Tag Archives: #oem

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Boeing announces additional quality inspections for 737 MAX planes

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The additional inspections come after the US Federal Aviation Administration said the 737 MAX should remain grounded.

Boeing has said it will add further quality inspections for the 737 MAX planes after a mid-air blowout of a cabin panel in an Alaska Airlines MAX 9 earlier this month, the head of its commercial planes division said.

In a letter to the global planemaker’s employees on Monday, Stan Deal, president of Boeing Commercial Airplanes, said the company will also deploy a team to supplier Spirit AeroSystems – which makes and installs the plug door involved in the incident – to check and approve Spirit’s work on the plugs before fuselages are sent to Boeing’s production facilities in Washington state in the US.

Boeing’s quality inspections announcement comes after the US Federal Aviation Administration (FAA) said on Friday that all 737 MAX 9 planes should remain grounded until Boeing provides further data following the near-catastrophic Alaska Airlines incident.

“For the safety of American travellers the FAA will keep the Boeing 737-9 MAX grounded until extensive inspection and maintenance is conducted and data from inspections is reviewed,” the FAA said in a statement.

Only after 40 planes are inspected will the agency review the results and determine whether safety is adequate to allow the MAX 9s to resume flying, the FAA said.

Alaska Airlines also said it was grounding its fleet of 737-9 aircraft for the same reasons.

Deal highlighted that the actions laid out in his letter are separate from the FAA’s ongoing investigation, but said that he planned to increase oversight of MAX production.

He said that in addition to the door plug inspections, Boeing teams will also conduct checks at 50 other points in Spirit AeroSystems’ production process.

Both Boeing and Spirit AeroSystems will also open their 737 production facilities to airline customers for carriers to provide their own inspections.

Boeing will hold sessions for employees on quality management, and bring in an outside party to conduct an independent assessment of its production process, Deal said.

“Everything we do must conform to the requirements in our QMS (quality management system),” Deal said.

“Anything less is unacceptable. It is through this standard that we must operate to provide our customers and their passengers complete confidence in Boeing airplanes.”

Boeing 737 MAX jets have been grounded worldwide in the past. In October 2018 they were grounded for almost two years after a crash in Indonesia killed 189 people, and another in Ethiopia five months later, which killed 157 people.

The aircraft was cleared to fly again after Boeing revamped its automated flight-control system that had activated erroneously in both crashes.


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Broken Supply Chain Hobbles Offshore S-92 Operators

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Aircraft’s dispatch reliability plummets as safety concerns rise

Supply-chain woes continue to adversely impact offshore helicopter operators, according to a notice recently issued by the International Association of Oil & Gas Producers’ (IOGP) aviation subcommittee (ASC). In a recent IOGP ASC safety notice to members, the organization branded the situation as “serious and deteriorating,” saying it presented “significant safety and operational risks.”

While the problems were particularly acute with regard to the Sikorsky S-92, with 86 percent of its fleet flying offshore energy, the ASC said the situation pervaded the entire industry. But the S-92, with its unique capacity to carry 19 passengers and service deepwater clients, drew the majority of the ASC’s attention based on operator surveys.

Data from the three largest civil S-92 operators—Bristow, CHC, and PHI, which together account for 61 percent of the fleet—revealed that 20 aircraft (13 percent of the fleet) are AOG while waiting for replacement main gearboxes. Three other operators reported another 11 S-92s are also AOG.

The overall AOG number is likely to double by the end of 2024 given Sikorsky’s low aircraft production rates—it delivered four S-92s in 2022. One operator reported that S-92 AOG days at the parts level increased from 214 in 2022 to 3,009 year-to-date.

Overall fleet dispatch reliability now hovers at 80 percent, as opposed to the industry average of 96 percent. The situation has triggered a variety of adverse maintenance practices, according to the ASC, including parts cannibalization, up by 50 percent to 106 percent, with more than 50 parts being taken from an aircraft entering maintenance “not uncommon.”

Maintenance extension requests to the OEM have increased by an average of 850 percent year-to-date. The time to complete a 1,500-hour inspection has increased by 75 percent (to 75 days), requiring 25 percent more manpower, and triggered a 57 percent increase in overtime.

The ASC concluded that the climate created the “potential and conditions for a serious safety event that is clearly growing unless action is taken.” Operators are forced into contracts that apply “punitive financial penalties for not meeting aircraft availability targets.”

According to the ASC, such provisions “will not improve availability, but will worsen the operators’ position further and potentially add further stress and risk to their maintenance departments.” It predicted that S-92 parts availability “has the potential to deteriorate further in the coming 12 months, leading to further reductions in aircraft availability.”

IOGP reiterated operator “resilience strategies” suggested earlier in the year, including raising stakeholder awareness and transparency, temporary sharing of contracted aircraft assets, and not punitively adding to operational risks via contract penalty clauses.

The ASC concluded that “effective local action and engagement between individual clients and contracted operators is essential if the safety risks are to be mitigated and our normal very high levels of safety performance maintained.”

Sikorsky president Paul Lemmo said the OEM was working diligently to resolve supply chain issues, significantly increasing main gearbox production and assisting its own suppliers with resolving bottlenecks. He partially attributed the issue to a post-Covid surge in S-92 flying hours, which increased by a fifth.

In a statement provided to AIN, Lemmo said the company is taking various actions to address the “unprecedented” S-92 spares situation, in part driven by a “22 percent increase in S-92 aircraft flight hours over the last three years. This increased utilization has added to the fleet operating hours but also created more pressure on parts required.”

“Sikorsky experts have provided S-92 suppliers technical and operational support so they can accelerate delivery of parts,” he added. The company “has been assisting S-92 suppliers throughout all tiers of the supply chain to source specialty metals, components, and other raw material.”

Lemmo said these efforts were beginning to produce results, noting that “we have increased main gearbox output by 40 percent in 2023 compared to 2022. We have delivered 31 year-to-date and project providing 40 in 2023 versus 28 delivered in 2022.” He said Sikorsky “will continue these efforts for as long as it takes to accelerate delivery of the parts our customers need.”

His comments built on remarks made by Sikorsky executives speaking at Heli-Expo earlier this year. Leon Silva, Sikorsky’s executive v-p of global, commercial, and military systems, admitted that ongoing supply chain problems had dragged down S-92 fleet utilization rates and dispatch reliability percentages “into the high eighties.”

He said the company “continues to work diligently on the supply chain” and had established what amounts to an emergency center at Sikorsky’s Trumbull, Connecticut facility to work with suppliers to resolve issues.

Aside from ongoing supply chain woes, Sikorsky’s commitment to the civil market remains suspect after the company was acquired by defense contractor Lockheed Martin in 2015. It has discontinued production of the S-76 rather than manufacture it with a federally-mandated crash-resistant fuel system.

Earlier this year, Sikorsky announced it was shelving the S-92B program and moving the anticipated certification date of its A+ upgrade for the helicopter into 2025, some three years later than originally planned. As a result, deliveries of A+ kits ordered today will not happen until 2026.

Several helicopters in the installed fleet of more than 300 S-92s have nearly reached their 30,000-hour life limit, but Sikorsky has no plans to extend it. Though the company continues to accept orders for the $40 million S-92, it cannot deliver one for at least two to three years, it said.


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Boeing Opens New Engineering and Technology Center In Brazil

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Boeing not just opened a new engineering and technology center in Brazil, but is working in partnership with Embraer to develop opportunities for SAF.

Boeing has opened its 15th global engineering site in Brazil. The center, based in São José dos Campos (SP), where the company began operations in 2014, will employ about 500 engineers and focus on sustainable aviation fuel (SAF) development.

Focus on Sustainable Aviation Fuel (SAF)

Boeing’s new Engineering and Technology Center has a primary focus of working with the State University of Campinas (Unicamp) to develop the third phase of the SAFMaps database. The database aims to understand the feasibility of the most promising inputs for sustainable aviation fuel (SAF) production in specific areas in Brazil. Boeing believes that Brazil can be vital in SAF production and is actively engaged in mapping agricultural opportunities for such via SAFMaps.

Boeing has also invested $2 million in initiatives that maximize social, economic, and environmental benefits for communities involved in developing raw materials for SAF. Brazil is one of the world’s leading sugar cane producers, a process that leaves behind straw and bagasse that cannot be used in food production but is optimal for biofuels.


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OEMs, Experts Exude Market Caution

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Manufacturers and leading rotorcraft valuation analysts expect the markets for both new and used civil helicopters to remain tight in 2023, squeezed by a triumvirate of pressures including inventory, inflation, and supply chain constraints.

While the civil market has mostly returned to pre-covid normal in terms of overall new helicopter sales and/or flight hours, price increases have placed increasing pressure on the already constrained preowned market. Meaningful forecasting in this environment, clouded by continuing economic uncertainty, is difficult, so much so that, for the first time in memory, Honeywell will not issue its turbine helicopter sales forecast at this year’s Helicopter Association International (HAI) Heli-Expo.

“[The helicopter market is] actually kind of a muddy picture,” said Jason Zilberbrand, president of aircraft valuation and consultancy Vref. “You know, it’s really difficult I think for people to figure out what’s going on, what they should do.” 

Jason Kmiecik, president of HelValues, concurs. “It is very difficult for anybody to say how 2023 is going to pan out,” he noted.

For the OEMs already reporting 2022 civil sales results, the trend appears to indicate more of the same, with perhaps small increases in production, but nowhere near enough to take pressure off the used market.  For 2022, Airbus Helicopters said it maintained its 52 percent share of the civil and para-public helicopter market in 2022 with 374 orders and 344 deliveries. Customer fleet hours, meanwhile, returned to pre-pandemic 2019 levels. Demand for the company’s turbine singles and light twins again led the way, collectively accounting for 342 orders, while demand for Airbus’s super-medium and intermediate helicopters, the H175 and H160, remained weak, drawing orders for just eight and 12 examples, respectively. 

“Our orders came from 203 customers in 48 countries, underlining the importance of our global network, as well as showing that in uncertain times, the role of helicopters is more essential than ever,” said Airbus Helicopters CEO Bruno Even. “[2022] was a year in which Airbus Helicopters solidified its recovery, in a context of instability with the war in Ukraine and a fragile supply chain.”

Bell Textron’s civil deliveries surged, but largely on the popularity of the high-production, low-margin Bell 505 light single. Overall, for both military and civil sales, Bell’s revenues dropped 4.9 percent from its performance in 2021, to $3.1 billion, while the segment reported a profit of $282 million. Bell said it expects modest growth in 2023 revenues—to about $3.3 billion—with comparable profitability. Bell finished 2022 with a backlog of $4.8 billion and delivered 176 civil helicopters, up from 156 in 2021. The totals included 83 Model 505s and 49 Model 407 singles, as well as 32 light-twin 429s. Deliveries of 505s posted the largest gain, increasing from 63 in 2021. For the period, deliveries of Bell 412s more than doubled, from seven to 15.

Both Airbus and Bell deliveries benefitted from the strength in the singles market, where “government agencies and municipalities are buying this stuff like Tic Tacs,” said Zilberbrand. Demand for both new and used single-engine turbine helicopters remains strong and supply is tight, according to market consultancy Aero Asset. It reported that the preowned singles market remained tight for most of 2022 worldwide, with some signs of loosening in North America during most of the year and in Europe during the fourth quarter. Sales for those models fell 12 percent in 2022 compared with 2021, according to Aero Asset. For the year, 212 units sold for a collective $387 million—down 15 percent by value from 2021.

VIP singles accounted for 60 percent of all transactions in 2022 while the supply of helicopters configured for emergency medical services remains at an all-time low. The number of utility helicopters for sale dropped 30 percent year-over-year. The supply of popular models remains tight, with just five months’ supply of the Airbus AS350B3/H125, Bell 407/GX/P/I, and Airbus EC130B4/H130 remaining at 2022 trade levels. Leonardo’s AW119, while ranked last, still showed a strong absorption rate of 10 months. 

“North American buyers accounted for nearly 60 percent of all single-engine transactions in 2022 while retail transactions in Europe fell 40 percent year-over-year,” said Aero Asset v-p of market research Valerie Pereira. “Inventory for sale plummeted 40 percent year-over-year, but rose in the fourth quarter and actually tripled in North America between the second and last quarters of 2022.”

But that inventory doesn’t stay on the market long, said HeliValues’ Kmiecik. More than 90 percent of the adjustments made in HeliValues’ Official Helicopter Blue Book from the Q4 2022 pricing review have recently increased. “The supply of in-demand aircraft will continue to diminish,” he said. “Some of what’s remaining on the market are aircraft that buyers have picked through and have passed on already. We’re starting to see a lot of emails from brokers looking for off-market aircraft because there’s more demand than supply on certain models.”

On the singles side, Kmiecik sees hot demand for Airbus AStars, Bell 407s and 206L-3s and L-4s, and newer MD 500 series aircraft while owners increasingly part out older aircraft. The light twin market is also very active for almost everything from the Airbus EC135 and EC145 models.  For medium twins, low-time Sikorsky S-76C+ and C++ models are finding homes in the VIP market; however, from a broader perspective, demand for S-76 models has diminished as they leave the offshore energy sector.

In the intermediate twin space, although the price of used Leonardo AW139s has dropped slightly in the last six months, the demand for leasing has increased. “Lease rates are going up faster than the [sales] values are dropping,” said Kmiecik. “The 139 is still one of the most also popular aircraft because it has proven itself to be a very reliable aircraft. Everybody loves it, they love flying in it, they love flying it, they love working on it.”

Leasing activity also is increasing on the heavy Airbus EC225LP and the Sikorsky S-92A, driving down supply and stimulating an eventual price increase, according to Kmiecik. “We are finally starting to see prices rise for the first time in years for the heavy class of helicopters,” he said, adding that recent transactions in the third and fourth quarters of 2022 drove up valuations on both the EC225LP and S-92A. EC225LP sales involved the utility or search and rescue sector, and S-92A sales remained in the offshore energy transport sector. Offshore’s increasing sole reliance on the S-92A as its main heavy twin-engine helicopter could pave the way for the Bell 525 as a second-source aircraft, particularly in the North Sea, depending on its eventual sales price and timing of its final certification, he said.

The likelihood that OEMs will significantly boost production to alleviate scarcity across all categories remains low, according to the experts. “I think they’re [the OEMs] strapped for resources,” said Zilberbrand, who doesn’t see supply and prices getting back to normal until 2024 at the earliest. “I think a lot of folks just didn’t come back after Covid and it’s going to reduce capacity. They can’t get stuff up fast enough and the stuff that they’re getting out is having more issues post-delivery.”

Kmiecik thinks OEMs will remain cautious about raising production in the face of economic uncertainty. “Given that behavior, odds are the used market will remain tight for newer and current production models,” he explained.

Longer-term, Zilberbrand thinks the market for turbine singles will likely erode in the face of eVTOLs. “While currently used turbine singles are worth their weight in gold from an operational standpoint, they’re getting really expensive to fix,” he noted. “We’re going to get to this point where [eVTOLs] are going to be forced on us. Insurance premiums are not getting any cheaper and a lot of stuff’s getting past the [maintenance] point of no return.”