SHEREMETYEVO (SVO) ENGINE & APU OVERHAUL SHOP PROJECT
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Date Department name Company name SHEREMETYEVO (SVO) ENGINE & APU OVERHAUL SHOP PROJECT 30.09.2020 Engine & APU Shop S7 Technics Prepared by: A. Starkov
Transcript of SHEREMETYEVO (SVO) ENGINE & APU OVERHAUL SHOP PROJECT
Date Department name Company name
SHEREMETYEVO (SVO) ENGINE & APU OVERHAUL SHOP
PROJECT
30.09.2020 Engine & APU Shop S7 Technics
Prepared by: A. Starkov
S7 Technics structure
DME
CFM56 engine repair shop Vladivostok LMS
Irkutsk LMS
OVB MRV
CFM56 engine repair shop
Aircraft painting facility Training aviation center
Date Name of presentation
Current State 15.09.21 Engine & APU Shop
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Engine & APU
maintenance
directorate
Engine Shop DME Engine Shop MRV Sales, customer
support, engineering
250 sq.m
2 production lines
9 employees
>220 performed events
6 years of operation
900 sq.m
4 production lines
6 employees
>20 performed events
2 years of operation
6 employees
DME & MRV support
Customized solutions
Hospital (quick-turn)
repairs
On-wing maintenance
Sheremet’evo project
14600 sq.m
6 APU & 3 engine production lines
>100 production & engineering staff
>50 supporting staff
Since 2022
S7 Technics
(S7 Engineering)
Date Name of presentation
15.09.21 Engine & APU Shop
Engine Maintenance Shops CFM56-3;-5B;-7B Major Services
ON-WING & ON-SITE MAINTENANCE
Fan Disc Replacement
AGB / TGB Replacement
Lease Return Inspection
BSI
Re-Preservation
HOSPITAL (QUICK-TURN) SHOP VISITS
HPT Blades Replacement
LPT NGVs Stg.1 Replacement
HPT NGVs Replacement
HPC Top / Bottom Case Repairs
CC Replacement
State of the art Engine & Aircraft Maintenance Shops (DME, MRV) together with SR Technics
Industry leaders’ quality - zero incidents with released products
Date Name of presentation
History of SVO project 15.09.21 Engine & APU Shop
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S7 Technics
selected by
Honeywell for the
APU 131-9A, 9B as
Channel Partner
End 2018 Start 2019 Mid 2019 Aug 2020 Oct 2021 I-II q.2022
Decision for CFM56-
5B, 7B overhaul
shop set-up
Engine & APU
project were
combined to reduce
investments and
operational costs
Start of building
reconstruction
Start of
equipment
mounting
EASA & FAA
certification
Total investments - $50 M
Date Name of presentation
15.09.21
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Engine & APU Shop
Engines & APU Overhaul approvals & certification:
• Honeywell APU 131-9A;-9B, Overhaul – EASA & FAA I q. 2022
• CFM56-5B;-7B Overhaul – EASA & FAA II q. 2022
• Engine and APU Components Repairs – EASA & FAA II q. 2022
Joint lines for Engines & APU Overhaul Shops:
• Inspection Line
• Logistic Center & Main Store
• Piece-Parts Repair Lines
• Machining Line
• Cleaning Lines
• NDT Line
Engines and APU Overhaul Shops (14.600 sq.m) with built-in APU Test Cell with Max capacity:
• 100 APUs per year
• 42 Engines per year
New Engines & APU Overhaul Shops combined in one building in SVO
Basic concept
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15.09.21
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Engine & APU Shop Engines & APU Overhaul Shops Layout
Engines and APU Overhaul Shops equipped with new state of the art machines placed on 6S & Lean principles
Centralized services (Cleaning, Inspection, NDT, Machining) for both, Engines and APU Overhaul
Date Name of presentation
15.09.21
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Engine & APU Shop Engines & APU Overhaul Shops Layout
Centralized services (Cleaning, Inspection, NDT, Machining) for both, Engines and APU Overhaul
Engines and APU Overhaul Shops equipped with new state of the art machines placed on 6S & Lean principles
Date Name of presentation Our strategy 15.09.21 Engine & APU Shop
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1) Delivery of the product/service for the engine and APU repairs demandable by the customer (market):
a) Industry leaders’ quality level
b) Competitive pricing and repair time
2) Development of long term WIN-WIN partnership with customers and suppliers
3) Supporting of the Team and production culture
4) LEAN, CI & process approach
5) Continuous development and implementation of new products/repairs in-house
Date Name of presentation
Quality since early beginning 15.09.21
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Cooperate with industry leaders & OEMs
• Honeywell - Channel partner
• CFM International - Parts & equipment
• Zeiss - Coordinate measuring machines
• SCHENCK - Balancing equipment
• DANOBAT - Grinding machines
• ATG - NDT line
Engine & APU Shop
• PJSC "UEC-Saturn“ - CFM56-5B;-7B Test Cell
• Safran Aircraft Engines - Test Cell equipment & correlation
• Safran Aero Boosters - Test Cell equipment
• MDS Aero - Test Cell upgrade
• FinnSonic - Engine & APU part/bearing cleaning line
• KOVOFINIŠ - Engine & APU parts cleaning line
First repairs will be done on S7 Technics’ own Engines
and APUs
Development of own ERP Engine & APU repair system
with mistakes prevention algorithms
Date Name of presentation
Challenge - People 15.09.21
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Working with industry leaders consultants
Engine & APU Shop
Hiring of engineering and shop floor experienced staff
with valid licenses
Hiring of Russian experienced specialists:
• Assy/disassy
• Testing, balancing
• Grinding, milling, drilling, turning
• Welding, painting and etc.
Development of the own PART 145, 147 training school
focused on Engine & APU operations
Internal training of SVO project personnel started from 2019
External training of SVO project personnel at OEM and
MRO leaders
Date Name of presentation
Challenge - Cost 15.09.21
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LABOR:
• Our model expectation is 20-30% less than in EU
• Maximizing of using CFM56 and 131-9A, 9B joint
lines
Engine & APU Shop
IN-HOUSE PIECE-PART REPAIRS DEVELOPMENT:
• Simple piece-part repairs to be done in SVO
• Complex piece-part repairs to be done together
with Russian companies which already have
competence and equipment
COST
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Challenge - Cost 15.09.21
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Engine & APU Shop
PARTS SUPPLY/EXTERNAL REPAIR:
• Work with engine & APU teardown companies
• Own stock with competitively priced used
serviceable material
• Competitive contracts with Engine & APU parts
repair OEM and MRO
• Focused material supply approach for each
Customer’s engine
COST
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Challenge - Delivery 15.09.21
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THE FOLLOWING IDEAS ARE BEING
IMPLEMENTED TO MAKE OUR PRODUCT
COMPETITIVE:
• Spare APU support – 4 ea in place now
• Spare Engine support – 2 ea in procurement
• Dedicated Logistics Team focused on parts
supply and turnover
• Sufficient parts stock level
Engine & APU Shop
TAT
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Challenge – Customs & VAT 15.09.21
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CUSTOMS QUESTIONS:
• Location which is close to SVO customs terminal
• Dedicated company at S7 Group - S7 Cargo
which is experienced and focused on customs
questions
Engine & APU Shop
VAT:
• Russian customers: zero VAT rate for supplied
material in case the special conditions in
contract are agreed
• Foreign customers: free for the whole invoice
Date Name of presentation
Challenge – Engine & APU testing 15.09.21
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APU Test Cell:
• Developed together with Honeywell
and at the final stage of installation
at SVO
Engine & APU Shop
Engine Test Cell:
• Under development together with ODK-
Saturn in Rybinsk (modification of Engine
Cell which was initially manufactured with
CFM56 testing capability)
Investments
Cost
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15.09.21
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Engine & APU Shop Again, our message
We are here to support our customers with demandable and competitive
service and product
We are open to work with all companies which will help us to make
our service and product better
We are constantly looking for High Tech and implement the best
solutions, such as:
Movable coordinate inspection machine
3D Laser surface scanners
Paperless technologies
Process engineering tools and more…
Continuous improvement and fighting with losses are our key principles
Date Name of presentation
Enter name of presentation
Thanks for your attention!
15.09.21
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