International Aero Engines (IAE) aims to reduce maintenance costs for the out-of-production V2500-A1 turbofan by up to 25% by the end of 1998 through initiatives ranging from improved repair techniques and use of advanced materials to new part-exchange schemes and shorter turn-around times.
"We've identified a broad range of targets," says IAE president and chief executive Barry Eccleston who adds that the cost-cutting study started in late 1996. "We've begun introducing some of the improvements and have achieved 8% of that 25% target," he says.
As part of the offensive, IAE has set up a V2500 repair council made up of multi-function teams from IAE, Pratt & Whitney and Rolls-Royce. The council is supported by an advisory group of airlines and repair shops. Better maintenance practices and improved communications between the overhaul companies and IAE forms part of attempts to reduce "hot-end" turnaround times to 45 days and a full overhaul to 60 days. At present, times for a full overhaul are between 65 and 72 days, but this already reflects a 24% improvement seen in the second half of 1996. The company is also continuing a price freeze for some life-limited -A1 parts and fan blades.
The cost-cutting effort, aimed at supporting some 300 initial -A1 engines now in service, is running in parallel with the introduction of an improvement package called the "Phoenix kit". Named after the Arizona headquarters of America West Airlines, for which the improvement was originally started, the kit will "-put a lot of hot end technology from the -A5 engine into the -A1", explains Eccleston. The resulting enhancement will boost hot-day performance, improve reliability and increase part life, hopes IAE.
The kit will concentrate mainly on materials, manufacturing and sealing technology developed for the higher thrust -A5, rather than entailing the direct use of -A5 parts. "If we find out it works on the turbine, we may try the same thing on the compressor," says Eccleston. "Some of the modifications exist already, some are in development and there are others that require more development," he adds.
IAE has a $13 billion orderbook from 70 customers with 290 V2500-powered aircraft in service. The highest-time V2500 has amassed more than 27,500h, while the highest-cycle engine has built up more than 10,500 flights.
Source: Flight International
