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Lufthansa Technik to carry out some Airbus A380 wing rib feet repairs

Lufthansa Technik will perform some Airbus A380 wing rib feet repairs, chairman August Wilhelm Henningsen told ATW in Hamburg. ...

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Discuss this Article 10

Night Watchman
on Mar 19, 2013

This is good news, all round.

The really significant point is that we read yet again that “one A380 wing rib repair is to take between 40 to 50 days”, well below the exaggerated time-estimate of 56 days made by the Emirates Engineers, and advanced by CEO Tim CLARK, ignoring the estimates of Airbus’ Engineers.

And this period of “40 to 50 days” is before the “learning curve” benefits kick in.

Riman10
on Mar 20, 2013

Maybe there are considerations that help extend the repair period for Emirates. It is not always wise to criticise the estimations of a carrier without access to all the pertinent information.

Night Watchman
on Mar 20, 2013

Thanks, Riman10.

No undue criticism involved.
Just a slight loss of patience over the continuing flow of hype & exaggeration that seems to keep coming out of that stable.

Maybe we have inside information, too.

SIA's first repair took 42 days. SIA had been discreet and professional, and all concerned have reportedly recognised that there will be, inevitably, learning-curve "pick-up", with some more time gains.

Emirates A380's are not exceptional. They neither deserve nor need exceptional concessions.

Emirates time-estimate in which they ignored Airbus' engineers' best & reasonable estimate, represented 1.33 x the SIA first run.

That is a 33% excess "straight off", in a context in which Emirates admitted to be wanting compensation for down-time, beyond normal guarantee indemnities.

Draw your own conclusions. I maintain that the Emirates' 56 days is an exaggerated task-time.

In that I am not alone.

I stand to be corrected. But the factual, objective evidence is against Emirates appraisal. The onus is on them to prove their allegations. Who is going to believe them ?

We should not be dealing in "perhaps" & "maybe".

Also, Airbus have completed their financial provisions (charged to P/L).

That means that the technical estimates (materials, labour, time, wage-rates and overhead, with in-built contingency margins) were all taken into account by the independent cost engineers, sent in by the insurers, who include consequential-loss assessors, who understand the business, the tasks & the environment.

Night Watchman
on Mar 20, 2013

PS !

By the way, I forgot to mention that the financial calculations for the provisions and the resultant amounts provided have, reportedly, been audited by the Airbus Auditors.

This means that all the technical work and cost analyses and build-up items, mentioned above, will have been gone through by the independent outside Auditors of Airbus.

These professionals will have leaned on technical conversations with the experts, and will have applied their own "coherence checks" on the items summarised in my post above, before validating the final provision figures.

They will not have based this work on Emirates' estimates. They will have gone through the OEM's standards and those of the OEM's chosen independent MRO partners.

Emirates do not make the industry manufacturing and MRO standards.

Night Watchman
on Mar 21, 2013

Of course, it is not beyond the wit of man to understand that Airbus are bound to consider Emirates as a valued client, just as Airbus do consider all their customers as "valued clients" (Boeing, too, in their problems, with the B787, for example).

It would not be surprising if, beyond the pure, "official guarantee" position, Airbus offered some gentlemanly & soothing sweeteners to their clients, including Emirates.

To facilitate such a gentlemanly option, it would doubtless be better if Emirates' Leaders were to adopt a policy of discussing such issues discreetly, in a sound-proofed conference room, between gentlemen, instead of reaching for the first microphone, sounding off in public, and making visibly ill-founded and exaggerated statements, in sundry approaches via the media.

In the eye of the beholder, apparent public posturing, and attempts at negotiating via the media are scarcely the best ways to "make friends and influence people" to mutual advantage.

TechGuru
on Mar 21, 2013

"..They will not have based this work on Emirates' estimates..."
This is a warranty repair paid for and done by Airbus. They had the details and estimate. The 56 days estimate was Airbus own and not Emirates. I have full details of the work involved. It is huge - 42 days with 40 mechanics on each aircraft.

Night Watchman
on Mar 21, 2013

Many thanks, TechGuru.

I agree entirely with the “hugeness”. You are right; Your phrase "42 days with 40 mechanics on each aircraft" is absolutely correct, in that it was reported as the SIA team’s official, actual, concrete task-time on the first A380 “treated”.

SIA did, reportedly mention, that they would expect learning-curve time-gains against that figure of 42 days. Obviously, One is not really in a position to confirm or contest that remark.

But all that is not the issue. I do not want to split hairs here; no question of that.

I saw one summary of key assumptions (NOT the original, obviously) with the “56 days” (which you mention : no problem with that), but with a remark imputed to Airbus, as a task-time reflecting "a worst case scenario, allowing generously for unforeseen issues".

That was NOT the standard. The standard was the “40 to 50 days”, mentioned or confirmed by LH Technik.

Emirates reportedly adopted the 56 days as "standard", factored it in, and took no account of "learning curve pick-up" in the subsequent computations.

Result: a minimum 33% overstatement or excess in Emirates “published anticipated estimates” versus the SIA experience of 42 days, and, I re-emphasise, excluding any learning-curve time-gains.

In fairness, Tim CLARK / Emirates has recognised the pleasant surprise (of the 42 days of SIA, as against Emirates -- “adopted”, if you wish -- “56 days”), and openly said this.

But they had already begun using the higher figures in “pitches for financial compensations from Airbus”.

Once again, thanks for your reaction. Please feel free to come back and tell me if I am mistaken. If that were to prove to be the case, I would recognise it and amend my analysis. That is no problem.

Night Watchman
on Mar 21, 2013

Clarifications. No intention of arguing just for the sake of arguing.

(1). In this context "guarantee" means "warranty".
-----------------

(2). Airbus did say, reportedly, inter alia :
•--- "It is a process taking weeks depending on how the airline wants to carry out the job," an Airbus spokesman said.

•--- “..... repairs will be made under warranty without further adjustments for disruption or the idling of A380s” ; this expresses exactly the spirit of what was frustrating Emirates, in my phrasing above , “.....in a context in which Emirates admitted to be wanting compensation for down-time, beyond normal guarantee indemnities”.

•--- “... to carry out a permanent fix, airlines operating aircraft delivered before 2014 will be able to send in the aircraft for a standalone repair job taking an unspecified number of weeks or add the task to a regularly scheduled heavy maintenance visit”.
--------------------------------------

It was an aviation publication, not Airbus, which wrote:
.....“ .....A380 operators face a 30,000 man-hour repair program to address the wing-crack issues. This would require eight weeks of downtime if done in one instalment, it said.”
------------------

NB : there are the “56 days” (8 weeks).
-------------------

Nowhere have I found an Airbus statement categorically saying, e.g. “.....it is job with a standard 56-day time- allocation”.

That is one of the key points against which I am driving in the Emirates pitch.

Night Watchman
on Mar 22, 2013

I make no apologies for hammering away at this point of Emirates’ exaggeration.

I do not "buy" the Emirates' approach, or the tentative arguments of those who support them in that approach.

The facts militate heavily against Emirates' attitude and behaviour. Just take a look.

The problems hit the headlines around mid-January, 2012.

There was never any denial of the fact by Airbus. Never.

Two JUNK POINTS were denied immediately : (a) that the phenomenon was an immediate threat to safety (certainly no more than there had been in the similar – not identical in detail, but identical in the principle – case of the first Boeing B747’s ; but there was not the web-&-tweet mediatisation of drivel in those days ; those items were handled professionally & with ease) ;

---(b) that it was because of British engineering at Airbus UK, … a point of absolute & ignorant clap-trap that was knocked on the head swiftly.

After less than 2 months of inevitable & understandable to-ing & fro-ing, necessary to get the facts under control, and to chuck out the “B-S” – BARELY 2 months – in early March, 2012, Emirates’ Leaders began “beating their gums” for COMPENSATION.

We were treated, e. g., to this sort of prose, even in good quality newspapers, the “Financial Times” among them, from about March 10 or 11, 2012 onwards :

•--- Emirates Airlines….., is seeking compensation over faulty engineering and technical woes faced with the Airbus A380. The world’s largest operator of A380's is PLANNING TO SEEK COMPENSATION from the aircraft maker after COMPLAINING of WIDESPREAD DISRUPTION and an EXPECTED LOSS OF REVENUE, the airline's president told the Financial Times yesterday.
----------------------
Just look at the exaggerated presentation, represented by the choice of vocabulary. At the premature dates indicated, it is all so immature, in comparison with the far more sober reactions of the other carriers concerned.
---------------------

Emirates has found wing cracks on the 10 A380s that have been inspected so far, AND ITS PRESIDENT IS CITED by the FT as saying that ALL 21 IN ITS FLEET WOULD NEED REMEDIAL WORK.

•--- The initial problem was Airbus’s attitude with dealing with the situation when THEY INITIALLY REACTED WITH DENIAL ABOUT THE CASE.
---------------
Poppycock ! See above !
---------------

•--- Last month (Feb. 2012), the European Aviation Safety Agency ordered all A380 superjumbos to be checked, while saying that THE PLANE WAS SAFE TO FLY.
--------------
What does that tell us about Emirates reaction ?
---------------

•----Emirates president Tim Clark told the Financial Times that the grounding caused "A LOT OF COMMERCIAL HARDSHIP"
. ……..

Compare that hyperbole with the moderate behavior in the lamentable & really dangerous case of the B787’s !

It is a good job the Emirates did not order any B787’s ! Just think of the ear-bashing that Boeing would be receiving from Emirates !

One need say no more ! Emirates had shot from the hip & exaggerated prematurely. Period.

The EASA had de-dramatised the whole safety scene in February, 2012 !

Airbus was preparing a flexible approach to solutions, to mitigate disruption.

Emirates were sounding off, exaggerating, and already clamouring for compensation !

Tim CLARK had lost yet another opportunity for remaining silent in public, with dignity.

Night Watchman
on Mar 25, 2013

Now this latest news should help to give a firm information- base. I picked this up from snippets in French press artcles, and from a piece in Flight International.
------------------------

According to recent articles or notes (seen to-day, March 25, 2013), EASA (European Aviation Safety Agency) is reported to be in the final stage of certifying Airbus’ A380 wing fix.

Europe's safety regulator has declared that certification for the Super Jumbo’s reworked wing is on track and nearing completion.
---------------
After some over-optimism & wishful thinking in 2012, Airbus had …… been quick to recognise that the process would move into early 2013.

The fix addresses the “wing rib-feet cracks” issue , which really became known in January 2012.

Aircraft already in service, plus those in advanced production on FAL, are being modified through a retrofit process which replaces hybrid ribs in each wing,. It also entails the fitting of some extra "local" reinforcement.

EASA (European Aviation Safety Agency) says it is "in the final stage of releasing" the closing airworthiness documentation to approve & mandate this full-life retrofit of already-in-service & undelivered Airbus A380-800’s

"Things are progressing normally & as planned," says EASA, adding that there is no delay in the approval routine.
"Target dates are provided as a very broad indication, as far as certification is concerned, and should always be taken with that in mind, for what they are : APPROXIMATE."

To-date, Airbus have actually delivered 100 x A380s. They are forecasting that deliveries will have reached about 120 in number, before the final solution is truly in place.

Certification of the final production fix will be carried out "at a later stage", says EASA.
Focus here will be the approval of the permanent solution of the problem, to be integrated into Airbus A380 wing production, going forward.

Airbus is to replace the hybrid ribs with all-aluminium components built from a more robust definition of the material, and make other improvements to the wing structure, all as an integrated operation in an upgraded production process.

Airbus’ plans are scheduled to commence deliveries to clients of of the first A380s equipped with these all-new wings in 2014.

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