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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

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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

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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


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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

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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

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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
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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

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