Introduction
When a major European airline faced an aircraft-on-ground (AOG) situation due to a damaged Boeing 787 Trent 1000 inlet following a ramp accident, it turned to ST Engineering MRAS & ST Solutions for their global reach and unmatched expertise in Nacelle Maintenance, Repair, and Overhaul (MRO) services. The remote Caribbean location and extensive inlet damage posed significant challenges, requiring a team with global capabilities to manage complex logistics and intricate repairs, ensuring the aircraft’s swift return to service.
Project Background
A ground handling incident damaged the structural integrity of a Boeing 787 powered by a Trent 1000 engine, grounding the aircraft. The airline required an OEM-licensed MRO with immediate access to exchange units and proven expertise in restoring damaged inlets under challenging conditions.
Challenges
The AOG situation presented several critical challenges:
- The aircraft was grounded in the Caribbean, with no nearby exchange unit or Nacelle MRO facility.
- On-wing repair was not feasible due to the extent of the damage, increasing downtime risk.
- Although ST Engineering had a Trent 1000 exchange inlet ready, no available freighters could transport such a large unit directly to the remote location.
- The damaged inlet arrived at MRAS during the peak holiday season, with many team members on leave.
- Some materials required for the repair were discontinued, potentially delaying the restoration process.
Innovative Solutions
MRAS & ST Solutions addressed each challenge with strategic, innovative solutions:
- ST Solutions collaborated with the airline to provide a lease exchange unit and coordinated logistics for repairs in North America.
- MRAS expedited the reception and repair process, minimizing costs and downtime for the airline.
- ST Solutions secured an Antonov 124 aircraft to transport the large inlet, overcoming logistical barriers.
- MRAS dedicated teams worked through the holiday season, including weekends, to accelerate the repair timeline.
- The team sourced alternative materials and adapted repair methods to address the issue of discontinued parts without compromising quality or safety.