The Airbus A350 XWB journey - behind the scenes videos

by Devesh Agarwal

Ahead of the first flight of the Airbus A350 XWB a set of videos from Airbus which gives us behind the scenes explanations on some aspects of the aircraft design, development, testing, manufacturing, and hand-over to the flight testing crew who will fly the aircraft today.

Like the Boeing 787, the A350 XWB heavily relies on composite materials to lighten the airplane. This video explains the use of composites in the A350. It is largely in French so you will have to follow the sub-titles.



The Final Assembly Line (FAL) is where all A350 airframes are built including the MSN (Manufacturer's Serial Number) 5000 series which were used for static testing on the ground, and MSN001 which will fly later today, god willing, weather permitting.



Prior to any form of flight, the airframe is tortured using special static testing rigs. Observe how the wing is flexed to a deflection of over 5.3 metres (17.38 ft), that is almost two floors of a building.



The first flyable prototype MSN001 is fitted with the Rolls Royce Trent XWB engines, the most powerful engine mounted on any Airbus airframe till date. Even more powerful than the Trent 900 engines on the A380; but then the A380 is powered by four engines, while the A350 is a twin jet.



The A350 XWB MSN001 is painted for flight.



After the first flyable prototype MSN001 is assembled, the manufacturing team turns the aircraft over to the flight test team, which accepts responsibility of the aircraft on behalf of the Engineering Division at Airbus. The flight test team then readies the aircraft and tests prior to the first flight.



MSN001 does not contain much of a passenger cabin. It is filled with mountains of test equipment.



The engines on MSN001 are powered up for the first time.



Fernando Alonso, who shares his name with the world champion Formula 1 Ferrari driver, joined Airbus in 1982 and is the head of Airbus Flight and Integration Test Centre. He will lead the flight test activities for Airbus.



Watch the A350 XWB first flight live.

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Video: Changing a Boeing 737 CFM56 engine at Southwest Airlines

by Devesh Agarwal

A CGI rendition of the Southwest Boeing 737 MAX

Without a doubt, an aircraft's engines are one of the most complex parts on an aircraft. After the airframe, the engines are the most expensive item an airline buys, and normally an airline signs separate contracts for the airframe and the engines.

With thousands of rotating parts, and temperatures reaching close of one thousand degrees, engines require regular maintenance. Almost all engine manufacturers like General Electric, Rolls Royce, Pratt and Whitney, CFM, and IAE, offer a concept of 'fixed total cost of operations' wherein the airline pays the engine vendor a fixed cost per hour of operation of the engines and the vendor is responsible for maintaining the engines. This concept is better known as "power by the hour".

Some airlines like US low cost carrier, Southwest Airlines, have extremely large fleets, and find it more economical to have their own maintenance and engineering operations. For Southwest, these engineering centres are based at their major hubs of Dallas, Houston, Phoenix, Chicago, and Atlanta. The centres routinely swap out the CFM56 engines of their all Boeing 737 fleet. Since an aircraft earns money for an airline only when it is flying, airlines always keep spare engines, which are swapped out, allowing the aircraft to be put back in to service quickly. The engine then undergoes repairs and maintenance offline.

The CFM56 engines powering the Boeing 737NG weigh about 2,500kgs each, and even the well experienced technicians at Southwest take between four and seven hours to do a routine engine swap. In the video, observe the synchronism of teamwork that makes this complex task look routine, a task Southwest technicians perform over 154 times a year.

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Videos: Behind the scenes of an A380 departure and an engine inspection

Our two videos today come courtesy Air France.

Have you ever wondered what happens around your plane while you are waiting for your flight to board and depart? In first video, Air France reveals an exclusive behind-the-scenes look at the frenetic activity performed by hundreds of people prior to the departure of an A380. Next go behind the scene at Air France Industries KLM Engineering & Maintenance (AFI KLM E&M) and see the inspection and maintenance of a GE90 engine, the largest civil aircraft engine in the world, from its arrival at the Air France hangar to the test phase at the new Air France engine test cell.





Below is a detailed graphic showing the engine inspection and maintenance process.

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Opinion: A date of ignominy in the Kingfisher Airline calendar

2010 Kingfisher Calendar. Copyright KingfisherWorld

Kingfisher is known for its super-sexy swimsuit calendar, featuring some of the most beautiful women in the world, and Kingfisher Airline's Chairman Dr. Vijay Mallya's son, Sidhartha, may love cavorting on the beach with them, but yesterday, October 4, 2012, witnessed a tragedy, and was, to borrow the words of FDR, a date that will live in infamy for the financially imploding airline.

The wife of one its employees committed suicide due to non-payment of her husband's salary for over six months.

Sushmita Chakraborti was not a model on a fancy calendar, nor would either of the Mallya father or son, like to cavort on the beach with her; she was the poor, 45 year old wife of a retired Indian Air Force officer, Manas Chakraborti, who is working, salary unpaid, as an engineer with Kingfisher Airlines. Living in a LIG (low income group) housing colony in airport suburb of Dwarka, in New Delhi, where she hung herself, she was the mother of an 18 year old college going son.

CNN-IBN reports, in her suicide note, Sushmita wrote,

"My husband works with Kingfisher where they have not paid him salary for the last six months. We are in acute financial crisis and so I am committing suicide"

Mrs. Chakraborti's suicide has stained in blood the Kingfisher Airline's image, and forever damaged the already tarnished the Kingfisher brand, once valued at over Rs. 1,000 Crore. The contagion is already spreading. The Reserve Bank of India has already instructed banks not to use the brand as collateral for loans.

Her death is in stark contrast to the extravagant uber-lavish lifestyle of the Mallyas, which has been loudly condemned across the country, yet shows no sign of abating. Even as Sushmita was dying, Dr. Vijay Mallya was overseas, reportedly on a vacation, leaving the airline CEO, Sanjay Aggarwal, to meet with Government officials, Kingfisher pilots, engineers, and other employees, with the same helpless platitudes that has plagued the airline for over a year. He too, he says, has not been paid his salary.

While many Kingfisher employees held candlelight vigils around the nation, in support of the grieving family, CNN-IBN reported, the airline’s company secretary Bharath Raghavan resigned.

Yesterday too, the airline extended the lockout to October 12, 2012, blaming the employees for "illegally" striking. Talk about the pot calling the kettle black.

Last yesterday, in a clear sign of the political clout of Vijay Mallya, the Income Tax department agreed to unfreeze the airline's bank accounts containing about Rs. 60 Crore. The authorities had frozen these accounts in May this year, when Kingfisher failed to deposit the withheld income taxes, deducted from employees salaries, since March 2009. This apart from non payment of service tax to the Excise department. It is important to note, that there is no sign that either Kingfisher Airlines or Dr. Mallya have cleared this liability.

Continuing the clout, the banks, who are owned more than Rs. 8,000 Crore by Kingfisher, and who, by their own admission, do not have collateral worth more than 10% of the loans, have agreed to release this money towards payment of employee salaries. Now, whether this money will be disbursed to the unpaid employees or squandered in more fancy lifestyle displays, is not known.

As this tumultuous week comes to a close, we offer our sincerest condolences to the Chakraborti family, and condemn the actions of the airline, its leader, and all his political benefactors who have allowed circumstances to degrade in to an abyss, resulting in this tragic act of desperation. Yesterday was a day of ignominy for you Dr. Mallya.

Comments are welcome. Messages of support are welcome. Any defence of Kingfisher or Dr. Vijay Mallya is very welcome. And last but not the least, please do cast your vote in our survey whether Kingfisher Airlines should be allowed to continue or be closed.

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Share your view: Strikers manhandle fellow employees at Kingfisher Airlines disrupting flights across the network

Our topic of this week comes thanks to the financial troubles at Kingfisher Airlines.

The flights of the financially ailing carrier have been disrupted across its India network due to striking engineers.

As per media reports, striking employees, after hearing that some employees received salaries, manhandled fellow employees, beat up a management executive, held passengers hostage aboard a flight for over three and half hours by refusing to connect aero-bridges or ladders to the arriving aircraft.

A statement issued by Prakash Mirpuri, Vice President-Corporate Communications, Kingfisher Airlines Limited, said

A section of employees of Kingfisher Airlines has not been reporting to work over the last fortnight and over the past 2 days, they have been threatening and even manhandling the other employees who are reporting to work as usual. We are anticipating disruptions and/or delays of flights across our network on October 1, 2012 as it is likely that a section of employees of Kingfisher Airlines may not report to work due to such threats. With a view to mitigating the impact of these anticipated disruptions, we are proactively cancelling several flights across our network for October 1, 2012.

As per the Press Trust of India, pilots from Mumbai have joined the striking engineers, adding to the disruptions. Mirpuri went on to say

We are monitoring the situation and continue to engage with this section of employees to see reason as such action is not only detrimental to the company but directly impacts the travelling public and it will be our endeavour to resolve the situation and restore normal operations at the earliest.

Unfortunately, it appears that non-payment of salaries have frayed the patience of the employees to breaking point. This does not appear to be a one or two wildcat strike. This is serious and appears long term.

The attack on an executive is a milder shade of one of the worst and recent industrial unrest in India, at Maruti's Manesar plant, which resulted in death, as is the holding of passengers hostage.

The country's civil aviation regulator the DGCA has indicated it will review the situation.

The platitudes offered by Mirpuri, though genuine, may not be enough to placate irate customers

We deeply regret any inconvenience that may be caused to our valued guests on account of this unprecedented action by a small section of employees and we are doing our best to minimise the impact of these anticipated disruptions.

Your thoughts please? What should Kingfisher Airlines now do? Share your thoughts via a comment.

Please remember, our DISQUS comment system also allows you to share your comments via Twitter and Facebook too. In case you want the airline to hear your comment via Twitter (we cannot guarantee they will read them), use their tag @flykingfisher in the start of your comment and share via Twitter. You can also tag the Chairman of the airline, @TheVijayMallya.

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Honeywell Technology Solutions trains its aerospace engineers as pilots. A first in India.

In a first of its kind in the Indian aerospace industry, Honeywell Aerospace and Honeywell Technology Solutions (HTS) trained 16 of its development engineers and graduated them with a private pilot's license (PPL). The PPL training was started in 2010 to train HTS engineers to think and act like pilots in real flight conditions.

There has always been a gap between pilots, and engineers developing aerospace and avionics solutions. With this training, Honeywell hopes to improve the engineers' understanding of the challenges pilots face, which leads to better determination of product requirements from a pilot’s perspective. Engineers also improve their technical communications skills in the language of pilots, improving Honeywell delivery of aerospace and avionics solutions.

Participants must attend 200 hours of classroom training and pass an exam, before completing in-air training. The program culminates with 20 hours of flying solo and 10 hours of flying cross-country.

Tim Mahoney, President and CEO, Honeywell Aerospace summarises the program

“By enabling our engineers to understand the cockpit from a pilot’s perspective is a new approach for India’s aerospace industry,” “Through their pilot training, these engineers can now truly understand what it’s like for a pilot flying an aircraft, and use the live interaction and experience to develop technologies that are even closer aligned with our customers’ needs.”

Honeywell’s avionics portfolio includes communication, navigation and surveillance systems, flight display systems, and flight control and management systems for general and business aviation, commercial air transport, military aircraft and space-based platforms.

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