Engineering and Maintenance

Qantas Engineering and Maintenance experience dates back to when the airline first commenced operations in 1920. Since then, Engineering and Maintenance has gained nearly as many years experience in contract work. The Engineering and Maintenance branch employs some 6,000 personnel (from a total airline staff of about 30,000).

From humble beginnings in the Australian outback, Qantas Airways has succeeded in establishing a reputation as one of the worlds most efficient Airlines.

Engineering Support

Engineering Support

With the experience gained in maintaining Qantas' own fleet of over 130 Aircraft, we can respond to Customer Airline requirements with flexibility and an understanding of operators concerns and constraints.

Qantas is at the leading edge of technological development, constantly improving our products, processes and systems. Focusing on continuous improvements/worlds best practice, striving to become the most cost efficient operation in the Airline industry. These continual improvements benefit Operators utilising Qantas Engineering services.

Aircraft Operators seeking a Quality Service at a competitive price, should contact Qantas for Engineering Support.

Aviation Maintenance

Aviation Maintenance

Qantas Engineering and Maintenance is an integral part of that reputation, providing world class engineering standards on a solid foundation of Safety, Quality, Reliability and Service.

Drawing on a wealth of experience in aviation maintenance, with collectively the largest and most sophisticated technical facilities in the southern hemisphere, Qantas Engineering and Maintenance has long been considered an industry leader as a source of standards in engineering excellence.

With the One Stop Shop total maintenance concept, Qantas Engineering and Maintenance offer a competitive, cost conscious, comprehensive range of Engineering, Maintenance, Inventory, Training and Support Services for B747, B767 and B737 Aircraft, Engines and Components. Qantas Engineering's highly skilled, experienced and motivated technical workforce, supported by extensive, complementary facilities located in Melbourne and Sydney, enable Qantas to provide an on time, cost competitive, quality product.

Services

Qantas Engineering is able to provide complete maintenance and overhaul services for a wide range of different aircraft types. These are performed in maintenance facilities in Sydney and Melbourne.

Aircraft Support Workshops and Aircraft Maintenance

Aircraft Maintenance

Qantas Engineering

Qantas aircraft maintenance has comprehensive capability for all maintenance and modification programmes associated with Boeing 737, 767 and 747 Series Aircraft.

Purpose built hangar and workshop facilities in Sydney for the 747 and 767, and Melbourne for the 737, along with world class technical expertise and planning, offer the optimum service in aircraft maintenance.

Qantas has 9 hangar bays at Sydney International Airport Maintenance Facility, a further 7 hangar bays are located at Melbourne International Airport Maintenance Facility. Several of these bays have dedicated docking to provide easy access to all areas of the Aircraft during maintenance.

Qantas Engineering

Adjacent supporting workshops, and a comprehensive spares inventory, ensure that aircraft maintenance is completed in a timely and cost efficient manner.

With many years of experience gained with our own fleet, Qantas can offer high quality maintenance and modification programmes to support your operation.

Utilising highly skilled and experienced technicians, assisted by an integrated computerised planning system, Qantas is able to complete a variety of customised maintenance inspections and modification packages including:

  • Routine Maintenance Checks - A, B, C, D, (or equivalent)
  • Minor/Major Airframe Repairs
  • Structural Inspections
  • Corrosion Prevention and Control Programme
  • Aging Aircraft Inspections
  • Aircraft Modification/Refurbishment (Section 41, Strut/Pylon Mod, Aircraft Re-configuration)

Aircraft Support

Aircraft Workshops in both Melbourne and Sydney, are an integrated part of our Total Maintenance Concept. Offering World Class Service and the high level of dedication and craftsmanship Qantas Customers have come to expect.

Aircraft Workshops offer an extensive range of Structural repairs from composite/carbon fibre to sheet-metal and machining.

Safety Equipment (such as slides, rafts and life jackets), Galley Modules, Engine Cowls, Cargo Containers, Radomes and complex assemblies such as Thrust reversers and Control Surfaces are also overhauled and repaired.

Specialist Aircraft Workshops Include:

  • Non Destructive Testing
  • Sheet-metal
  • Composite and Carbon fibre
  • Fitting and Machining
  • Hoses and Tubes
  • Survival and Safety Equipment
  • Wheels and Brakes
  • Fabric and Trimming
  • Chair Maintenance
  • Cabin Interior Refurbishment
  • Paint and Surface restoration
Component Maintenance
Component Maintenance

Qantas Component Workshops perform Cleaning, Inspection, Overhaul, Repair, Modification and Testing of over 15,000 individual line items.

Total Maintenance support cannot be achieved without quality component workshops. These facilities are complemented with highly skilled and experienced Technicians, providing high quality cost effective component overhaul that challenges accepted industry standards.

Experience gained with the Qantas fleet ensure preventative maintenance concepts are applied to Customer components, providing optimised component performance and cost savings to the customer.

Specialised component maintenance services, tailored to Customer requirements are also available.

Qantas Avionics workshop accomodates a 624m2 laminar flow class 100 standard 'Clean Room' where Temperature, Humidity and Cleanliness are all strictly controlled.

Testing of a wide range of Electronic components is provided by 'State-Of-The-Art' ITS 700 and ATEC 5000 Test stations permitting functional tests to be performed quickly and accurately.

Avionics, Radio, Electrical, Pneumatic, Hydraulic and Mechanical components are all monitored throughout the workshop by a computerised tracking system to ensure competitive turn times are maintained.

Engine Support Workshops and Engine Overhaul

Engine Support Workshops

Qantas Engine Support Process line workshops in Sydney and Melbourne provide extensive in house capability for the refurbishment and modification of piece parts associated with Aircraft, Engine and Components.

Composite Repairs/Replacement

Refurbishment of Engine composite areas such as compressor and turbine air-seals, cowls etc. on Rolls Royce, Pratt & Whitney, General Electric and Allison Engine types.
Cleaning

Cleaning

Using a variety of chemical cleaning processes such as acids and alkaline's, along with decarbonizers, solvent washing, grit and bead blasting, vapour degreasing and ultrasonic cleaning.

All cleaning processes comply with stringent environmental standards.

Combustion Liners

Combustion Liner refurbishment is accomplished on a variey of Engines and APU's

Heat Treatment

Qantas vacuum furnaces and ovens can accommodate Heat Treatment of parts to a Maximum Temperature of 1300 degrees C. Local stress relieving of parts using portable stress relieving units is also performed.

Machining

The Engine Machine shop repairs a multitude of piece parts using equipment such as Multi axis Mills, Vertical Borers, Multiaxis Lathes, Cylindrical and Surface Grinders and Electrical Discharge Machinery.

The majority of this equipment is Computer Numerical Controlled (CNC).

Welding

A variety of welding processes are performed using Titanium, Stainless Steel, Inconel, Aluminium, Magnesium and Carbon steel materials.

Plasma & Thermal Spray

The Plasma Spray area has several Booths, one using a fully computer controlled multi axis robot arm for the spraying process. Spray applications currently in use include Abradable, Bond, Hard, Soft and Thermal materials.

Shot Peening/Tumbling

Steel Shot, Ceramic and Flap Peening processes are available. The Vibro Finishing area processes Blades and Vanes to obtain surface finishes up to 20 Microns.

Non-Destructive Testing

NDT is performed using Fluorescent Penetrant, Magnetic Particle inspection methods. (All other NDT techniques are accomplished by the Aircraft NDT Section).

Electroplating

A variety of processes are performed including:

  • Conversion Coatings - Anodising, Black oxidising, Dichromating and Phosphatising.
  • Plating - Brush, Cadmium (LHE), Chrome, Copper, Electroless Nickel, Dichromate, Gold, Nickel Cadmium, Silver, Sulphamate Nickel and Tin.

Engine Overhaul

Qantas Engineering

Qantas has two large and extensively equipped Power Plant overhaul facilities, located in Melbourne and Sydney, offering quality service at a cost effective price and competitive turn time.

These facilities are supported by 4 Power Plant test cells and a wide range of specialist workshops that accomplish the repair, overhaul and refurbishment of hot and cold section modules.

Qantas specialises in the following Engine & APU Types:

  • Rolls Royce RB211-524 Series
  • General Electric CF6-80C2
  • CFM 56-3 Series
  • Allison T56/501 Series
  • APU Types: Garrett Series 331, 660, P85 and P95, Pratt & Whitney Series 901, GTCP 85 Series (13 variants)

With continuous investment in advanced technology, Qantas can offer total engine maintenance and overhaul support. This investment, along with an experienced workforce is our commitment for a quality product of the highest standard.

Customers can benefit from our fleet experience and Engine Condition Monitoring Analysis to provide maximum engine reliability, ensuring a cost effective operation.

Qantas Engine Test facilities are capable of testing turbo-prop engines up to 5,000 ESHP, jet engines with or without re-heat, and fan engines up to 100,000 lb thrust. All test cells conform to required Environmental and Safety standards.

Qantas has on-site representation from CFM, Pratt & Whitney, Rolls Royce and General Electric engine manufacturers.

Line and Minor Maintenance
Qantas Engineering

Line Maintenance Engineering Support is available at all Australian International and Domestic Terminals.

Comprehensive ramp and engineering services are provided 24 hours per day by some of the most highly experienced and qualified engineers available in Civil Aviation.

Transit Check inspections, as per individual Maintenance requirements, can be accomplished efficiently and confidently by our highly motivated engineering crews.

Sophisticated ground support equipment and specialist vehicles ensure that your Services achieve reliable 'on time' departures.

Qantas Technical support is never far away, whether it is Fault diagnosis and Troubleshooting, AOG Spares support or Pooling arrangements, Qantas Engineering Line Maintenance will provide world class assistance to avoid or minimise service disruptions to operators experiencing technical difficulties.

All Qantas Line Maintenance Stations can communicate with inbound Aircraft for advice on incoming defects, facilitating the preparation of appropriate resources to preclude unscheduled extended ground time.

For Operators with extended stopovers (subject to location), Qantas Line Maintenance can perform Supplementary or Minor Maintenance inspections up to A Checks - Optimising the Aircraft's down time.

Qantas Engineering has Line Maintenance representation at various locations throughout the world. Many Qantas Engineering Customers benefit from the expertise and services they provide.

Material Logistics and Systems
Qantas Engineering

Initial Provisioning Recommendations for Main Base Inventory

Utilising our computerised modelling techniques, Qantas can recommend main base spares holdings for the introduction of new aircraft types, with protection levels tailored to the investment and operational needs required by the customer.

Material Sourcing

Qantas Materials Management & Logistics expertise, together with overseas purchasing offices in Europe and North America, will ensure that Customer material sourcing requirements will be met with vendors of a very high quality standard.

Inventory Availability

Qantas has an extensive range of aircraft inventory available to support maintenance and overhaul programs for a wide range of customer engineering requirements. Coverage can be adequately provided for the following aircraft and engine types:

Aircraft

  • B747-200/300/400
  • B767-200/300
  • B737-300/400

Engines

  • RB211-524 Series
  • CF6-50/80C2
  • CFM56-3 Series
  • Garrett 85/331/660/700 APU's
  • PWA 901 APU

Warranty Administration and the Implementation of Warranty Procedures/Systems

Qantas Warranty department, subject to assignment approval, offers a comprehensive warranty support service to all Third Party Customers. Services include:

  • Claim Administration
  • Material Repair and Credit Recovery
  • Service Bulletin Claim and Cost Analysis
  • Vendor Interface Issues
  • Warranty Training/Familiarisation
  • Administration of Performance Guarantees
  • Arranging In House Assignment Approval etc.

Our Warranty expertise is validated by years of experience servicing the domestic and international airline operations and a range of customer networks.

Technical Support Services
Technical Engineering Support

Technical Services provide specialised engineering support in all disiplines of Aircraft engineering. Structural, Systems, Electrical, Avionics, and Performance specialists provide excellent technical expertise for maintenance operations on Qantas and Customer aircraft, engines and components.

Production Planning provide a service to ensure maximum utilisation of Manpower and Resources, rescheduling work flow for cost effective maintenance.

Qantas Engineering also provides a 24 Hour Maintenance Watch service for Qantas and Customer Aircraft operational support.

Services provided by this group include:

  • Condition Monitoring and Reliability of Engines, Airframes and Components.
  • Evaluation of Vendor Service Data and Bulletins.
  • Development and evaluation of Maintenance.
  • Programmes for Aircraft, Engines and Components.
  • Evaluation and stress analysis for Aircraft modifications and repairs.
  • Development of repair schemes to restore integrity to worn and damaged parts.
  • Interior design and cabin refurbishment/reconfiguration.
  • Aging Aircraft and Corrosion Control and Prevention Programme inspections.
  • Technical evaluation of Aircraft, performance and payloads.
  • Technical Records and Technical Data Acquisition.
Engineering Training
Tech Training

The high quality of engineering personnel available to maintain Qantas and customer aircraft, engines and components is the direct result of the priority Qantas gives to all aspects of training.

Qantas has long been willing to share its technical and management expertise with other operators throughout the world. This is achieved principally by the continuous training of apprentices, tradesmen, licenced engineers and instructors in Australia or at the customer's home base.

Qantas Technical Training offers a comprehensive range of classroom and on the job training programs relevant to industry developments and specific customer needs.
Flexible, comprehensive training, as well as modular packages are available and can be tailored to meet specific customer requirements.

Quality training facilitates quality work and increased maintenance productivity.

Qantas Engineering Training encompasses two broad categories:

  • Type Training
  • Non-Type Training

Type Training

Courses include, with CASA Part 66 licence outcome:

  • Airbus A330 A, B1 and B2;
  • Airbus A380 B1 and B2;
  • Boeing B737-200/300/400 A, B1 and B2;
  • Boeing B747-200/300/400 B1 and B2;
  • CFM 56-3C1/3C2;
  • General Electric CF6-80C2; and
  • Rolls Royce RB211-524D/524G.

Methods include:

  • classroom based theory;
  • on the job training (OJT);
  • practical consolidated training (PCT);
  • practical on course (POC); and
  • recognised prior learning (RPL).

Non-Type Training

  • Borescope
  • Confined Space
  • Certifier induction
  • Engine ground run
  • General Familiarisation
    - Airbus A330
    - Airbus A380
    - Boeing B737
    - Boeing B747
  • Ground handling
  • Overhead crane
  • Refuelling
  • Walking forklift