closing the panels. But it was not work all the time because of 3-shift working system.

20. Access Panel solution SOLUTION
Access panel removal and installation reference task cards are created for every possibility of working zone and also cabin interior (galleys, lavatories, seat tracks, ceiling panels etc.) on the aircraft. These task cards includes detail information to removing and installing the panels with detailed figures.
And also panel index lists issued for all zone to use in maintenance action

21. Access Panel solution RESULT
Every maintenance package has got its individual panel index lists. One for removing the panels which should be removes in this maintenance action, and one for installing panels which was removed in maintenance. All panels are removed before maintenance, after all job cards and EO’s are applied, all panels are closed with the installation task cards.
Access Panel M/H values are removed from the task card’s itself and added to panel index for helping to planning also

22. New Hangar Project for VIP and Training aircrafts
Current Situation
Number of aircraft:
CESSNA 172 S – 10
DIAMOND DA42 and 42 NG – 2
1500 m2 closed hangar is avilable in İSTANBUL ATA AIRPORT
Maintenance check interval for types of aircraft:
CESSNA 172S - .A, B, C, D
DIAMOND DA42 Tipi uçaklara A, B, D Bakımları yapılmaktadır .
For training aircrafts, predicted yearly FH utilisation;
CESSNA 172 S; 650 FH
DIAMOND DA42; 300 FH
Intervals of the checks;
A CHECK- 50 FH
B CHECK- 100 FH
C CHECK FH
D CHECK- 1 year

23. New Hangar Project for VIP and Training aircrafts
Future overview
Future plan: at the beginning 140 pilot will be trained a year than this number will reach to 300 or more after new deliveries of aircrafts.
In 16-month – 140 pilot will FH real flight simulation fligth.
In a year 2014 –will have 20 aircraft for training, and predicted yearly utilisations will be 855
C Check will be estimated every 3 days
1 C Check = 50 M/H (aprx.)

24. New Hangar Project for VIP and Training aircrafts
Future overview
As of 2014, will increase the number of aircraft, new hangar project is implemented due to lack of place of Atatürk airport. Aydın hangar has started to line maintenace immedietly, and waited for the base maintenance approval.
Current Situation
Future plan

25. Studies of A and C check shortening the TAT of B737NG
Within the context of the continuous improvement of business development carried out by the unit according to the needs of the units, to include all the processes are carried out maintenance or overhaul.
Studies of A and C check shortening the duration of B737NG TAT;
New material and toll kits
Keep ready to use be used materials, tools and kits before the maintenance
People organized for erranding the material and tool to the technichian who is still work on the aircraft in maintenance action.
Put the board with PC for easy access to maintenance docments (AMM, IPC, CMM etc.) for every aircraft which is in maintenance action.
with above type actions, all working distances are shorthend for technician in maintenance action then gained up to %40 time for TAT.

26. THANK YOU