Locations: Lufthansa Technik in Frankfurt

The Maintenance Hub
4.000 staff service more than 700 aircraft in flight operations

Lufthansa Technik's base at the Frankfurt airport buzzes around the clock, 365 days a year: Frankfurt is Lufthansa Technik's central maintenance location. Lufthansa's aircraft and those of more than 100 other customers are serviced here in three shifts. Starting with pre-flight inspections for every flight, the weekly and monthly maintenance work is performed here as part of ongoing flight operations. Much of the work is done during the nighttime hours. During this time, the errors or defects found during the day are corrected so that by the next morning the aircraft is technically perfect and ready to fly.

In Frankfurt, a total of about 4,000 Lufthansa Technik personnel, of these 200 engineers in a variety of specialty fields, ensure that technical services are performed without a hitch. By and large, aircraft electronics technicians and aircraft mechanics work here. In Frankfurt, about 250 apprentices are participating in trainings at the moment. 

Accommodation even for the largest aircraft

The focal points of the Lufthansa Technik maintenance center at Frankfurt airport are the four gigantic hangars with a floor space of altogether 90,000 square meters. The largest of them, the A380 hangar in the South of Frankfurt airport, covers an area of 25,000 square meters in the current phase of construction. It is as big as four football fields and has room for three Airbus A380 or three Boeing 747 jumbo jets at the same time. The second phase of construction, to be completed by 2015, will provide the capacity for simultaneous maintenance work on six A380s, thus becoming the largest aircraft hangar in Europe.

In addition to the maintenance hangars, office space and workshops are located on the 436,000 square meters total space of Lufthansa Technik's Frankfurt base. About 200 staff in the workshops cares about the perfect condition of engines, landing gears and brakes, wheels and seats as well as rescue and safety systems. An engine test facility allows jet engine testing after maintenance with reduced noise impact. The logistics center of Lufthansa Technik Logistik Services at the Frankfurt airport ensures fast materials supply.

The Frankfurt maintenance base currently services more than 700 aircraft, including about 260 aircraft belonging to Deutsche Lufthansa. Lufthansa Technik provides Total Technical Support TTS® for a third of these customers. TTS® fully integrates technical support for these customers – including the most complicated repair work and maintenance, up to stocking of spare parts, engineering services, logistics and technical training. Corresponding sub-programs are also offered in the engine, landing gear and component areas with Total Engine Support TES®, Total Material Operations TMO® and Total Component Support TCS®. 

Constant monitoring of all aircraft in the Maintenance Control Center

Lufthansa Technik's Maintenance Control Center monitors the technical status of the serviced aircraft worldwide, both on the ground and in the air, and controls necessary procedures. The structural statuses of the aircraft and the due dates for required and planned modifications and tasks are constantly tracked and monitored. Everything that is part of fleet management is controlled here around the clock and around the world.

At the Lufthansa Traffic Control Center in Frankfurt, staff compile all required data on the Lufthansa fleet operating worldwide using what is known as the ACARS system (Aircraft Communications Addressing and Reporting System), a data network using HF radio and satellites, and analyze it. Potential faults are immediately detected. An example of this is Engine Condition Monitoring or ECM, a system which Lufthansa played a substantial role in developing. The core of ECM is the maintenance computer at the Lufthansa base of operations in Frankfurt. This computer receives Lufthansa aircraft engine data from all over the world and runs comparisons to determine any possible faults. In this way staff gets to know about the upcoming work even before they welcome the aircraft for maintenance.