A 380 Maintenance

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
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
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
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
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
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
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:
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
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
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
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
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
Crack growth
Glare
Fatigue Cycles
Page 14
Laser-Beam-Welded Fuselage Panels
Laser welding seam cross section
Damage-tolerance test specimen
Conventional repairs
Page 15
A380 CFRP Applications
CFRP centre wing box
Horizontal stabilizer
Rear pressure
bulkhead
Large CFRP structure demonstrator

Page 16
Maintainability & Reliability
Page 17
A380 Maintenance in Design

Design Process
Customer
CustomerExpectations
Expectations
==Requirements
Requirements
==Service
ServiceExperience
Experience
Customer
Customer
satisfaction
satisfaction
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
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
Removal Frequency
Task
MMEL
Time
Remove
Time
Replace
Time
Test
Total
Time
Maintenance Task Analysis
Page 20
Radome and Radar Antenna Installation
A380
A340
A320
External
access
5 meters
Page 21
Body Landing Gear Installation
Page 22
Water & Waste Tanks, Tailplane Trim Actuator and

APU Installation
Water tanks
Waste tanks
Max
Oxygen bottles
Standard
Page 23
Rear Fuselage, Tailplane Trim Actuator and APU

Installation
THS actuator installation
Rear Fuselage
APU removal
simulation
Page 24
Horizontal and Vertical Tailplanes
HTP accessibility
Elevator actuator removal

simulation
VTP layout
Page 25
Wing Access and Installations
Wing accessibility
AGU installation
Flight control actuator removal simulation

Page 26
e ts
arg
nT
sig
As
System
System
Components
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
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
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:

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
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
Airports and Facilities
Page 32
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
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
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

Nose-in Position
Page 36

15 m*
NOTE:
* MINIMUM
NECESSARY
DISTANCE TO
MOVE AWAY A
TRACTOR WITH A
TOW BAR
98 m
10 m
10 m
10 m
100 m

Nose-in Position
Page 37
5m
29.5 m

Tail-in Position
Page 38

100 m
10 m
10 m
10 m
93 m
10 m

Tail-in Position
Page 39
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
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
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.
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

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March 2003

A380 Maintenance in Design

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

The A380 Family: Flagship of the 21st Century

A380 - The Aircraft

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

The Case for Advanced Technology

Cash Operating Costs

Performance : fuel burn

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

Size effect & current AIRBUS technology

Cash Operating Costs

Advanced Technology - Systems

2E/2H Flight Controls

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

5000 psi Hydraulic

Onboard Maintenance System Concept

Control, reporting display,

Onboard Information Network

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

S/W and data

OMS Access from Portable Terminals :

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

Nose gear area Cargo holds

Main gear area

Tail cone (Internal)

Flight Controls / Hydraulics Architecture

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

4 fully independent systems

10% of maintenance cost

160 computer units

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

New concepts are needed.

IMA - Principles and Benefits

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

A380 Electrical Power Generation

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

Variable Frequency AC Generation

Compared with constant frequency generation:

A380 Advanced Technology - Structure

GLARE upper shell

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

CFRP Center Wing Box

GLARE Fuselage Upper Shells

A340 barrel fatigue test

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

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

A380 CFRP Applications

CFRP centre wing box

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

Large CFRP structure demonstrator

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

Maintainability & Reliability

A380 Maintenance in Design

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

Maintenance Task Analysis

Radome and Radar Antenna Installation

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.