Repairing a gas turbine can be a protracted affair: after it
arrives in Oberhausen, the machine is dismantled into its individual parts for
diagnosis. Then the customer receives a quotation for the necessary repairs.
Colleagues cannot start work on the actual repairs until he gives the green
light. No wonder it can take up to 12 months for the customer to get his
reconditioned machine back.
As part of the Base Camp 3000+ ‘Change2Grow’ initiative, MDT has
developed a concept aimed at cutting lead times for repair orders in respect of
THM gas turbines. “The new concept means that individual components are sent
for repair as soon as they have been diagnosed. The customer will have been
given a fixed-price quotation up front. He pays an agreed amount, regardless of
how much work actually proves necessary,” Ingo Janssen, Head of Engineering
& Repair Gas Turbines, explains. In order to estimate a realistic price,
both past experience and the history of the machine in question are taken into
account. The neat synchronization of diagnosis and repair can cut the lead time
to about six months.
In another approach, MAN PrimeServ Turbo holds replacement parts
for the Brazilian oil company Petrobras. Turbine blades, for example, used to
be dismounted, sent to an external service provider for regeneration and then
re-fitted. Instead, blades from the parts pool are fitted while the fatigued
blades are still being regenerated. “We can further reduce repair times by
rotating parts. The pool concept is standard for the MGT with a particular view
to accommodating customer requirements in the Power Generation segment and
boosting our competitiveness,” says Marcel Sicker, Product Manager in
Oberhausen. By combining the two approaches, MDT is aiming to achieve lead
times of around three months in the medium term. Holger Berghaus, Head of
Engineering Operations, sums up the benefits of the pool concept: “The machines
are back in action sooner, reducing the need for investment in replacement
machines. We can also manage the capacity utilization of our workshop better
and are more flexible when it comes to unscheduled repairs.”
Gunnar Stiesch has been Head of Engineering Engines since 1 May. His goal: more sharing and synergies in engine development.
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