A400 Sustainment

MDSS0021PR11
28 September 2011
MRO Military Europe Conference
A400M Sustainment
Overview of planned A400M In-Service Support
Presented by Stephan St h MIEGEL Head of A400M Customer Services Airbus Military
DRAFT
MDSS0018PR11
May 2011
Content
1. 2. 3. 4. 4 5.
A400M Programme Overview Main Support Design Characteristics A400M Maintenance Concept A400M M i t Maintenance S Support S l ti t Solutions A400M MRO Network
AIRBUS Military. All rights reserved. Confidential and proprietary document.
1. A400M Programme Overview g
The Most Versatile High Capacity Airlifter

Self Protection Optimized for tactical operations in hostile environments Air-to-Air Refuelling Fast-jets and helicopters
Aerial Delivery Airdrop of paratroops and load at high and low altitudes
Tactical T/O & Landing Operations from unprepared airfield Autonomous ground operation
Able to operate in the most varied environments aried en ironments
Specifications
42.4 m 139 ft 14.7 m 48 ft
45.1 m 148 ft
Maximum Take-Off Weight Maximum Landing Weight Maximum Payload Maximum Fuel Weight Maximum Range (Ferry) Cruise S C i Speed Range dR
141 000 kg 122 000 kg 37 000 kg 50 500 kg 4700 nm Mach 0.68 0.72 M h 0 68 0 72
310 850 lb 268 960 lb 81 570 lb 111 330 lb 8700 km
Customer Base
8 Countries 8 Operators 174 Aircraft
Belgium 7
France 50
Germany Luxembourg Malaysia 53 1 4
Spain 27
Turkey United Kingdom 10 22
A400M Programme Schedule Overview

2011 2011
Series Series Productiono oduct o oduct Productio n Launch Launch
2012 2012
2013 2016 2016 2017 2013 2014 2014 2015 2015
2018 2017
2019 2018
IOC IOC TC TC
First First Delivery Delivery
SOC1.5 SOC1.5
SOC2 SOC2
SOC2.5 SOC2.5
SOC3 SOC3
SOC1 SOC1
MSN7 MSN6 MSN7 MSN6 FF FF FF FF
Series Production
7 TU 1st Delivery
st FR 1st Delivery FR 1 Delivery
46 UK 1 st Delivery
18 22
SP 1st Delivery
TU
1st
Delivery
9
16
UK
1st
SP 1st Delivery
133
Delivery
BE(LU) 1 st Delivery
DE 1 Delivery
DE 1st Delivery st MY 1st Delivery
BE(LU) 1st Delivery

Programme target Programme target Internal Milestone Internal Milestone
MY 1st Delivery
Page 7
2. Main Support Design Characteristics pp g
A400M Reliability
Airbus A320 Family Fleet Operational Reliability (%)
100
A320
98.7
98
A319 A321 Entry into service

96
94
Airbus A320 Family Fleet totals more than 31 million flight hours 18 million take-offs
A400M Reliability based on A320 fleet experience
92
1990
1995
2000
2010
A400M - Maintenance Programme
Maintenance Intervals
Line (A-Check) Base Base (C-check) (C-check) Depot (D-Check)
Maintenance Downtime in 12 years
EFFECT
60 Days 150 Days 24 Months 72 Months
~ 84 Days
and resulting in significant reductions in Life Cycle Costs compared with current air transport aircraft.
Deployed A400M Operations

Maintenance-Free Operating Periods
Maintenance-Free Operating Period design concept minimises corrective maintenance in the field, ensuring: g 15 days Maintenance-Free Operating Period during autonomous operation with minimum of servicing, supported by a Short Deployment Kit stowed on board, can be accomplished by Load-Master
150 days / 500FH without Scheduled Maintenance during autonomous operation supported by Ground Kit and Long Deployment Kit containing ground equipment, spares and standard tools for corrective maintenance.
3. A400M Maintenance Concept p
A400M Maintenance Concept

Maintenance Concept - Principles
Assumed Operation Environment (Location) At MOB

It is the base of operation of the A/C located in the Nations home state. Equipped with operational and maintenance facilities necessary AGE and personnel to at facilities,
least Maintenance Level 1, and logistic means.
At DOB
It is a temporary base outside MOB, where logistic capabilities of MOB are not available
for i f immediate use b t equipped t receive and support a certain number of A/C . di t but i d to i d t t i b f A/Cs
At FOS
It is an operating strip without any personnel, operating facilities and AGE. Therefore the A/C should be operated autonomously p y
These are the assumed common conditions, when Nation support solution is known the specific solution established will be adapted based on these principles.

Maintenance Concept - Principles
A.Maintenance Levels.(Detailed in the following slides) A Levels

Level 1 Maintenance (ML1) Level 2 Maintenance (ML2) Level 3 Maintenance (ML3)
B.Maintenance Activities Categorisation.

Preventive Maintenance. Scheduled Maintenance. Predictive Maintenance. Corrective Maintenance. Deferred Maintenance. Immediate Corrective Actions Specific Maintenance. Activities to recover the A/C form the occurrence of abnormal events ( ABDR, Hard
Landing, Bird Strike,etc)
Maintenance Level 1 ML1 Ground Handling and Servicing. Flight Servicing. Corrective, Preventive and Specific Maintenance that will be performed in the Flight Line.
Following conditions /situations are considered, among others, for ML1 :
ML1 maintenance activities will performed during short deployment -except preventive except maintenance (*) when A/C is operated autonomously. ML1 maintenance activities will be performed during long deployment -except preventive maintenance (*) when A/C is operated and supported at a DOB. ML1 maintenance activities will be performed at a MOB in appropriate hangar or at the apron. p pp p g p
Acquisition of this capability means availability of qualified personnel, means and facilities. Also necessary interfacing capabilities shall be considered. Separated considerations shall b d h ll be done f d l for deployed conditions. d diti
A400M Maintenance Concept.
Maintenance Level 2 ML2 Corrective, Preventive and Specific Maintenance that will be performed at a MOB or MRO. Tasks beyond the ones accomplished at ML1 to facilitate the return of the A/C to its operational condition.
Following conditions /situations are considered, among others, for ML2 :
During ML2 maintenance the A/C will be unavailable for flight. g g On A/C in a hangar at least properly equipped for ML2. Off A/C in specialized workshops. For major troubleshooting or specific maintenance by team(s) of specialists with appropriate means and tools in the operational area p With trained and qualified, specialised technicians with the required skills.

Maintenance Level 2 Short Description. (Contd) As a brief scoping of the ML2 activities following table could be used as a reference: activities,
ML2OnA/C(*)
CChecksandmultiples,excluding4Cand 8C,includingsystemsfunctionalchecksandstructural 8C i l di t f ti l h k d t t l visualinspections(ie.Zonal Program) Applicablepredictivemaintenance,asderivedfromthe A/Cstatus. CorrectiveMaintenanceanddeferredmaintenance(as Corrective Maintenance and deferred maintenance (as applicabletomaintenancevisit). ModificationsEmbodiment(SBEmbodiment) Reworksandrepairs(asapplicabletomaintenancelevel) .
ML2OffA/C
OffA/CLRUmaintenance,diagnosisandrepairby replacementofmajormodulesand/orSRUs. l t f j d l d/ SRU Modificationsembodiment(SBsembodiment) Enginedisassemblyandenginere work. Engine disassembly and engine rework ..
(*) Block Checks concept for scheduled maintenance is used as a reference for the description.
Maintenance Level 3 ML3 Corrective, Preventive and Specific Maintenance that will be performed at a MOB or MRO . Tasks beyond the ones accomplished at ML1 and ML2 that will be performed through the use of more extensive facilities, skills and materials to facilitate the return of the A/C to its operational condition. Following conditions /situations are considered, among others, for ML3 :
During ML3 maintenance the A/C will be unavailable for flight. g g On Nations appropriately equipped facilities or /and Airbus Military MRO or/and Airbus Militarys Service Providers. On Airbus Militarys Supplier repair facilities (OEM) With trained and qualified, specialised technicians with the required skills. q , p q

Maintenance Level 3 Short Description. (Contd) As a brief scoping of the ML3 activities following table could be used as a reference: activities,
ML3OnA/C(*)
Preventive4Cand8Cchecks,includingheavy structuralinspections(fatigue,corrosion,NDTs) t t li ti (f ti i NDT ) Applicablepredictivemaintenance,asderivedfromthe A/Cstatus. CorrectiveMaintenanceanddeferredmaintenance(as applicabletomaintenancevisit). applicable to maintenance visit) ModificationsEmbodiment(SBEmbodiment) Reworksandrepairs(asapplicabletomaintenancelevel) Removalofmainequipmentforoverhaulandrestoration. .
ML3OffA/C
OffA/CLRUandSRUmaintenance,diagnosisand repair. i Reworkandrepairofenginecomponents(inside modules) Manufacturingofdesignateditems. Designandmanufactureofparticularrepairs. ModificationEmbodiment
..
(*) Block Checks concept for scheduled maintenance is used as a reference for the description.
Maintenance Programme Framework. Maint. Maint Program Preventive Maintenance will be based in the Initial Maintenance Program (MRBR) and Certification derived scheduled requirements. During the life of the A/C these requirements will evolve with the design and in service experience acquired.
The current Interval Frameworks used for the assessment of the Scheduled Maintenance are as follows :
PfSS Minimum Limits Concept / Block A Check C Check Fatigue Corrosion C i Threshold /Interval 400FH /5 Months 15 Months 5000FC /2500FC 5Y /10Y PPH Framework Goals Concept UsageP.Targets CalendarTargets Fatigue Corrosion Threshold/Interval From500FHto From3Moto60Mo 5000FC/2500FC 6Y/12Y
4. A400M Maintenance Support Solutions Considerations (Approaches f In-Country S l ti (A h for I C t Solutions) )
ISS Services Approach

A400M Customer Services based on the discussions held with all the Nations in
preparation of the ISS Solutions has taken the initiative to develop an ISS services approach based on the following principles:
1. Provide first class support designed for military specific needs with the same quality
of customer services that has led Airbus to become a preferred supplier to the worlds airlines.
2. Keep the Global Approach concept: develop a common set of ISS services
applicable for all customers, even with ISS arrangements established on a Nationby-Nation basis, with the benefit of optimizing the overall ISS services development.
3. Recognize that ISS Services for each Nation must reflect differing operational
requirements, service performance levels, industrial solutions and schedules.
ISS Solutions Deployment and Implementation

Integration Concept /Modular approach
ISS Support Solutions (Performance Based Solution Concepts) ( p )
A400M ISS Airbus Milit tary
Tech. Information Services
Tech. Support Services
Material Support Services
Aircraft Maintenance & Repair Services
A400M Support Services
Training Services
Entry Into Service
Fleet Management & Operations
Supplier Support Services
Maintenance Support Solutions

Support Solutions Possible Scenarios
In Country There are many possible scenarios for the Maintenance solution for a National / In-Country Support solution in accordance with the expected Customer requirements and Airbus Military Needs.
In the following slides some of the most representative models currently being discussed by Airbus
Military with Nations are p y presented ( examples). (3 p )
24

Maintenance Levels Allocation MOB Op. O Operat. ML1 ML2 On ML2 ML2 Off ML3 On ML3 ML3 Off
Air Force
Air Force
Airbus Military OEM Princi ple AIM

Provide r(s)
Airbus Military (AIM) OEM

Principle
AIM MRO
Spec. Capabiliti es
MOB ML1 () Support(*) (AIM)
ML2 g Sharing (AIM)
Air Force M i t Maintenance Capabilities (MOB ML2 off)
The different allocation of the MLs responsibility has a direct impact on the model of solution to be used and in the feasibility of achievement of a defined Performance based concept by the service provider.

Core Approaches 1 : Maintenance Levels Allocation MOB Op. O Operat. ML1 ML2 On ML2 ML2 Off ML3 On ML3 ML3 Off
Air Force
Airbus Military (AIM) OEM AIM AIM MRO

Princi ple

Principle
Provid er(s)
MOB ML1 pp ( ) Support(*) (AIM)
Air Force
Maintenance Capabilities p (MOB ML2 off)
AIM MRO
Spec. Capabiliti es

Core Approaches 1 : Maintenance Levels Allocation MOB Op. O Operat. ML1 ML2 On ML2 ML2 Off ML3 On ML3 ML3 Off
Air Force
Airbus Military (AIM) OEM AIM AIM MRO

Princi ple

Principle
Provid er(s)
MOB ML1 pp ( ) Support(*) (AIM)
Airbus Military (AIM) Maintenance Capabilities (MOB ML2 off)
AIM MRO
Spec. Capabiliti es
4. A400M MRO Network
A400M MRO & Maintenance Services
28 Oct 2010
Airbus Military MRO Network Concept (1/6)

Needs of Development of MRO Network Concept.

Ensure worldwide support for Airbus Military Fleets. New Airbus Military Products / Platforms about EIS. (A400M, MRTTs) ( , ) Customers are in the move to concentrate in their Mission looking for a full support to the fleet (FISS/FSA) High Performance required by Customer in terms of quality, effectiveness and efficiency. Optimization of Investments, resources and increase of flexibility is mandatory. p , y y
Airbus Military MRO Network Goals To be Known as the most efficient Fleet Support entity worldwide Provide an efficient and a full integrated support to customer mission achieving mission, recognition of Airbus Military as a competitive provider of Maintenance Services for Airbus and non Airbus Military Platforms and Products Enhance Customer Satisfaction answering more diverse and extreme customer requirements i Increase capability of developing new Maintenance Services obtaining more efficiency and flexibility, being able of implement National tailored Service Solutions for Airbus Military Customers. Coordination and implementation of maximum synergies with Airbus network
29
28 Oct 2010

Airbus Military MRO Network Concept
Group of selected Maintenance Support and MRO Service Providers sustaining close support and cooperation with Airbus Military for the Services Business on regards Maintenance and Maintenance Support and fully coordinated with the Airbus MRO Network. Network
External and Internal MRO Services Providers will be included in the MRO Network by compliance of the established admission conditions. All Members of MRO network will be subject to a defined contractual scheme. Inside the MRO Network members, Airbus Military will identify a group of preferred /core Service Providers that will have, after the compliance of dedicated additional conditions, specific /additional allocation of works acting/used as core Airbus Military capabilities for Maintenance Services.
Capabilities Pool for supporting/sustain the Airbus Military Services Model.

A400M High Level Maintenance Services Model
A400M Customers
AIRBUS MRO Network
Custo mer 1
Custo mer 2
Custo mer 3
Custo mer n
MSG Mngmt.
MSG Engineering
MSG Global Programming
MSG National Del. (MSK) Feedback
Support Solution t Ope eration
Airbus Military MRO Network
Airbus Military 1
Joint Venture
TIER 1
XXX
XXX
30
(Knowledge / Performance)
Members under Airbus GTAs
Airbus Military Core MRO Network
AIRBUS MILITARY (Prime e)
A400M Programme (Management Level)
Airbus Military -Operative CoCs (Management Level and Core Operations / Fleet Knowledge)
28 Oct 2010

Airbus Military MRO Network Membership Adherence Conditions. Enabling Conditions for MRO Network Membership.
Compliance with Quality Standards (Baseline EASA-FAR 145 requirements), Airworthiness ( EASA FAR requirements) Baseline & Local) standards (See Annex 1) and Security regulations and requirements (baseline program and local) as required (See Annex 2) Acceptance of assessment / audit requirements of Airbus Military. (A1068 as guidelines) Able and willing to implement/support Airbus Military requirements on Operational, Organisational and IS/IT subjects. O i ti l d bj t Acceptance / Commitment to support Lessons Learnt Process and Benchmarking practices to support Performance Continuous Improvement . Accept the possibility of Airbus Military to manage the Global Workload.
Adherence Conditions for MRO Network Membership.

Able to accept the Enabling Conditions above. Commitment two (2) Airbus Military Platforms Models. Capable and willing to support Airbus Military for Maintenance , Repair and Embodiment
Services and in at least other (1) Maintenance Services Domain. Capable to support Airbus Military in FISS/FSA (PBH) Services and In-Country Support Solutions, if requested. Capable and willing to support Airbus Military for different Nations Military Customers.
31
28 Oct 2010

Airbus Military Core MRO Service Providers Additional Conditions.
Compliance of adherence conditions. Capable and committed to support Airbus Military in ALL Maintenance Services Domains as MRO on
request. request Capable and committed to support Airbus Military in FISS/FSA ( PBH) Services and In-Country Support Solutions (as main provider and on request). Capable and committed to support Airbus Military for ALL Different Nation Military Customers in the Region. quality, Region ( quality regulatory and Security requirements + specific customers requirements) requirements). Committed to implement/support Airbus Military requirements on Operational, Organisational and IS/IT subjects.
Airbus Military MRO Network Exclusions Exclusions.

Organisations providing only engineering services or logistic services or materiel management
services or AGE services or IS /IT tools for maintenance and/or technical data management .
32
28 Oct 2010

MRO Network Contractual Concept ( and growth to Support Solutions).
Annex Annex Purchase Agreement Annex
General Terms Agreements (GTAs)

Under this U d thi contractual f t t l frame work the general conditions f MRO k th l diti for Services shall be defined and shall be agreed with the MRO Service Provider entering into the Airbus Military MRO Network.
Note: Key to ensure an efficient use of this Airbus Military MRO Network is to define general Q-Requirements (e.g. based on EASA Part 145) acceptable by all Nations (or future A400M Customers)
General Terms Agreement
(G) (T) (A)
Quality Requirements q
Annexes
Purchase Agreement
(P) (A)
Project Spec. Requirements (eg. Work Package,)
Nation's MRO / Single Service Event

Specific requirements for Nation's MRO Solution defined
and agreed within a Purchase Agreement (PA) Single Service Event defined by the corresponding Work package, negotiated price, TAT and agreed by an Purchase Agreement (PA).
(for the specific Project)
33
28 Oct 2010

MRO Network Initial Deployment Targets (Internal). These targets are the ones to be obtained in a established period of
order to consider the MRO Network as an implemented concept. 60 Months ( 2010-2015) in
All MROs supporting/ performing Airbus Military FISS and In-Country Solutions to join the AM MRO
Network (as per defined schedule). Deployment and availability (on-time, on-quality) for the existing Airbus Military commitments for new fleets support as per contractual requirements(Basic Support for Airbus Military Commitments). Deployment of necessary Airbus Military organisation and processes to support Network. Initial Limited Number of Members Target 2011: 2 MROs (A400M requirement). Target 2015: 4/5 MROs (A400M requirement). Establish an effective operative way of working and solid contractual scheme. Homogeneous membership among selected MROs. Network Model and Processes adaptation among Airbus and Airbus Military needs.
Ensuring the coming platforms EIS and the ongoing offered In-Country / National solutions for : A400M Program EIS and OCCAR Customers contracting a National Support Solution. Airbus Military Offers for other Platforms. y
34
A400M Sustainment - Summary

The A400M offers the same high quality of ISS to military customers as expected by commercial airlines : Minimum Maintenance Downtime
Maximum Aircraft Mobility and Utilization Customized ISS Products and Services Maximum Availability + Low Life M i A il bilit L Lif Cycle Costs
A400M: the airlifter for the 21st Century
MDSS0018PR11
May 2011
2011 AIRBUS. All rights reserved. Confidential and proprietary document. This document and all information contained herein is the sole property of AIRBUS. 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. 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 will be pleased to explain the basis thereof. AIRBUS and AIRBUS MILITARY them logo, A300, A310, A318, A319, A320, A321, A330, A340, A350, A380, A400M, A330MRTT,C212,C295,CN235 are registered trademarks
List of abbreviations
A/C ABCM ACOC APU CF ATLN CPO CR CW CWB EBCU EVAC FAA FAL FT FTH FTO GRS HTP HQ ICP IFA JAA Aircraft Alternate Brake Control Manifold Air Cooled Oil Cooler Auxiliary Power Unit Center Fuselage Alternate Central Programme Office Change Request Calendar week Central Wing Box Emergency braking control unit Evacuation Federal Aviation Administration Final Assembly Line Flight Tests Flight Test Hours Flight Test Objectives Guide Restrain System Horizontal Tail Plane Handling Qualities Integrated Control Panel Integrated Fuselage Assembly Joint Ai J i t Airworthiness Authority thi A th it LG LS Mod MSN NBCM NF OTC OWB PAG PEPDC PTD RF R/I RTD RTO S&IT SS St T/O VSS V/UHF VTP WFF Landing Gear Lower Shells Modification Manufacturer Serial Number Normal Brake Control Manifold Nose Fuselage Operational Test Card Outer Wing Box Premium A t GMBH P i Aerotec Primary Electrical Power Distribution Center Paratroopers Door Rear Fuselage Removal/ Installation Remain to do Rejected Take Off Systems and Integration (Engineering Organization) Side Shells Station Take Off Stick Shaker Speed Very Ultra High Frequency Vertical Tail Plane Wing Fuselage F i i Wi F l Fairing

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MDSS0021PR11

MRO Military Europe Conference

AIRBUS Military. All rights reserved. Confidential and proprietary document.

1. A400M Programme Overview g

AIRBUS Military. All rights reserved. Confidential and proprietary document.

The Most Versatile High Capacity Airlifter

Able to operate in the most varied environments aried en ironments

AIRBUS Military. All rights reserved. Confidential and proprietary document.

42.4 m 139 ft 14.7 m 48 ft

310 850 lb 268 960 lb 81 570 lb 111 330 lb 8700 km

AIRBUS Military. All rights reserved. Confidential and proprietary document.

Germany Luxembourg Malaysia 53 1 4

Turkey United Kingdom 10 22

AIRBUS Military. All rights reserved. Confidential and proprietary document.

A400M Programme Schedule Overview

2013 2016 2016 2017 2013 2014 2014 2015 2015

First First Delivery Delivery

MSN7 MSN6 MSN7 MSN6 FF FF FF FF

st FR 1st Delivery FR 1 Delivery

DE 1st Delivery st MY 1st Delivery

BE(LU) 1st Delivery

2. Main Support Design Characteristics pp g

AIRBUS Military. All rights reserved. Confidential and proprietary document.

A319 A321 Entry into service

A400M Reliability based on A320 fleet experience

AIRBUS Military. All rights reserved. Confidential and proprietary document.

A400M - Maintenance Programme

Maintenance Downtime in 12 years

AIRBUS Military. All rights reserved. Confidential and proprietary document.

Deployed A400M Operations

AIRBUS Military. All rights reserved. Confidential and proprietary document.

3. A400M Maintenance Concept p

AIRBUS Military. All rights reserved. Confidential and proprietary document.

A400M Maintenance Concept

Assumed Operation Environment (Location) At MOB

AIRBUS Military. All rights reserved. Confidential and proprietary document.

A400M Maintenance Concept

A.Maintenance Levels.(Detailed in the following slides) A Levels

B.Maintenance Activities Categorisation.

AIRBUS Military. All rights reserved. Confidential and proprietary document.

A400M Maintenance Concept

Following conditions /situations are considered, among others, for ML1 :

AIRBUS Military. All rights reserved. Confidential and proprietary document.

A400M Maintenance Concept.

Following conditions /situations are considered, among others, for ML2 :

AIRBUS Military. All rights reserved. Confidential and proprietary document.

A400M Maintenance Concept.

AIRBUS Military. All rights reserved. Confidential and proprietary document.

A400M Maintenance Concept.

AIRBUS Military. All rights reserved. Confidential and proprietary document.

A400M Maintenance Concept.

AIRBUS Military. All rights reserved. Confidential and proprietary document.

A400M Maintenance Concept.

AIRBUS Military. All rights reserved. Confidential and proprietary document.

4. A400M Maintenance Support Solutions Considerations (Approaches f In-Country S l ti (A h for I C t Solutions) )

AIRBUS Military. All rights reserved. Confidential and proprietary document.

ISS Services Approach

AIRBUS Military. All rights reserved. Confidential and proprietary document.

ISS Solutions Deployment and Implementation

A400M ISS Airbus Milit tary

Tech. Information Services

Tech. Support Services

Material Support Services