November 3, 2022 - No. 40 In This Issue : Strategies for increasing speed, improving reliability, and reducing costs Smarter MRO : Why Robinson helicopters have such tall rotor masts? : United Launches Calibrate: Apprenticeship Program to Grow and Diversify Aircraft Technician Pipeline : Rocket maker Firefly Aerospace looks to raise up to $300 mln -sources : Ball Aerospace wins $176 million contract to build and operate 10 satellites for Space Development Agency : Aircraft Maintenance Company Breaks Ground on New Hangar at CVG : Porter Airlines building new aircraft maintenance base at YOW to support growing fleet : Construction Underway on New $5.4 Million Ground Engine Run Up Project at St. Louis Downtown Airport Strategies for increasing speed, improving reliability, and reducing costs Smarter MRO Few leading airlines and maintenance, repair and overhaul (MRO) companies have figured out how to exploit opportunities to reduce the cost of MRO operations. What do they know that their competitors don't? It's tougher than ever to perform MRO operations efficiently and effectively. From outside, material costs are rising. From inside, siloed processes, disparate systems, and data overload make it hard to coordinate the whole MRO process, from scheduling and forecasting to inventory management and replenishment. Only a few airframe, engine and component MRO companies have an approach that enables simplification, standardization, speed, and "do it right the first time" quality. But those that do are reducing total costs by 8-15 percent initially and achieving a sustainable competitive advantage with continuous improvement. Implementing the following five strategies can help MRO organizations in their efforts to become more efficient and effective. Achieve short and consistent turnaround time (TAT) using a combination of lean, Six Sigma, theory of constraints, and information: • Improve the design and planning of maintenance • Reduce inventory, while increasing service levels • Select the right MRO IT solution and extract value from that investment • Craft a fact-based outsourcing strategy See the link to this NASA/Hobbs article: Deloit: Strategies for increasing speed, improving reliability, and reducing costs Why Robinson helicopters have such tall rotor masts? (Photo Robinson R44. (Fedor Leukhin, Wikimedia (CC BY-SA 2.0)) By NODUM - 2022-10-27 A helicopter flies by and to a great surprise of your friends you immediately identify it as a Robinson. With confidence too, even if it is flying quite far away from you. And that’s because Robinson helicopters have a distinctive feature – a tall rotor mast. Robinson R44. (Fedor Leukhin, Wikimedia (CC BY-SA 2.0) A rotor mast is a platform, a column, which separates the fouselage of a helicopter and its main rotor. It’s hardly a technical term, but people do use it (we asked). Especially to describe helicopters that have low-mounted engines. Some details about Robinson helicopters Frank D. Robinson founded the Robinson Helicopter Company at the age of 43 in 1973. Prior to that, Robinson worked on a number of exciting helicopter projects at companies like Cessna, McCulloch, Kaman, Bell and Hughes. Robinson was often regarded as a tail rotor expert. He was a talented engineer and a real wizard when it came to helicopter aerodynamics. THe R22 is a popular choice for flight schools. (Ian Kirk, Wikimedia (CC BY 2.0) In his namesake company Robinson aimed to create an affordable, easy-to-operate and easy-to-maintain helicopter. He wished his aircraft to be a bit like a car – suitable for a variety of different tasks, not taking up too much space when parked and able to be repaired with relatively simple tools. Robinson’s first helicopter R22 took off for its maiden flight in 1975. As you may imagine, it was piloted by mr. Robinson himself. In 1979 the Robinson R22 went into series production and soon became the most popular two-seater helicopter in the world. The R22 is a very compact two-seat helicopter, perfectly suited for pilot training, personal recreational flights, work on large cattle farms and a wide variety of other tasks. It is 8.74 meters long and is equipped with a four-cylinder 92 kW Lycoming engine, mounted behind the cockpit. The diameter of the twin-blade rotor is 7.67 meters. Such dimensions allow the R22 to be transported on a car trailer without taking off its rotor – an experienced pilot can land his R22 directly on a trailer. This is one of the reasons why Robinson chose a two-bladed rather than a three-bladed rotor – it doesn’t have to be taken off or folded for transport. The R22 on a simple car trailer. (David Lippincott, Wikimedia (CC BY-SA 3.0) In 1990, a larger, more powerful and more comfortable version of the R22 came along, called R44. This 11.66 meter long Robinson seats 4 people and has a Lycoming 6 cylinder 183 kW engine that powers a 10 meter twin-bladed rotor. The Robinson R44 is one of the best-selling general aviation helicopters in the world. In 2007, an even more spacious Robinson model – the five-seater R66 – came off the ground. At 8.99 meters long, it is shorter than the R44 and has the same diameter main rotor. The biggest mechanical difference is that the R66 has a turboshaft engine instead of a piston engine. Robinson R66 – the largest helicopter of the range. (Waerfelu, Wikimedia (CC BY 3.0) Robinson helicopters are very popular and easily recognized by that interesting column on which the main rotor is situated. Robinson helicopters and the tall rotor mast Robinson’s first model, the R22, was designed as a cheap and easy-to-maintain helicopter. Thus, the manufacturer had to look for ways to simplify the construction of the aircraft and its controls. Mi-2 and Robinson R44. Mi-2’s engines are on top of the fouselage, while Robinson’s powerplant is at the rear. (Dmitry Terekhov, Wikimedia (CC BY-SA 2.0) The R22 has a simple welded steel tube frame covered with an aluminum, fiberglass and plexiglass skin. Its cabin is quite cramped, which is understandable, having in mind how compact this helicopter is. Robinson had to find some creative ways to make this work. Instead of the two separate cyclic sticks (joysticks, sort of) that would normally be between each pilot’s knees, Robinson helicopters have what’s known as a T-Bar – one teetering stick, mounted between the pilots, which splits into two handles. The larger Robinson R44 and R66 use hydraulic controls, while the R22 has a mechanical control system. By the way, an interesting fact – the lack of hydraulics on the R22 is actually an advantage for pilot schools. Young pilots get used to more sensitive handling characteristics, which require more attention, more care and smoother movements. At the same time, of course, the lack of a hydraulic system reduces the cost and mechanical complexity of the R22. However, pilots often say that the Robinson R22 is surprisingly tricky to control due to its light weight, lack of hydraulics and stabilization systems. Once you master the R22, other helicopters seem quite easy. Cockpit of the Robinson R22. You can see the T-Bar cyclic control. (NJR ZA, Wikimedia (CC BY 3.0) Robinson helicopters use two-bladed main rotors, while many other small helicopters use a three-bladed rotor design. A two-bladed rotor is technically cheaper and makes transporting the helicopter a lot easier. The Robinson rotor uses a teetering hinge mechanism – as one blade rises, the other goes down. This mechanism, reminiscent of a seesaw, is relatively simple (remember – they tried to cust the costs down), but the helicopter is not as maneuverable as it could be with a multi-hinge main rotor. Because of the teetering hinge mechanism the tips of the Robinson rotor blades have a greater amplitude of vertical movement, which is one of the reasons why the manufacturer had to raise the main rotor up. If we add all of this together, the teetering main rotor, low-mounted engine and small fuselage result in a larger gap under the rotor. And that is why Robinson helicopters have a tall rotor mast. There are other helicopters that have teetering main rotors, but they do not have such distinctive rotor masts like Robinsons. This is because many such helicopters are larger and more powerful and have their engines above the cockpit. For example, the Bell 206 has a two-bladed teetering rotor, which is also mounted quite high, but this visual tower is not created because the engine compartment is right under the rotor. If the engine of the Bell 206 was behind the cockpit, that section between the fuselage and the rotor would also be a tall mast. Bell 206. (Tony Hisgett, Wikimedia (CC BY 2.0) The tall main rotor mast has some advantages. It reduces the risk of the rotor blades colliding with obstacles. Robinson R22 is 2.72 meters high. In comparison, another popular two-seater Guimbal Cabri G2 is 2.37 meters tall. Those extra centimeters make it less likely that the tip of the rotor blades will catch on a bush or a fence. After all, the R22 was developed as a very versatile helicopter, suitable for pilot schools (students sometimes do not land quite straight and stable) and for farmers. The Australians use their R22 helicopters to herd cattle, expertly maneuvering between trees, fences, buildings and cows. Obviously, this advantage is less important for the larger R44 and R66, but it is still nice to have that teetering main rotor away from the ground. Of course, there are downsides to Robinson’s tall rotor mast design. Pilots sometimes say that Robinson helicopters can be caught by the pendulum effect, when the helicopter starts swinging and becomes difficult to control. Why Robinson helicopters have such tall rotor masts? United Launches Calibrate: Apprenticeship Program to Grow and Diversify Aircraft Technician Pipeline United Calibrate United Airlines announced Nov. 2 the launch of Calibrate, an in-house apprenticeship program that will help grow and diversify its pipeline of Aircraft Maintenance Technicians (AMTs). The inaugural class starts next week in Houston as the airline plans to train more than 1,000 people at about a dozen locations by 2026, with the goal of at least half being women or people of color. Calibrate is a 36-month program in which participants "earn and learn" getting paid while completing the full-time certification and training process. Since participants get paid while they train, they forgo the expense of going to a technical school – which can cost up to $50,000. United will start accepting external applications in early 2023. "Calibrate is a great opportunity for people who are interested in pursuing a rewarding career as an aircraft technician but don't have the resources or support they need to attend traditional technical schools or colleges," said Rodney Luetzen, United's Vice President of Line Maintenance. "This program will provide life-changing opportunities, help to diversify our workforce and give us access to an even bigger pool of talented, qualified, motivated people." The apprenticeship program, a joint effort between United, the International Brotherhood of Teamsters (IBT) and the Federal Aviation Administration, accelerates the path toward becoming a United AMT while also growing the airline's ranks of Ground Service Equipment mechanics and Facility Technicians. United expects the second Calibrate apprentice cohort to start in early 2023, also in Houston, and will then expand to more than a dozen locations including San Francisco and Orlando. The program will focus on helping apprentices gain the skills and knowledge required to test for and obtain their A&P Certificate, including hands-on and classroom training. Additionally, participants will be mentored by United's world-class technicians, building relationships and acquiring union seniority as they progress through the program. "The Airline Division has done an excellent job of promoting the Aviation Maintenance Technician craft," said Sean O'Brien, General President of the International Brotherhood of Teamsters. "This program creates the diversity that the Teamsters are known for and will provide great jobs for not only our current Teamster members, but also the next generation." United has about 9,000 highly trained and certified aircraft maintenance technicians globally with combined wages and benefits totaling more than $140,000 at the top of their pay scale. These are highly skilled jobs – the airline actively recruits from trade schools and the military – and United provides an onramp to this career through entry-level positions. Several United leaders started out as aircraft mechanics, including the airline's current Vice President of Line Maintenance. Currently, United has Base Maintenance AMTs, Line Maintenance AMTs, and shop-based AMTs, inspectors and other licensed professionals at 50 locations worldwide. The airline plans to open new line maintenance stations in Raleigh-Durham, N.C. later this year and in Fort Myers-Southwest, FL and Nashville, Tenn. in early 2023. https://www.aviationpros.com/education-training/news/21285812/united-launches-calibrate-apprenticeship-program-to-grow-and-diversify-aircraft-technician-pipeline Rocket maker Firefly Aerospace looks to raise up to $300 mln -sources FireFly Aerospace, the U.S. rocket builder that reached orbit in space this month, joining the likes of SpaceX and Rocket Lab, is seeking up to $300 million in a private fundraising round, according to people familiar with the matter. Firefly has yet to specify the valuation it is seeking, the sources said. The space company was valued at more than $1 billion when private equity firm AE Industrial Partners became its controlling shareholder in March. The Cedar Park, Texas-based company aims to complete the funding round by the end of the year, said the sources, who spoke anonymously because the matter was confidential. Firefly Chief Executive Officer Bill Weber told Reuters in an interview this month the company was raising funds but did not provide details. A FireFly spokesperson declined to comment when asked about the fundraising, as did a spokesperson for AE Industrial Partners. Weber said in the interview that fresh funding would help the company complete construction of manufacturing facilities for its Alpha rocket in Cape Canaveral, Florida, and accelerate development of a bigger rocket the company plans to build with Northrop Grumman Corp (NOC.N). Firefly's Alpha rocket reached orbit for the first time on Oct. 1. It is among a handful of U.S. space companies vying to launch small satellites into space. Firefly is already taking orders of roughly $15 million per launch for its 95 foot-tall Alpha rocket, offering governments and satellite companies a medium-sized ride to space. SpaceX's bigger Falcon 9 rocket costs $62 million and Rocket Lab's smaller Electron rocket costs $7 million. Firefly was rescued from bankruptcy in 2017 by Ukrainian-born entrepreneur Max Polyakov's Noosphere Ventures. U.S. national security concerns forced Noosphere to sell its majority stake in FireFfly to AE Industrial Partners, ending a months-long crisis that prevented the company from launching its rocket. Investments in space companies with capital-intensive projects have fallen in the third quarter, as decades-high inflation and rapidly rising interest rates force investors to focus on companies with viable products. Venture capital investments in space companies fell 44% from a year earlier, according to a quarterly report from VC firm Space Capital. https://www.reuters.com/markets/us/rocket-maker-firefly-aerospace-looks-raise-up-300-mln-sources-2022-10-31/ Ball Aerospace wins $176 million contract to build and operate 10 satellites for Space Development Agency Ball Aerospace developed an ESPA-class standard interface vehicle for the U.S. Air Force Space Test Program. Credit: Ball Aerospace The satellites, projected to launch in 2024 and 2025, are part of the agency’s NExT program WASHINGTON — The Space Development Agency announced Oct. 4 it awarded Ball Aerospace a $176 million contract to build, operate and secure launch services for 10 experimental satellites. The satellites, projected to launch in 2024 and 2025, are part of the agency’s NExT program, designed to demonstrate low-latency data transport and beyond line-of-sight command and control. NExT is short for National Defense Space Architecture Experimental Testbed. Under the agreement, Ball Aerospace will manufacture the satellites, integrate government-furnished payloads, procure rideshare launches, provide the ground control system and operate the satellites from its facilities in Colorado. The NExT experiments are in support of the Space Development Agency’s constellations of data transport and missile-tracking satellites in low Earth orbit that the agency will deploy over the next few years. Once the NExT payloads are in orbit, SDA will assess their utility before they are incorporated into operational systems. SDA has selected the payloads but did not disclose specifics on what missions they will perform. “NExT is an exciting program that has a lot of tie-in with our mission partners and will help to advance future tranches of the national defense space architecture,” said Derek Tournear, SDA director. “Ball Aerospace is excited to work with SDA on the upcoming NExT program,” said Dave Kaufman, president of Ball Aerospace. The company for decades has built satellites for the Defense Department, NASA and theNational Oceanic and Atmospheric Administration. https://spacenews.com/ball-aerospace-wins-176-million-contract-to-build-10-satellites-for-space-development-agency/ Aircraft Maintenance Company Breaks Ground on New Hangar at CVG F&E Aircraft Maintenance's expansion will create nearly 250 full-time positions. (Hebron, Ky.) – A groundbreaking was held Tuesday at the site of FEAM AERO’s new three-bay hanger at Cincinnati/Northern Kentucky International Airport. Governor Andy Beshear joined local officials from Boone County and leaders from F&E Aircraft Maintenance (FEAM AERO) to celebrate the $40.2 million investment that was announced in March. The company’s new hangar at CVG will create nearly 250 full-time positions, including at least 124 Kentucky-resident jobs. The 150,000-square-foot facility will house Boeing 767 aircraft. Jobs created at the new hangar will include aircraft mechanics and technicians, ground support equipment mechanics, administrative personnel and management positions. “The momentum we are seeing across the commonwealth is not possible without existing companies continuing to invest and to believe in our communities,” Gov. Beshear said. “This expansion will provide a huge boost to the Northern Kentucky economy and provide incredible job opportunities for the region. I am thrilled to be here today celebrating this groundbreaking and am excited to see FEAM AERO continue to succeed here in Kentucky.” Leaders at the company, which currently employs 300 people at CVG, noted the new operation will provide ample aircraft maintenance capacity and resources for its growing airline customer base in support of cargo operations such as Amazon and DHL. Boone County Judge/Executive Gary Moore congratulated FEAM AERO on the groundbreaking for its second maintenance, repair and overhaul hangar facility in Northern Kentucky. “Air cargo continues to grow at a significant rate at CVG. In September, CVG reached a new landed weight record with nearly 1.2 billion pounds of aircraft landing at the airport,” said Judge Moore. “As freight volume at CVG continues to increase, FEAM AERO’s services to our two air hubs are critical in keeping the global supply chain moving.” Construction is expected to be completed by the end of 2023. https://www.eaglecountryonline.com/news/local-news/aircraft-maintenance-company-breaks-ground-on-new-hangar-at-cvg/ Porter Airlines building new aircraft maintenance base at YOW to support growing fleet Porter Aviation Holdings Inc., parent company of Porter Airlines, and the Ottawa International Airport Authority (OIAA) are investing over $65 million dollars in YOW’s future. Porter is in the process of building two aircraft hangars, over approximately 150,000 sq. ft., to maintain its growing fleet, featuring the new Embraer E195-E2 and existing De Havilland Dash 8-400. OIAA is constructing a new taxiway and related infrastructure to support the hangar development, as well as future opportunities in this section of the airport. The hangars are being built in two phases: phase one is scheduled for completion by the end of 2023, and phase two in the first quarter of 2024. YOW will be a primary maintenance base for the E195-E2, with Porter hiring 200 local team members, including 160 Aircraft Maintenance Engineers (AMEs). Other positions include shop technicians, stores clerks and administrative support. These represent highly-skilled roles that will be based in the city. Additionally, 150 construction jobs will be supported during the building process. Porter is in the process of building two aircraft hangars, over approximately 150,000 sq. ft., to maintain its growing fleet, featuring the new Embraer E195-E2 and existing De Havilland Dash 8-400. Porter Image “Ottawa has been a critical location for Porter throughout our history and the multi-million dollar facilities we’re building to maintain aircraft here is only the latest example of our desire to meaningfully invest in Canada’s Capital Region,” said Michael Deluce, president and CEO, Porter Airlines. “We anticipate our presence in Ottawa will grow in the coming years, supported by the maintenance base and future aircraft deliveries that give us the ability to consider new routes.” The airline has up to 100 E195-E2s on order, including 50 firm commitments and 50 purchase rights. The current Dash 8-400 fleet includes 29 aircraft. OIAA is currently constructing Taxiway Romeo in the airport’s north field area. The $15 million taxiway represents the first airside expansion project in the AAIO’s 20-year history. It will accommodate Porter’s hangar development plans, as well as federal government needs, and possibly other commercial aviation-related development. “YOW was Porter’s first destination when they launched in 2006. We believe it’s very fitting that YOW is an important part of their expansion plans and their future, and look forward to the benefits that come with such an extensive maintenance operation,” said Mark Laroche, OIAA President and CEO. “We are particularly pleased that sustainability factors so prominently in Porter’s plans, which fits perfectly with YOW’s ambitious commitment to net-zero operations (Scope 1 and 2 GHGs) by 2040 or sooner.” In addition to daily line maintenance performing scheduled tasks on the E195-E2 and Dash 8-400, the Ottawa facility will have the following capabilities: • Indoor parking for up to eight aircraft • Structures shop for repairs and modifications of metal and composite aircraft parts • Component repair shop to repair and overhaul cabin equipment • Wheel shop to repair and overhaul main and nose wheels • Battery shop to repair and overhaul aircraft main and emergency batteries • Porter’s imminent introduction of the E195-E2 to its fleet provides the ability to operate throughout North America, including to the west coast, southern U.S., Mexico and the Caribbean. The aircraft will initially be deployed from Toronto Pearson International Airport, with Ottawa, Halifax and Montreal seeing new service with the E195-E2 over time. The first of up to 100 new aircraft are scheduled to be delivered to Porter by the end of 2022, and initial routes will be announced leading up to the first aircraft deliveries. The hangars are designed by Scott Associates Architects, with PCL Construction acting as Construction Manager, together with Span Construction & Engineering. Sustainability The hangars are designed and will be built with sustainability in mind, including the following features: • A predominantly electric fleet of vehicles that will be used for towing and servicing aircraft, as well as ground support. • Design criteria that exceeds current energy efficiency standards, including for insulation, heating, ventilation, air conditioning, lighting and electrical power systems. • The hangars are clad in Insulated Metal Panels (IMPs). • Superior to the standard metal siding usually found on aircraft hangars. • The anticipated lifespan is greater than 60 years. • Constructed with approximately 35% recycled steel and, at end of life, can in turn be recycled. • Constructed from materials that have a low embodied carbon footprint – 28% lower than conventional tilt-up assemblies. • The structure spans 85.6 m (280 ft.). This substantial clear span has been achieved using prefabricated trusses. The steel tonnage to span ratio is approximately 30% less than conventional rolled steel section beams. • Fire protection involves dual systems. In addition to a conventional sprinkler system, the aircraft parking and maintenance areas are equipped with an instantaneous foam deluge system. In the event of a fire, the multi-layers of fire suppression do not rely on a conventional single source of water supply. The city hydrant system is fully supplemented by an onsite underground water storage tank containing approximately 1.2 million litres of water. Stormwater management has become an important factor in both commercial and industrial developments. Instead of rain/stormwater flowing directly to and overstressing existing city mains, two 173,000-litre underground tanks are being installed at the Porter hangars to capture excess. https://skiesmag.com/press-releases/porter-airlines-building-new-aircraft-maintenance-base-at-yow-to-support-growing-fleet/ Construction Underway on New $5.4 Million Ground Engine Run Up Project at St. Louis Downtown Airport Construction is underway at St. Louis Downtown Airport on a new Ground Engine Run-Up and Compass Calibration Pad that will benefit aircraft maintenance providers and support high-tech aerospace manufacturing jobs. St. Louis Downtown Airport is the busiest general aviation airport in Illinois outside of Chicago, and was named 2020 Reliever Airport of the Year by the Illinois Department of Transportation’s Division of Aeronautics. The airport is located on one thousand acres in Illinois just across the Mississippi River from downtown St. Louis in Cahokia Heights and Sauget. The project will improve production safety, reliability and efficiency, boost airport businesses and increase global competitiveness for Southwestern Illinois and the State of Illinois. The airport secured $5 million in state funding through the $45 billion Rebuild Illinois Capital Infrastructure Plan Governor J.B. Pritzker signed into law in 2019. The Ground Engine Run-Up and Compass Calibration Pad project includes new airfield pavement with jet blast deflectors to perform aircraft maintenance tests requiring the operation of an engine at high power on the ground for several minutes generating elevated noise levels. The aircraft maintenance tenants that will utilize this new facility currently conduct more 500 high-power engine run-up tests a year. They have indicated that the existing locations for such tests are no longer sufficient given the powerful engines of today’s modern aircraft, which running at full throttle can cause blast damage more than 1,600 feet away. The new Engine Run-Up will be located 1,850 feet from other parked aircraft and isolated from airport operations. The area will reduce aircraft engine run-up noise by more than 50% and will accommodate the airport’s largest aircraft. “The Ground Engine Run-Up project is necessary to support current and future operations of our key tenants at the airport. It is part of our overall airport infrastructure implementation plan that supports 25 airport tenant manufacturing and aviation operations, ensures tenant leasehold longevity and supports future airport business growth,” said Mary Lamie, Executive Vice President of Multi Modal Enterprises at Bi-State Development. Bi-State Development owns and operates St. Louis Downtown Airport. Baxmeyer Construction in Waterloo, Illinois, was awarded the contract for the $5.4 million project, with St. Louis Downtown Airport covering the cost above the $5 million IDOT grant. The new Engine Run-Up and Compass Calibration Pad is expected to be completed in less than a year. “We appreciate the investment by the State of Illinois for this important project and are confident that it will enable us to continue to grow the annual economic impact of the airport,” said St. Louis Downtown Airport Director Sandra Shore. St. Louis Downtown Airport continues to be a significant contributor to the local and state economies. According to the most recent study conducted by the Illinois Department of Transportation (IDOT), St. Louis Downtown Airport contributed more than $422 million in economic impact for the region in 2019, including factors such as on-airport activity and visitor spending. It remains a major employer in the St. Louis area, providing 1,522 full-time and part-time jobs to the region. St. Louis Downtown Airport is owned and operated by Bi-State Development. https://www.aviationpros.com/airports/press-release/21285808/construction-underway-on-new-54-million-ground-engine-run-up-project-at-st-louis-downtown-airport Curt Lewis