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Replacing an engine block in just 10 weeks? MAN ES has once more demonstrated what can be achieved with good teamwork.

In mid-June, MAN PrimeServ received an appeal for help from Spain. The plant in a power station in the Spanish exclave of Melilla was down because of an engine failure. The customer wanted to restart electricity production as quickly as possible in order to safeguard the city’s power supply. MAN PrimeServ was therefore left with just 10 weeks to supply a replacement and carry out the repair. Alejandro Manrubia, project manager with MAN PrimeServ Germany, recalls this stressful period: “Normally, it takes six months just to produce a new engine block. But thanks to the support we received from colleagues in Power and Production, we were able to get hold of a finished engine block very quickly and assure the customer that we could help.” It was a great feat of coordination between PrimeServ, Purchasing, Assembly, Production, Logistics and Commissioning, as all sorts of crucial decisions had to be made within a matter of days, or even hours.

Antonov-cargo-aircraft
The AN 124 has a length of just under 70 meters and a wingspan of 73 meters. It can carry loads up to a total weight of 120 tons.

Normally, it takes six months just to produce a new engine block. But thanks to the support we received from colleagues in Power and Production, we were able to get hold of a finished engine block very quickly and assure the customer that we could help.

Alejandro Manrubia, Project Manager at MAN PrimeServ Germany

crankcase-transport
The crankcase for the customer in Spain weighed over 50 tons and was thus clearly too heavy for a normal cargo aircraft.

Transport by Antonov

It soon became clear that the only way to transport the engine block was by air. A normal cargo aircraft was out of the question owing to the size of the engine block, which weighed in excess of 50 metric tons. So Simon Nonnenmacher’s shipping team booked one of the largest transport planes in the world, an Antonov, and made arrangements for an abnormal load to be moved from the airport in Malaga to the job site by road and then ferry. Meanwhile, the remaining spare parts were delivered by the overland route.

The MAN PrimeServ team arrived in Melilla in mid-July to remove the old engine block and fit the new one, take care of the pipework and then recommission the engine. “The repair clashed precisely with the summer vacation season. We were grateful for the flexibility shown by production colleagues in Augsburg, who were able to provide manpower at short notice despite shutdown. In addition, we had to drum up a team from various branches, including Benelux, Fort Lauderdale and Saudi Arabia in addition to Augsburg and the two Spanish establishments in Valencia and Las Palmas,” Alejandro Manrubia relates. He alternated with his colleague Magdalena Haug on coordinating the work on site.

Mission accomplished

MAN PrimeServ was able to hand the engine over to the customer on 30 August, two weeks ahead of the agreed deadline. Probably no one in the project team slept much during this period, but the customer’s delight at how quickly and professionally the job was handled more than made up for all the hard work.

50
metric tons is how much an engine block weighs. Too much for a normal cargo plane, which is why an Antonov was used for the transport to Spain.

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