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Maintenance & Engineering

Aircraft Mechanic

The duty of an aircraft mechanic includes working with the diagnostics of electrical and mechanical issues, the replacement of defective and worn parts and the inspection of aircraft according to approved maintenance program.

At Cargolux, the aircraft mechanic is either assigned to hangar or line duties.

Our line support is available on a 24 hour/7 day basis to cover all Cargolux and customer turnarounds.

Our base maintenance, which is conducted in our hangar, is covered from Monday through Friday in support of B747-400/-8 A and C-checks and modifications on Cargolux and customer aircraft.

All work is performed in accordance with strict authority requirements.

Our line and hangar mechanics are trained to the highest level and are constantly involved in troubleshooting systems, providing recommendations on repair and procedure improvements, which contributes to high maintenance standards and on time performance.

Occasionally, the mechanic will be stationed abroad to provide technical support at that station.

A mechanic may also be send to outstations to support AOG situations.

All our mechanics have the possibility to progress in their carrier in accordance to company policies and requirements.

Maintenance Support Shops

The production shops are an important part of the Maintenance & Engineering Division. Most of the shop personnel works on both the aircraft in the hangar and components in a shop environment. The technical complexity of an aircraft requires specific skills for the various aircraft systems and the maintenance of the aircraft components.

As a shop mechanic, you are trained in the shop on component maintenance and attend external training courses by the component manufacturer or specialized training organizations. The shop repair capability lists all components that your shop is allowed to work on and release to service under the various aviation authorities, namely the American FAA and the European EASA.

The Maintenance & Engineering division has the following support shops:

1. Engine Shop
The Engine Shop is responsible for ensuring that the Rolls Royce and General Electric engines of the Cargolux fleet are ready to be installed on the aircraft when required. The shop prepares the removed engines for shipment to the various repair facilities, where major repairs and overhauls are performed. The Engine Shop overhauls the RR thrust reversers.

2. Wheel and Brake Shop
With about 400 wheels and brakes used on the Cargolux fleet, this constitutes a very busy shop. The wear and tear on wheels and brakes is very high when an aircraft lands at 300 kmh on a rough runway and brakes to a full stop.

3. Machine & Accessory Shop
This shop carries out precise machining to build tooling and equipment. The shop also machines component repair parts such as bushings, fittings and shims to the final close tolerances. When special tooling is required to assist in the aircraft or component repairs, the Machine Shop takes care of it.

4. Sheet Metal Shop
Sheet metal work is an “art” in the realms of aircraft maintenance. It requires great skills to form and fit metal pieces together flawlessly. Good preparation, planning the job ahead and attention to detail are essential. A good repair is free of any tool markings and has a smooth and aerodynamic finish. This is the biggest shop in terms of staff numbers.

5. Interior Shop
This is a small shop, which is tasked to take care of the equipment in the aircraft galley, lavatory, the flight deck and cabin seats. The crew and passenger equipment has to be maintained in perfect condition.

6. Hydraulic Shop
The hydraulic shop mechanics repair hydraulic pipes and tubing on and off the aircraft. They also repair hydraulic components in the shop, e.g. flight control actuators, hydraulic valves and coolers.

7. Pneumatic Shop
Here, a large variety of pneumatic actuators and valves of the aircraft and the engines are repaired and tested, e.g. the high-speed air-driven flap motors. The shop uses an impressive soundproof test cabin for testing the components before returning them to service.

8. Avionics Shop
This shop spends most of the time repairing power drive units (PDU’s) for the cargo loading system. Extensive troubleshooting is required to locate the faults before rectifying the problems. Sophisticated and dedicated test benches are used to test the PDU’s after repair. A good electrical/ electronic background is required.

9. Ground Equipment Shop
With its large fleet, Cargolux also requires a lot of ground equipment such as tow trucks, ground power units, maintenance platforms, special lift devices and more. They all need to be maintained and repaired in order to be ready for use when the aircraft lands.

10. Welding Shop
High precision welding of aircraft parts made of different materials and alloys requires great expertise. The X-ray inspection of every weld is unforgiving and will detect the smallest flaw and enclosure in the weld. The strictest welding criteria apply to the welding of aviation parts.

11. Cargo Loading System Shop (CLS Shop)
The cargo systems have to be fully functional at all times. This means that each of the hundreds of mechanical drive systems used for loading and unloading the cargo requires maintenance and repair. Cargo is our main business so the loading and locking systems are very important.

12. Composite Shop
The modern age aircraft design relies increasingly on composite material for components, panels and fairings. The repair of this material is complicated, it needs special techniques, and the use of bonding resins applied in a clean and controlled environment to ensure best repair results.

13. Paint Shop
Many components that are overhauled in our shops are subject to re-painting. Also, the aircraft appearance is very important to our business. Our aircraft are ambassadors for Luxembourg and Cargolux throughout the world.

14. NDT Shop
The NDT shop takes care of all non-destructive testing requirements. This includes specialized methods such as eddy current testing and X-ray testing for the detection of cracks and faults in load bearing structures of the aircraft before catastrophic failure occurs.

15. Calibration Shop
Due to the large number of testing devices such as torque wrenches and ohmmeters, we need a specialized team of calibration experts to ensure that these devices are running perfectly and are precise at all times. It is prohibited to use test devices on an aircraft unless they are calibrated.

Compliance Monitoring and Quality Assurance inspector

To become a quality assurance inspector, you have to progress through various levels in the maintenance organization and have an eye for detail and respect of regulations.
This is the top-level job which holds a large amount of responsibilities.
Quality assurance inspectors are usually recruited from among our more senior mechanics, who have a proven record of being thorough and precise in their handling of the aircraft and workshop documentation. They have a detailed knowledge of the regulation to ensure that the EASA, FAA and DAC rules and regulations are strictly followed.

Technical Records

Technical Records is a department of the M&E Engineering Group. The main functions of the department is the collection, processing, archiving and safeguarding of aircraft, engines and aircraft components, maintenance records and the related updates or verifications in the electronic database. Besides extensive regulatory requirements, the safeguarding and systematized archiving of aircraft maintenance records plays a crucial role in maintaining the value of the asset. Technical Records is involved in aircraft phase-in and phase-out exercises, lessors mid-term lease inspections and produces monthly reports to aircraft/aircraft engine lessors and owners.  

Material Management

Main responsibilities:

  • to establish the requirement for spare components for airplane operation,
  • Sourcing and procurement of new aircraft parts and supplies,
  • Selection of component repair organizations,
  • to create repair orders and follow up of component repairs at vendors,
  • Support airline in critical requirement for components through lease, loan or AOG (Aircraft On Ground) component purchase.

Material Control

Main responsibilities:    

  • receiving and shipping of components and supplies required for aircraft maintenance,
  • controlling and reviewing the condition and documentation of components to ensure airworthiness is maintained,
  • storing and controlling aircraft components,
  • preparing and delivering part kits required for aircraft scheduled maintenance.

Production Planning

Main responsibilities:

  • planning and scheduling for accomplishment within the specified aircraft flight hours, cycles or calendar limits, all tasks which are due for a pre-planned maintenance slot with the help of our MRO software,
  • ensuring that all engineering controls for special inspections, AD's, CMR’s, modifications, hard time components and all deferred defects are monitored and planned,
  • compiling all aircraft maintenance work packs for the Cargolux fleet,
  • securing Cargolux and customer maintenance slots in liaison with Network Management, Maintenance, Sales and Production departments,
  • preparing and communicating the maintenance forecast for all hangar checks,
  • compiling all D-Check work packs performed at an outside MRO facility,
  • providing on-site support during heavy maintenance visits performed at an outside MRO facility for Cargolux and all subcontracted aircraft,
  • preparing all third party maintenance work packs as per customer request and as per the daily flight schedule for all customer line checks,
  • providing maintenance work scopes for the pre-check meetings, RFQ’s and heavy maintenance visits.