The news made headlines: MTU Aero Engines secured an 18 percent stake in the A320neo engine and took on 30 percent of final assembly on all PW1100G‑JM Geared Turbofan engines. Almost five years later, the green light has been given for assembly of the first PW1100G‑JM production engines at MTU’s site in Munich. In August of this year, the U.S. Federal Aviation Administration (FAA) certified MTU for assembly and tests. However, MTU’s responsibility for its product does not end with delivery of the first engine to customers. The company has also thoroughly prepared for providing airlines with in-service engine support.

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December 2010: All systems go for newcomer
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December 2010: All systems go for newcomer

Airbus announces the overhaul of its successful A320 family. Innovative and efficient engines characterize the A320neo (new engine option). The PW1100G‑JM Geared Turbofan engine is developed in partnership by Pratt & Whitney (P&W), MTU Aero Engines and Japanese Aero Engines Corporation (JAEC). It consumes up to 16 percent less fuel, flies more quietly, reduces operating costs, and emits less CO2 and NOx.

September 28, 2011: Final assembly for 30 percent of engines
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September 28, 2011: Final assembly for 30 percent of engines

MTU secures a program stake of 18 percent and takes on a third of final assembly work plus tests for all PW1100G‑JM engines. Never before has the company been responsible for the complete final assembly of a commercial engine with such high unit volumes. As well as the low-pressure turbine, which is assembled at MTU’s Polish site in Rzeszów, and the first four stages of the high-pressure compressor, the company is also contributing brush seals to the program. In addition, it manufactures part of the high-pressure compressor with a nickel blisk design.

February 10, 2015: Conversion of test beds
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February 10, 2015: Conversion of test beds

At MTU’s site in Munich, Development Test Bed III is converted so that it can be used as a production test bed for the PW1100G‑JM. The goal is to shorten the set-up and tear-down times. The monitoring station, for example, is equipped with a complete second inspection system, which is designated exclusively for the PW1100G-JM production acceptance runs. A test bed for the PW1100G‑JM is also installed at MTU’s site in Hannover, where a portion of the engines are to be maintained in future.

June 16, 2015: MTU becomes part of MRO network
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June 16, 2015: MTU becomes part of MRO network

Go-ahead for the worldwide MRO network: together with its partners P&W and JAEC, MTU signs an agreement that seals their cooperation in the maintenance of the PW1100G‑JM in the context of International Aero Engines LLC. In the future, MTU Maintenance will also maintain the engine. The first engine for training purposes arrives at MTU Maintenance in Hannover on March 4, 2016.

August 3, 2015: Gearing up for final assembly
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August 3, 2015: Gearing up for final assembly

The final assembly line developed by MTU is characterized by a high degree of flexibility. Given the high rate of production, the work is carried out at six assembly stations using a system resembling a flow line, where the engine is successively put together from pre-assembled components and modules. This way, several engines in various build stages can be assembled and completed concurrently. The ramp-up of PW1100G‑JM assembly is expected to be complete by the end of 2018, and around 100 employees will be working in a six-day and multiple shift pattern. A total of about 400 people will then be working in the production of the PW1100G‑JM program at MTU.

August 11, 2016: FAA grants approval for assembly and testing
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August 11, 2016: FAA grants approval for assembly and testing

The U.S. Federal Aviation Administration (FAA) certifies MTU to assemble and test the PW1100G‑JM. This makes MTU one of only three manufacturing sites worldwide that are certified for the A320neo engine. Previously, the German Federal Office of Civil Aviation (LBA) had already certified MTU Maintenance Hannover to maintain the PW1100G‑JM. This approval is also valid for the European Aviation Safety Agency (EASA) and is recognized by the FAA and the Canadian TCCA.

Autumn 2016: Delivery of first PW1100G‑JM fully assembled at MTU
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Autumn 2016: Delivery of first PW1100G‑JM fully assembled at MTU

The first production engine for a A320neo completely assembled at MTU will be shipped to Airbus in Toulouse, France.

Outlook
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Outlook

MTU will be delivering further PW1100G-JM production engines in the second half of 2016. Their first port of call is the Airbus plants in Hamburg or Toulouse, where the casing is put on the engines. Next, the engine is sent to the respective final assembly line. 20 working days are planned for final assembly of each A320neo engine following the ramp-up.