Airplane Heavy Maintenance | Mega Pit Stops | Episode 1 | Free Documentary
Mega Pit Stops - Episode 1: Airplane Heavy Maintenance - Airbus A330-300
At Lufthansa Technik Malta, 700 hidden figures keep aviation the safest way to travel. The highly trained team specializes in aircraft safety checks and overhauls. They inspect and repair fleets from airlines around the world. The ultimate Mega Pitstop!
Their recent project: Kilo Romeo - An Airbus A330-300. Effort of this Pitstop: 25.000 manhours. Time is a crucial issue, as Kilo Romeo is already scheduled for the next flight. From now on the team only has 40 days to deliver a good as new aircraft.
The whole cabin gets stripped down. Engineers remove, check, repair and reinstall millions of pieces. Seats, kitchen- and bathroom monuments, wall and floor panels. In multiple workshops specialists refurbish every single item - racing against a tight schedule. Once all parts of the cabin are completely dismantled, inspectors check and overhaul every inch of the aircraft’s base structure. The steel frame, isolation and dozens of kilometers of cable. Not a single screw stays unchecked.
At the same time another unit scans the plane’s exterior for damages. Especially the sides and roof often get seriously hit by lightning strikes and need to be patched. Mechanics also cautiously take off and refurbish the six tons Rolls Royce engines. From the wings to deep into the fuel tanks: The engineers review every security relevant parts - multiple times. To make sure the passengers are safe. A fascinating and rare insight - only on Mega Pit Stops!
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I worked for 45 years in aviation, now retired. This documentary was very accurate and is giving me flashbacks for my younger years. The most schedule disruptive item on the list is the finding of structural corrosion…the proverbial can of worms.
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They left out alot
Sir your salary
@@Narayan_channelI am already over 100k this year
@@backyardlures4767What did they leave out?
Probably the most underappreciated job in the whole airline industry. Respect to these guys!
Unsung heros
It is the most (AME) underappreciated job in the Aviation industry by the general public ,this job should be one of the most appreciated and respected professions out there.
underappreciated and underpaid.
Finally someone said those magical words 😂. I can feel those words because i am too an aircraft Engineer 😅
@Giuliano Matrix totally agree with you buddy, whenever i do maintenance on aircraft, i always think of the pax seating in an aircraft looking out of the window at altitude of 36000 feet and thinking what if one of those technician messed up with the bolt or imporper torque.🤔😅
Apart from all the engineers, I think the filming team also deserves some respect. Taking shots in all kinds of confined spaces with parts worth millions of dollars, where each engineer is trying to do his job and not to hurt people or equipment, is surely not an easy task. I really hope they got along well during the filming.
factos
good..token...fet..i...well....
Fully agree.
Absolutely!!!!
A big appreciation to the people that work behind the scenes to create such wonderful and safe flights
Indeed
thank you for appreciating us :)
Thank you for your hard work @giovanniepaulo9242
Amazing documentary...The best line was said by the technician while removing the passenger seat and seeing all the dirt the passengers leave behind... "I am always dreaming to maybe find... a diamond "
You'd be amazed at the things we found in this job. Most of them were... Not good.
As a potential Mechanical engineer, I really appreciate the great work everyone does to ensure the safety of people. Unsung heroes, exactly why I love Engineering.
The maintenance in the first world is very accurate and time consuming. How are the maintenance crews in third world countries. Are they up to standards.
I hope you are on your way to doing this! You will never be unemployed, wherever you live and you will be able to choose where to live. There is a massive, world-wide shortage of licensed aircraft engineers (as we call them in the UK and Europe, mechanics and repairmen I think in the US). I kind of wish I had gone that route into aviation, which is a wonderful business to work in.
@@jan22150 generally yes. 20 years ago or so I could not be so certain, but if you look at the accident statistics for aviation they are incredible. I think in 2017, excluding small turboprops with 30 or fewer seats, no-one in the world died in an accident in an airliner. That was an anomalous year but only possible because normal years have very, very good safety statistics.
@@randomxnpI'd say the shortage is due to the pay, a lot of people leave the job due to the small potential salary growth meaning experienced engineers will leave, which is why so many people want to be pilots (their wages continue to grow throughout their career to upwards of 400k p/a), where as an AME/LAME will go from around 30K as a 1st year apprentice, to 130k as a senior LAME. Hopefully the maintenance get the pay rise they deserve shortly.
Being an Aircraft Maintenance Engineer was my first ambition as a little boy. I am always awestruck to see how planes are taken apart and put together again. Hats off to these men....and women(edit)!
And women :)
@@ErictheRN ...and yes women...my apology. Regards.
Did u get to be an air tech? :) I hope ur dream came true
@@Ahn-mu3db ....no I didn't... thanks for asking.
Congrats to all aviation maintenance workers around the world for millions of lives are in their hands. Best wishes from Brazil. God bless you
I was a Maintenance Engineer; What a mammoth task to overhaul one full aircraft to ensure that it is safe for the next 6 years and for all its passengers! How much effort in organizing every thing? And when I imagine how to organize the maintenance of Military Aircraft during a war!!
I flew the 330 years ago. The passenger variants sit on a roughly 1 degree nose down rake, which is why when they lifted the plane on the jacks they first had to bring the nose up level before lifting at the wings. The 330 is a great aircraft to pilot, and I miss flying it.
I'm currently studying Aircraft Maintenance Technology in the Philippines.. I'm inspired with this guys RESPECT
me too
San kayo nag aral? Ilang years?
I enjoy watching these supervisors telling the aviation maintenance professionals how to do their job.
It’s kinda the supervisors job and responsibility
Hats off to these guys for making our air travel safer!
Lufthansa Technik, the best in the aircraft MRO industry. It was an honor to be part of the family.
Hi iam an aircraft mechanic too.Can i get your contact num?
These are unsung hero's behind the scenes of safe travel
Hats off to all the engineers.......
It’s all common sense! This is just over sensationalised !
Efficient us Maltese 😁
Only aerospace engineers.
These little things holds everything together...That sums up engineering and life....No big or small...Everything has its value
here i am afraid to take apart 6 screws on my laptop in fear of not being able to put it all back.
Your head is the missing screw
That is being done every single day in Haiti.
Only took them 39 days though.
A hammer will do the job fine
Fixed a PS3 controller once. Just couldn’t put the putter plastic back together though and threw it away
What a mammoth project !!! These men and women are miracle workers. Five Stars to each !!!
I wouldn't like to be in the shoes of that manager, what a responsibility and challenging job. Hat off.
Ikr, I was thinking that too, I'm only a student but it's already a headache lool
True, that's why he's an experienced professional for the job.
I love the fact that the guys are speaking English, that's very professional.
Jeremy Cubs Us Maltese speak our native language (Maltese obviously) and English. A lot of people also speak Italian, French, Libyan and Arabic.
English is the international language of aviation...all the manuals...inspection reports etc are in English
Respect for every single engineers & mechanics. bravo.
thanks
Even the Boeing ones? :P
@@PP-ed9cf ¹¹ssaaaaaaas
Im korean aviation mechanic. Thank you for rooting
Antonmursid🇮🇩🙏🙏🙏🙏🙏
Its a could have should have job for me. Fascinating and now I live 15 miles from a major cargo hub with major maintenance facilities.
Did this on corporate aircraft 42 yrs. Enjoyed the Huge amount of work to accomplish. Also liked the use of channel locks, some times ya gotta do what ya gotta do. Airplanes are not easy. Concentration is a must, the industry needs to understand that but they do not. They continue to push the techs to exhaustion. It is easy to loose the EDGE when you are worked to hard by the employer, unfortunatly they don't care.
@Flight Forensics corporate and commercial aviation are 2 dif beasts. There is a higher standard in corporate aviation in my opinion. I agree with Glenn, management will push you to the brink of sanity with mandatory hrs, days, weekends for months on end.
Corporate jobs are different than working at a repair station. You get trained on the aircraft they operate. Repair stations you train with more experienced tech's and you go from there. 2 head's are better than one. Any tech that is worth a damn always gets his work inspected. We are human
I wouldn't say they didn't care necessarily, it's probably more an issue of cost and the almighty dollar unfortunately.
Sfo. Moc, understand and agreed...
48 years helicopters and aeroplanes. Most days I loved it some days I bloody hated it. Glad I'm now retired.
Respect for the Engine Mechanic Doing all they can to make it Fly Safely
The amount of wisdom, knowledge and work which is needed for us to go from place A to place B without dying on our way...
ok...my...bos...my...fand...merja...u...i....ol...taiem...onlain...entar...nat...cet...kormo...sob...somoa...u...token...good...ame....liek...kore...love...merja
One of the best insights into airliner maintenance that I have seen.
The way the technician was maneuvering inside the fuel tanks reminds me of the superheater tubes i used to maneuver during some routine power plant boiler inspections
The satisfaction of watching the plane fly again after 40 minutes of maintenance with only me involved in the task and KZhead being my companion along the way.
Proud have been part of the Aviation Mainrenance planning and scheduling! Time is of the essence, tight scheduling, in between this one also has bx1's 2's and AOG'S, additionally daily sched. of daily work for mechanics. somewhat exciting, nerve wrecking @ same time.There is no garage in the air for Passenger Travels. one small setback can turn into a huge one i.e Lcc southwest @ xmas! Big up to Maintenance so much can be said" Credit to all in Aviation Industry"✈️ 🇧🇧 A&p licensed, Planner/scheduler. Aviation school Teachers also deserve credit.🙏🏾
I am an Aircraft Power Plant Engineering in an Airline MRO Company its like Lufthansa Technik but different country, I have been worked for 1 year. this Video really gives me knowledge and experience to me. big thanks for this channel showing the most beautiful and high definition Video.
ok...good...token...daman...well....sopna...mom...roje.. codaitam...cei...
In 2022, I was on a flight that caught fire in the engine. The trained pilots saved the day. I kept thinking who was in charge of maintenance or it was just a bad day for the craft but a lucky day for us. Maximum respect to the engineers and filming crew
AMAZING INSIGHT IN THE WORLD OF AIRCRAFT MAINTENANCE, LUFTHANSA has one of the best safety records.
Congrats to all of you! You're doing an awesome job, you're keeping all of us safe during the flights. Thank you!🙂👏👏
I’d love to see an in-depth documentary like this on a cargo conversion
These are dedicated and awesome engineers avoiding every petty mistake. Good workers.
👍💕to all Aeronautical engineers kudos for all the passion, time & effort you put in in your daily work so that we can fly safe & sound. Blessings to y'all.💖💯🙏
The one who cleans the fuel tank!!! Respect to every part of this complex job. 🙏 It's a cool job to be part of it, nevertheless ❤️
This is a real responsible job, disasters happened because of fe wrong screws were used or the fuel tanks were not cleaned well. Great upload, thanks for sharing.
Glad you liked it. My dad worked in airplane maintenance for Air Canada. It is indeed a job with a lot of responsibility and you have to brave icy temps in winter. He found that super tough.
I worked at hartsfield international airport back in the 90s as part of my security career I'm retired now. Back in the 90s I spent 3 years as a contract security officer there. One of my final assignments was working at the technical operations center that Northwest airlines operated for all of their non-747 aircraft. 747 maintenance was done at Duluth Minnesota at the TOC there. I got a chance to watch airframe and power plant personnel literally strip an aircraft down in the same way you're seeing in this documentary A medium maintenance check would run around 14 days, what you see in this documentary is a heavy check which runs between 21 to 28 days or at least it was back when I was working there as part of the facility security team. There were three shifts averaging about 400 personnel, specialist in airframe, power plant and avionics. Part of the job is to literally rebuild an aircraft from the ground up as necessary if something major requires it. One of my biggest memories was being at the East gate personnel control point guard station at 5:30 in the morning listening to twin Jet engines being run up as part of the final systems check, prior to return to service ., And feeling the guard post literally move because of the vibration, and noise from the engines. It's a memory that will stick with me forever.
I was one of those mechanics Great duty until 9/11
People everytime forget importance of an Aircraft maintenance engineer and give all credit and respect to pilots🙂
Instead of sleeping I’m watching this
Kudos to these guys and girls for doing such an amazing job. I know it is quite an undertaking but they made it look easy.
This is detailed job to the max... Its very specific stuff
now..pich...7o...le
Fantastic level of skill, cooperration,and consentration, those folks display. After that, the aircraft is as good as new. If not better. Facinating to watch. Respect Guys. 👍👍👍😊
We also have Lufthansa Technik here in the Philippines! When passing by the MIA, I saw one BA A380 inside one of their hangars.
oh me too
@@lhencalot8339 I never even imagined seeing an A380 in front of my eyes even for just quite a bit! #HappyMe
uh... they have maintenence there but they're not yet ready to have them in service? Isn't all the work done to accept the A380 at MNL, except there was not enough interest from investors to start a route to and from MNL?
It's rare to see such a big High tech task. The Engineers are like Hollywood actors performing in precision. Small team doing a great job with clean maintenance. Very well directed, photographed and presented. Thanks.
It's incredible how much hard work and great effort that is put into these incredible machines, massive respect to all the mechanics and engineers....
I'm enrolling in school to start a new career in this field. I've always injoyed taking thinks apart and putting them back together.
Wish you the best.
Have tons of family members making great money doing this work with nothing but a certificate or an associates degree and an FAA license. Highly recommend. Pay has also gotten significantly better in the last several years.
There’s a book about a guy that this work but I forgot the title or the name of the author it should be a good read you can probably google it and find it.
Very young team leaders, must be super smart people! :)
or very high turnover ;)
Respect to all the flight maintenance engineers.
Just imagine all them peanuts and tic tacs under those seats after 6 years :D
45:41 It’s like your house needs to be safe to fly Same guy from UP?
Currently taking aircraft maintenance in college, hope i could work on one of these big companies someday. The work they do is just fascinating and inspiring!!!
I am studying aircraft maintenance too
Is it hard to study aircraft maintenance?
@@Justin-ne6rw it’s not hard bro do it you have to put dedication and study for your test
For all those studying aircraft mx, start watching air crash investigation videos on here. Mentour Pilot and Air Safety Institute are good ones. You'll look at your job in a different light.
@@Justin-ne6rw There a book written by mechanic , but I forgot he’s name it will show you the in and outs of these career. You can google it and find out.I have done research on this career.There’s businesses that also sell books about these career including FAA. The is a school in New York a high school where you earn your high diploma along with your A&P certificate. The other way doing is joining the AirForce. Best wishes.
Amazing the hours and dedication put in to keeping a plane flying. The cabin engineer removing the seats saying he'd aleays dreaming to find a diamond reminds me of when my wife lost an earring in the aeroplane toilet. I was on my hands and knees looking for it. Luckily I did find it under the foot pump for basin water, and saved me having to buy her a new pair 👍
Andre is really young! Good to see young engineers
Qué gran vídeo!!! Felicitaciones a todo el equipo y muchas gracias por hacer nuestros vuelos más seguros.
"D" Check the most comprehensive servicing that adds longevity for each aircraft!
It is amazing that despite so many costs an aircraft still makes profit
That's why they employ their own engineers.
Is it? They charge you for everything while onboard, from food to water or WiFi
1st class suit cost you 40000$
not too often though. You really see airlines going bancrupt constantly like Thomas Cook, Monarch, Air Berlin, Germania... . Or there are huge airlines still around which are making huge losses (South African Airways, Etihad, Alitalia..). Having a profitable airline is very hard.
@@jamesonly9998 Since when does Lufthansa charge you for food and water? You must be flying budget airlines only
Re bearing : it is a relief when I see the engines moving
Truely..similar feeling
Enjoyed this so much.
kzhead.info/sun/q8OyeNiefnpmoYE/bejne.html
vary...good...spek....capte....wll.....ebreteg....wll....i
Proud to be an Aircraft Maintenance Technician ♥️✈️
@Jake Penny yeah those tanks are known as a center thanks usually no fuel 😁
@Jake Penny so where is the tanks?. And why is it never filled?
@@fiqhriprimanazon6720 obviously compressed air. those tanks only hold the chemtrail fluids.
@@Horstroad lmao
How much do you make monthly approximatley?
As pessoas que trabalham por trás dos bastidores tem total importância na realização do trabalho. Parabens a todos eles que fazem acontecer.🎉
I guess they do it in Malta because of the guaranteed good weather. Amazing country and wonderful language - a mixture of arabic and italian, truly unique.
At first, I thought they were speaking English for the documentary. However, I heard several different accents., and didn't hear a foreign language. I wonder if they typically speak English amongst themselves, because of the diversity.
@@carlwilliams6977 I know they introduced that Filipino girl, her title card said Lufthansa Technik Philippines rather than Malta, so they have different divisions, and she was probably on secondment, there was another Filipino guy working alongside her at one point as well. so yes, you're probably right.
Beautiful.. I learn more watching how the team works and how the team leader instructs them to focus on their assigned tasks.. The team leader is very encouraging.. and. his. workers is like a family .. I learn many things watching your video.. Hope more nice video to come .
Ggg un
Ya😊 c😊😊😊😅huí huy guu
Ya g tu g tu gy ya😮 ya g ffytg ya guggff g hoy ya g😅😮y tú gg
You have no idea how much I admire the people who invent the airplane, light bulb, iPhone. I want to build my own airplane, amen! 🙏🏻🔥🥰💕💙😍👏🏻
Engineer: we need to use an air pump because we can't have electricity in the fuel tank. Film crew: but we need to go in with our camera equipment to film him. Also engineer: Ok that's fine
Barry Richards it is fine the electric tools have electric motors which have commutators and brushes that arc when in use unlike a camera that has no moving components
Causing static is the main issue because it builds up an electrical charge, so special footwear is probably worn. Things need to be earthed so the camera eqpt and cameraman will be fine as long as they're also earthed.
Ever heard of battery operated cameras?
How the hell did man build an airplane? Genius.
It's called combining science with technology. When the human brain understands what works in nature and then exploiting it for his ends. This is what engineering is all about. It's about finding the loopholes and exploiting the laws of physics. It's not only genius but it essential to human existence.
by studying the creators plane birds how you think
plane go brrrrr
O2
I work on the Latam MRO, and we operate this kind of check, even 12 years. The safety is one of the principals that rules our work daily. We really have to disassembly all the aircraft to open access to inspections of each component and surfaces inside and outside. We realize tests and the acft goes away only when everything is operating properly. ✈
I respect everyone in the team for team work... All the best👍💯
The turbines are removed only during Engine overhaul. What you remove from the aeroplane are engines. I know I'm just being picky. Thanks for a great presentation. Cheers.
I fly Lufthansa.... Great to see them taking this kind of care. All the people look like the real deal. I like all these international folks and making things happen. Great to see.. Well done.. ==BOZE==
Well, at 25:30 there's some error, the flaps' task is to increase the lift force of the wings, not to increase air resistance. At take offs it is needed, so that the aircraft needs a shorter runway to achieve the amount of lift required to take off. At landings the flaps' task is the same, to increase lift, if there wasn't any flaps available, the aircraft would need much more speed (to have sufficient amount of lift), and therefore a much longer runway to land.
yeah the commentary on this video is shocking. However they're not wrong that deployed flaps cause an increase in drag (air resistance) but that's not their primary function.
@@christopher4636 by writing " flaps' task " I thought it was obvious that they do increase the drag, slightly, but yeah you're right, I should have mentioned it
What an interesting video. Amazing how much work goes into it.
this channel deserves more subscribers than what it has. BRILLIANTLY!!!!!!!!!
thank you much for the Love and Dedication to ur work who always think the safety of all the future passengers...SALUTE to all of you.thank u...
I love the quiet confidence, of these professionals. 👍🏻😷🙋🏻♂️🇩🇰
This has remind me of time wen I worked as apprentice in one of the biggest Jet Engine Workshop... that was Wonderful time
The fact that such a huge body involving abundant engineering application is just so profound. Hats off to all the engineers and mechanics.
@
Gonna start a Certificate II in Aeroskills in two weeks, this will start my career as a aircraft maintenance engineer, hope one day I can be doing it on the big planes.
Wow, incredible job !! Very complicated, delicated and extremely exhausting. Totally solute these people and they are doing a great job !!
now..pich..69..p
they're amazing great, i feel like they're the best in the world
A big salute to the whole team !
According to the math, in order to complete a 40 day "D check" like they call them in Canada, or "Block check", it would take 26 persons, working 24 hours a day, for 40 days.
40 days doesnt seem like a enough..WOW! Very impressive.
WOW...this team is extremely concentrated at all times!
Hats off to the the whole team. 👌
Great job guys bcz of ur hard work we can fly safly but i would appreciate safety helmets at work for ur safety.
their hats are (fashioned) safety helmets
They're doing maintenance, not manufacturing
When you look at the Crew doing the job you realize that,they are multi nationals and for that I salute Lufthansa for
I worked in a large hangar in the midwestern US. We had any number of foreign nationals working there, and it's almost embarrassing how much better some of them were than our local guys. Our guys mostly saw it as a job to do. The foreigners seemed to see it as a reason for living. I could barely understand some of them when they spoke, but watching them work was mesmerizing. They were true masters of their craft.
I love all these documentaries, one thing would be nice when your telling measurements in Imperial, also give Customary measurements. Nevertheless amazing.
26:39 OMG look at the straps, they are twisted, must be flat.
I love work in this type of working environment... Its very challenging... Philippine Airline beke nemen?? Hahaha
magkano kaya ang sahod 🤔
@@emransampao9730 malaki siguro.. Hangar eh.. Hindi biro, dito palang sa video.. Hehe
Actually, sobrang baba ng sahod ng Aircraft Mech sa pinas kaya daming umaalis at nag aabroad
Great Video Documentary and Great Respect to the Unsung Heroes of Aviation team . Brilliant Job Done :)
My God! what a huge task to repair and maintenance work of flight! I find no words to express my feelings. Its just a wonderful work. Challenging task. Its the capacity and intelligence of the humanity, that god has blessed to humanity ! Finally many many thanks for posting such a wonderful video...
If they made a weekly program about this, with a different plane each week, I would definitely watch. Of course if they did they would have false drama, like that dude in the wing would be overcome by fumes or they would be missing an entire row of seats.
leper...ol...xx...n...vedeo...ame...kob....balo...pai..ame...amara...lepe...coda...da...na...sobaira...da
You could do a different part of the plane each week. The difference in jobs between the cabin crew and the engine crew is pretty profound. In fact, just removing and reinstalling all that insulation so the inspectors can check the skin is a major chore. It took me longer to do insulation in the environmental area of a 737 than it normally does to replace some major components.
so the Pilot episode is about airplanes?? nice
All respect to that guy going inside the fuel tank and sweeping off contaminants by himself.
Incredibly interesting very interesting video. Hats off to the entry team of maintenance department.
ok. .i...well. ..mantanek...depat.mant.. worken....enjeneare...job.....i...well..sex..ce...i.....china...well
thank you so much for this document.
Every part of the world there is Filipino! Mabuhay!
Its not every part of the world-Lufthansa Technik has a branch in Manila Airport so of course there will be Filipinos working there, just like the Maltese guys working in the Malta branch
Nice video!