Air France Industries-KLM E&M Advances Parts Repair Capabilities

Air France Industries-KLM E&M Expands In-House Repair Capabilities Amid Supply Chain Challenges

Addressing Supply Chain Disruptions and Fleet Groundings

At Le Bourget, Air France Industries-KLM Engineering & Maintenance (AFI KLM E&M) is intensifying efforts to develop internal repair capabilities in response to persistent delays from engine and aircraft equipment suppliers. The ongoing global supply chain disruptions have compelled the maintenance, repair, and overhaul (MRO) specialist to increasingly rely on in-house repairs to maintain operational readiness for both its own fleet and those of its customers.

A pressing example of these challenges is evident in Air France’s Airbus A220 fleet, where nine out of 43 aircraft remain grounded due to issues with Pratt & Whitney GTF engines. Specifically, failures involving combustors and bearing No. 4 have led to significant operational setbacks. Géry Mortreux, Air France’s executive vice president for engineering and maintenance, highlighted the severity of the problem, noting that oil leaks from bearing No. 4 can necessitate engine removal after only a few hundred flight hours. He emphasized that this issue is expected to persist as Pratt & Whitney has yet to deliver a permanent fix.

Strategic Enhancements in Maintenance and Repair Operations

To mitigate these operational risks, AFI KLM E&M is implementing advanced vibration measurement and analysis techniques to better predict engine removals and optimize maintenance scheduling. The company is also adopting Pratt & Whitney’s recommended changes in oil types to address the bearing issues. In parallel, AFI KLM E&M is investing heavily in expanding its MRO infrastructure. This month, the company inaugurated Leap-1A engine test cells at its Paris and Amsterdam facilities, with plans to introduce Leap-1B test cells later in the summer. On the CFM Leap turbofan engine alone, AFI KLM E&M has developed 200 distinct repair procedures. Additionally, the company has introduced 49 additive-manufactured replacement parts for cabin components, underscoring its commitment to innovation in repair technologies.

Anne Brachet, AFI KLM E&M’s executive vice president, expressed growing frustration with supplier delays during the Paris Air Show on June 16. She called for greater cooperation from suppliers in developing parts repair capabilities, citing a recent complaint filed against Woodward for alleged anti-competitive practices as a catalyst for some progress. Brachet contrasted the current 50 to 60-day delays with previous Lean Six-Sigma initiatives, where even a one-day reduction in turnaround time was considered a significant achievement.

Navigating a Competitive and Evolving MRO Landscape

AFI KLM E&M’s expansion of repair capabilities occurs amid increasing competition and scrutiny within the European MRO market. Competitors such as SIA Engineering Company have recently secured substantial contracts, including a $1 billion agreement with Singapore Airlines, intensifying the race to provide advanced repair solutions. The industry trend toward extending aircraft lifespans is driving capacity expansions across Europe, raising questions about Air France-KLM’s ability to sustain its competitive position. Rivals are responding with strategic initiatives, including KLM’s introduction of new routes and the delivery of Boeing 787-10 aircraft aimed at strengthening operations in North America.

As AFI KLM E&M adapts to ongoing supply chain pressures, its proactive enhancement of internal repair capabilities reflects the broader challenges and opportunities shaping the global MRO sector. While a return to pre-pandemic operational norms remains uncertain, these efforts are critical to mitigating disruptions and maintaining fleet reliability in a rapidly evolving market.