March 2003
Presented by
Norbert SEEHAFER
A380 Design Maintenance Manager
A380 Maintenance in Design
Advanced Technologies and Maintenance
AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
The A380 Family: Flagship of the 21st Century
A380-800
A380-800
555
555seats
seats 560t
560tMTOW
MTOW 8000nm
8000nm
A380-800F
A380-800F
150t
150tpayload
payload 590t
590tMTOW
MTOW 5600nm
5600nm
Page 2
A380 - The Aircraft
AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
A380-800 / A380-800F
SPAN
261.3 ft / 79.6 m
LENGTH
238.6 ft / 72.7 m
HEIGHT
79.0 ft / 24.1 m
Page 3
AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
Technology Issues
Page 4
The Case for Advanced Technology
To achieve Cash Operating Cost target for a 21st Century aircraft
Baseline
0
Drag
and sfc
Airframe weight
Systems
Cash Operating Costs
Performance : fuel burn
-5
new technology
required
-10
-15
Airline target
-20
AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
Maintenance cost
Engine
Airframe
Systems
Size effect & current AIRBUS technology
New technologies
Cash Operating Costs
per seat mile
Page 5
Advanced Technology - Systems
2E/2H Flight Controls
AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
Variable Frequency
Generation
2 Electric/2 Hydraulic
5000 psi Hydraulic
Power
Onboard Maintenance
and Information System
Integrated Modular
Avionics
Page 6
Onboard Maintenance System Concept
Uplink
Downlink
Control, reporting display,
customisation programming
Recording
Printing
Onboard Information Network
Aircraft
Condition
Monitoring
Data Loading
& Conf.
Monitoring
Centralized
Maintenance
Consulting
AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
Links
Acquisition
and
processing
Ops.
data
S/W and data
bases loading
Conf. Acqui.
Fault
acquisition
Tests activation
A/C Systems
and engines
Maintenance
Electronic
Documentation
BITE
Page 7
OMS Access from Portable Terminals :
Areas to be covered by Aircraft Wireless LAN
AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
Cockpit &
avionics bays
Main deck
Nose gear area Cargo holds
Upper deck
Engines area
Main gear area
Tail cone (Internal)
Page 8
Flight Controls / Hydraulics Architecture
APU
Features:
AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
4 fully independent systems
2 x dissimilar system architectures
2 x conventional hydraulic systems
2 x electro hydraulic systems
Hydraulic pressure 5,000 psi,
tested with no fluid degradation and
no component erosion
Actuators studied since 1990 and
flight tested on A320 and A340
Gen
Eng.1 Eng.2
Gen
Eng.3 Eng.4
Benefits:
Weight reduction
System segregation
Redundancy and operational reliability
Maintenance costs
Maintainability
Smaller pipes easier more reliable
connections
Electro pumps for ground use
Page 9
New Avionics
On very long haul aircraft Avionics / Electronics count for :
45 % of pilot reports
10% of maintenance cost
50 % of A/C
modifications
160 computer units
35 % of total delays
AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
New concepts are needed.
A380 Avionics / Electronics will be
Integrated
Integrated
Modular
Modular
Open
Open
Page 10
IMA - Principles and Benefits
LRU A
Application A
LRU B
Application B
traditional avionics
AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
display
RDCs
AFDX-Ethernet Bus
Network
Main features:
Redundancy of two or three
to meet system dispatch
and availability objectives
Connection between the
avionics network and open
world (not proprietary)
through secure
communications interface
Fewer spares through
common modules
Teleloading of data
Page 11
A380 Electrical Power Generation
AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
Variable Frequency AC Generation
GEN 1
GEN 2
AC1
AC2
APU
GEN
GEN 3 GEN 4
AC3
AC4
Compared with constant frequency generation:
Weight reduction
Maintenance cost reduction
Reliability improvement
Page 12
A380 Advanced Technology - Structure
GLARE upper shell
CFRP Rear
Pressure Bulk Head
CFRP Tail
AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
CFRP floor
beams
CFRP panels
Aft Fuselage
Laser Beam Welded panels
CFRP Center Wing Box
Page 13
GLARE Fuselage Upper Shells
A340 barrel fatigue test
Crack length
Standard Alloy
AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
Crack growth
Glare
Fatigue Cycles
Page 14
Laser-Beam-Welded Fuselage Panels
AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
Laser welding seam cross section
Damage-tolerance test specimen
Conventional repairs
Page 15
A380 CFRP Applications
CFRP centre wing box
AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
Horizontal stabilizer
Rear pressure
bulkhead
Large CFRP structure demonstrator
Page 16
AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
Maintainability & Reliability
Page 17
A380 Maintenance in Design
Design Process
Customer
CustomerExpectations
Expectations
==Requirements
Requirements
==Service
ServiceExperience
Experience
Customer
Customer
satisfaction
satisfaction
AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
Multi-disciplinary Teams
Maintainability
Maintainability&&Reliability
ReliabilitySkills
Skills
MAINTENANCE
MAINTENANCE SPECIALISTS
SPECIALISTS INTEGRATED
INTEGRATED IN
IN
THE
THE DESIGN
DESIGN TEAMS
TEAMS
Page 18
Maintenance Philosophy
Setting
Settingnew
newstandards
standardsfor
for
maintenance
maintenancecosts
costs
Efficient
Efficientmaintenance
maintenanceprogramme
programme
AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
Make
Advanced
Technology
work for
Maintenance
Handling
Handlingof
oflarger
largerand
andheavier
heavier
equipment
equipment
Minimise
Minimiseneed
needfor
fornew
newskills
skillsand
and
processes
processesfor
fornew
newtechnology
technology
High
Highoperational
operationalreliability
reliability
High
Highcomponent
componentreliability
reliability
Minimise
Minimiseramp
rampmaintenance
maintenance
Early
Earlyaircraft
aircraftmaturity
maturity
Page 19
Maintainability Methods
Landing gear
Change Time
Control surfaces
CHECK LIST
A
X
THS actuator
Accessibility
Testability
Engine QEC
Remove/Replace
Human Factors
Servo actuators
APU
Generator
Brakes
Computers/Modules
Remarks
X
X
X
X
Servicing/Lube
Reparability
Handling
AGU
X
X
EDP
Wheels
AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
Removal Frequency
Task
MMEL
Time
Remove
Time
Replace
Time
Test
Total
Time
Maintenance Task Analysis
Page 20
Radome and Radar Antenna Installation
A380
A340
AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
A320
External
access
5 meters
Page 21
AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
Body Landing Gear Installation
Page 22
Water & Waste Tanks, Tailplane Trim Actuator and
APU Installation
AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
Water tanks
Waste tanks
Max
Oxygen bottles
Standard
Page 23
Rear Fuselage, Tailplane Trim Actuator and APU
Installation
AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
THS actuator installation
Rear Fuselage
APU removal
simulation
Page 24
Horizontal and Vertical Tailplanes
AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
HTP accessibility
Elevator actuator removal
simulation
VTP layout
Page 25
Wing Access and Installations
AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
Wing accessibility
AGU installation
Flight control actuator removal simulation
Page 26
e ts
arg
nT
sig
As
System
System
Components
AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
Ve
r
M e if y D
ets es
Ta i gn
rg
et
Achieving Operational Reliability and
Maintenance Cost Objectives
Top
TopDown
Downapproach
approachto
toassign
assignaircraft
aircraftlevel
leveltargets
targetsto
to
systems
systemsand
andcomponents
components
Bottom
BottomUp
Upapproach
approachto
tocompare
comparecomponent
componentthen
thensystem
system
results
resultsto
toarrive
arriveback
backat
ataircraft
aircraftlevel
level
Page 27
Example: Deriving Operational Reliability Targets
Competition
Marketing
Airlines
Aircraft Level
Target
Engineering
System Targets
0.2
0.1
AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
Probablistic
methods
Failure
Conditions
52
Engine
50
Nac
49
53-57
46
45
44
42
38
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
Design Concept
21
Aircraft
Comparison
Studies
Functional Failure
Objectives
Pd = 10-n
Pi = 10-m
Page 28
AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
Maintenance Programme
Page 29
A380 Maintenance Programme Interval Framework
The A380 Maintenance Programme will be designed to
allow maximum flexibility by allocating task intervals in
usage parameters (flight hours, flight cycles, calendar time)
which allows operators to develop:
a pre-packaged plan with tasks allocated to letter checks
a flexible plan allowing task to be allocated to visits
according to limitations, resources and downtime
Target intervals for design are:
AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
A
Check
C Check
Heavy Layover
Repeat Layover
750 FH
18/24 months
120/144 months
60/72 months
Page 30
Maintenance Programme Development
The A380 Maintenance Programme will be developed in
accordance with the MRB process
MSG 3 revision 2002 will be used
The development activities will be inaugurated in early
AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
2003 through the formation of the A380 Industry Steering
Committee
Working Group activities will follow throughout 2003/2004
Preliminary work is underway to ensure that advanced
technology features are fully compatible with maintenance
programme objectives
Page 31
AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
Airports and Facilities
Page 32
AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
Main Surveyed Airports
ASIA-PACIFIC
EUROPE
US
Rest of World
Tokyo (NRT, HND)
Hong Kong (HKG)
Singapore (SIN)
Bangkok (BKK,BKK II)
Taipei (TPE)
Seoul (SEL II)
Sapporo (CTS,HKD)
Sydney (SYD)
Brisbane (BNE)
Melbourne (MEL)
Auckland (AKL)
Beijing (PEK)
Shanghai (SHAII)
Guangzhou (CANII)
Osaka (KIX, ITM)
Okinawa (OKA)
Fukuoka (FUK,KMQ)
Nagoya (NGO,NGOII)
Kagoshima (KOJ,KMI)
Jakarta (CGK)
Kuala Lumpur (KULII)
Manila (MNL,MNLII,SFS)
London (LHR,LGW, STN)
Paris (CDG, ORY)
Frankfurt (FRA)
Amsterdam (AMS)
Rome (FCO)
Madrid (MAD)
Munich (MUC)
Luxembourg (LUX)
New York (JFK, EWR )
Los Angeles (LAX)
San Francisco (SFO,OAK)
Honolulu (HNL)
Miami (MIA)
Chicago (ORD)
Memphis (MEM)
Anchorage(ANC)
Washington (IAD)
Dallas (DFW,AFW)
Orlando (MCO)
Indianapolis (IND)
Atlanta (ATL)
Denver (DEN)
Detroit (DTW)
Minneapolis (MSP)
Vancouver (YVR)
Montreal (YUL)
Toronto (YYZ)
Sao Paulo (GRU,VCP)
Rio (GIG )
Delhi (DEL)
Mumbai (BOM)
Fort de France (FDF)
Pointe Pitre (PTP)
Buenos Aires (EZE)
Johannesburg (JNB)
Dubai (DXB)
Jeddah (JED)
Riyadh (RUH)
Santiago (SCL)
Doha (DOH)
Mexico (MEX)
La Reunion (RUN)
Karachi (KHI)
Note: Airports with highest number of predicted A380 movements
or requested by airlines and some leading cargo airports
Page 33
AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
A380 Ramp Set Up
Page 34
Turn-Round Time: A380 operated as 747
Turn-Round Time in minutes
A380-800 Baseline1a @ 555 pax - PBB @ D1&D2, standard MD servicing
0
Bridges
Deplaning/Boarding&LPS
10
30
40
80
90
100
110
120
123'
2
22
37
22
27
0
18
21
81
Catering @D2R
Catering @D4R
39
0
Catering @D1R
20
Catering @D5R
AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
70
31
Bulk
Catering @D7R
Catering @D9L
Cleaning
30
21
Potable Water
Refuelling
60
14
LD-3 cargo AFT
Waste Water
50
LD-3 cargo FWD
Freight
20
20
48
Equipment
positioning / removal
Consistent with Ramp Layout RL01/B1a/800/std
Page 35
Maintenance Facilities - Hangar
29.5 m
5m
29.5 m
5m
16 m
SUGGESTED HANGAR ARRANGEMENT
AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
Nose-in Position
Page 36
Maintenance Facilities - Hangar
15 m*
NOTE:
AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
* MINIMUM
NECESSARY
DISTANCE TO
MOVE AWAY A
TRACTOR WITH A
TOW BAR
98 m
10 m
10 m
10 m
100 m
SUGGESTED HANGAR ARRANGEMENT
Nose-in Position
Page 37
Maintenance Facilities - Hangar
5m
29.5 m
SUGGESTED HANGAR ARRANGEMENT
AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
Tail-in Position
Page 38
Maintenance Facilities - Hangar
100 m
10 m
10 m
10 m
AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
93 m
10 m
SUGGESTED HANGAR ARRANGEMENT
Tail-in Position
Page 39
AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
Airline Involvement
Page 40
A380 Programme - Airline Involvement
4 20 major airlines have been shaping the
design of the A3XX / A380 for seven years
4 They represent two thirds of seats offered in
aircraft with more than 400 seats
4 They all operate 747-400s on a wide range of
mission types : very short to very long haul,
high comfort to high density layouts, in all
passenger, combi or freighter configurations
4 They are the core of the global airline
alliances taking shape
AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
4 Half of them are based in the Asia-Pacific
area
4 Their expertise in their business is widely
recognized
4 By the end of 2002 over 100 CFG meetings
have been held
Unprecendented airline involvement
from day one
Page 41
AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
Page 42
This document and all information contained herein is the sole
property of AIRBUS S.A.S. No intellectual property rights are
granted by the delivery of this document or the disclosure of
its content. This document shall not be reproduced or
disclosed to a third party without the express written consent
of AIRBUS S.A.S. This document and its content shall not be
used for any purpose other than that for which it is supplied.
AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
The statements made herein do not constitute an offer. They
are based on the mentioned assumptions and are expressed
in good faith. Where the supporting grounds for these
statements are not shown, AIRBUS S.A.S. will be pleased to
explain the basis thereof.
AN EADS JOINT COMPANY
WITH BAE SYSTEMS
Page 43
