GEnx MRO Network evolves as production accelerates
The worldwide network of GEnx engine overhaul facilities is evolving to meet increased customer demand resulting from an accelerated build rate.
The GEnx engine family continues to set records as the fastest-selling engine in GE Aviation
history, with more than 1,500 engines already on order. Plans are in place to boost the GEnx
build rate by 50% this year, making nearly 300 new engines available for delivery annually.
And as production of the GEnx engine accelerates to meet customer demand, the network of GEnx
overhaul facilities has continued to take shape as well.
GE Aviation recently announced a GE-Branded Services Agreement (GBSA) with Air France-KLM for the
Maintenance, Repair and Overhaul (MRO) of the GEnx-1B. Also announced was a new joint venture
with Evergreen Aviation Technologies (EGAT) named GE Evergreen Engine Services, which will
provide MRO services for both the GEnx-1B and GEnx-2B powerplants.
to watch the GE and Evergreen joint venture announcement.
“Of course, the focus has been on building a next-generation MRO network for GEnx that is highly
responsive to customer needs,” says Kevin McAllister, president and CEO of GE Aviation, Services.
“These new agreements underscore our commitment to an MRO network that offers customers a choice
of facilities and geographies.”
With the new agreements, Air France-KLM and GE Evergreen Engines Services join a network that
includes GE Aviation overhaul facilities in Prestwick, Scotland and Petropolis, Brazil. An
additional GEnx MRO network shop, Abu Dhabi Aircraft Technologies (ADAT), received FAA and UAE
General Civil Aviation Authority approval for quick-turn operations late last year and ultimately
will overhaul both the GEnx-1B and GEnx-2B engine models.
The GEnx network of overhaul shops also includes Air India, which has a GBSA for GEnx-1B engines.
CFM International customer flydubai recently became the 100th airline to join the TRUEngine
program, qualifying all of its CFM56-7B engines.
A young airline, flydubai launched just five years ago and already operates a fleet of 32
CFM56-7B-powered Boeing Next-Generation 737 aircraft.
flydubai celebrated another milestone this past April with the achievement of 500,000 engine
flight hours with its CFM56-7B fleet.
“CFM engines provide us with the reliability and efficiency that is a key component of our
operations,” says Ghaith Al Ghaith, flydubai CEO. “We are looking forward to our next half a
million engine flight hours with CFM engines and to enlarging our fleet.”
The airline is already in growth mode. Last November, flydubai announced an order of up to 200
LEAP-1B engines to power Boeing 737 MAX aircraft, and also ordered 22 additional CFM 56-7BE
engines to power Boeing 737-800 aircraft.
In 2013, GE Aviation, Services created what’s now known as the Mature Fleet team, a group charged
with developing and implementing innovative products and services tailored to operators with
aircraft engines that are approaching the end of their service life. That team has been
travelling around the world, meeting with regional operators of smaller fleets who may not have
worked closely with GE before.
One-on-one customer meetings and mini-symposium events have taken place in Moscow, Jakarta and
Tokyo, and more activities are planned in the coming months in the Middle East/Africa and Eastern
“Our goal is to establish relationships with these operators, and most importantly, to listen to
them so we can better understand their needs,” says Marty Fritsch, director of mature fleet
strategy for Services.
“The operators we’re reaching out to don’t have as many technical and engineering resources,”
Fritsch adds. “We can provide specialized technical support, bringing our resources to them, in
an up-close-and-personal manner they can appreciate and benefit from.”
Airline operators and MRO shop leaders attending these meetings are presented with an overview of
GE’s services portfolio, focusing on specific products and services tailored to mature fleets,
such as engine exchange programs, “green time” leases, purchase/leasebacks and the new Firm Fixed
Price Plus (FFP+) arrangements.
A team from GE Aviation demonstrates a non-destructive test on a GE90 engine performed by a
Google Glass-enabled crew. This prototype presents an opportunity that exists right around the
corner and promises to yield incredible efficiencies in maintenance.
As CFM International marks its 40th anniversary year, the company has more cause for celebration:
In April, CFM was named the 2013 Boeing Propulsion Supplier of the Year.
The award, which recognizes exceptional performance and contributions to Boeing’s success during
2013, is based on meeting or exceeding quality, on-time delivery, post-delivery support and
affordability goals, while demonstrating the ability to anticipate and respond to changing
“We take great pride in our long relationship with Boeing and the fact that we have delivered
nearly 14,000 engines on time and on spec,” says Jean-Paul Ebanga, CFM president and CEO. “Our
commitment is to continue to deliver to those very high standards.”
CFM has delivered more than 13,650 CFM56 engines to Boeing since becoming the sole engine
supplier for the Boeing 737 aircraft. This unique sole-supplier relationship was extended in 2011
when Boeing chose CFM’s advanced LEAP-1B engine to power its new 737 MAX, scheduled to enter
service in 2017. Development of the LEAP-1B is on schedule, with testing set to begin this
GA Telesis recently signed a materials agreement with GE Aviation that provides CF6-80C2 engine
parts to GA Telesis Engine Services (GATES), its full-service engine overhaul and repair facility
based in Helsinki, Finland.
GE Aviation has been working with GA Telesis since the company’s founding in 2002.
Basil Papayoti, GATES’ president, says the newly signed agreement comprises a full service
material offering for CF6-80C2 engine overhauls. “Our strategy from the beginning has been
OEM-centric, and this relationship with GE complements our overall GATES material strategy.”
The GATES shop in Helsinki provides comprehensive commercial engine services, including overhaul
of GE CF6-80C2 and CFM International CFM56-5B/5C engines, plus repair and modification, with the
capacity to overhaul up to 200 engines annually.
Since signing two license agreements to become an independent GE TRUEngine authorized MRO
provider for both CF34 and CFM56 engines in 2013, StandardAero has completed 36 qualified
Engines submitted for qualification by GE have included:
22 CFM56 aircraft – owned by North American mainline airline customers
14 CF34 aircraft – owned by regional airline customers from around the world
StandardAero was the very first independent TRUEngine authorized MRO provider for CF34 engines
and the second for CFM56 engines.
Since entering service in 1995, the GE90 engine family has reached 40 million flight hours, with
more than 1,725 engines flying with 63 operators worldwide.
That number will continue to grow as record numbers of GE90-powered Boeing 777 aircraft are
delivered to customers. The engine achieved 20 million flight hours in 2010, but doubled that
number in just four years while retaining its 99.98% reliability rate.
Production levels for the GE90 rose from 180 engines in 2012 to 220 engines in 2013, with 230
scheduled for delivery in 2014. The engine backlog has grown to more than 600.
GE launches online database tool for TRUEngine qualification status