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.
Why MRAS?
ST Engineering – Solutions & MRAS stood out as the ideal partner for this complex project due to several key factors:
- With over 95 years of aerospace industry leadership and a team of 1,000+ skilled professionals, MRAS offers an unparalleled MRO experience.
- As one of the few MROs globally licensed by the OEM, ST Engineering – MRAS & ST Solutions has access to global exchange units and the tools, expertise, and access to 787 OEM manuals & spare parts necessary to complete the repair.
- Our strategic locations near major transportation hubs and ownership and access to exchange assets allow us to respond quickly and minimize the airline’s downtime.
Conclusion
MRAS’s global MRO network, access to a global pool of exchange units, and commitment to providing world-class support to our customers ensured the successful restoration of the B787 T1000 inlet and got our customers grounded aircraft flying again.
