Overhaul Services

Pending Steve Paine

Engine repair, overhaul, and workscope management at Rolls-Royce network overhaul bases

Service Overview

Overhaul Services covers Engine Repair & Overhaul and TotalCare Workscope & Shop Management, in order to carry out shop visits at a Rolls-Royce network overhaul base.

Engine Repair & Overhaul

Actual repair and maintenance of engines in the overhaul shop

Workscope & Shop Management

TotalCare workscope definition and shop visit management

TotalCare Coverage at a Shop Visit

Customer Specific

Coverage at a shop visit depends on the contract and on whether the event is qualified or non-qualified. The general inclusions for the engine build standard stated in the TotalCare contract are:

  • Provision of Parts (as defined in the TotalCare Agreement)
  • Required labour: strip, in-house repair, rebuild, and work recording
  • Outside specialist repair
  • Associated overhaul base charges (service fees, handling fees, test fees, pool charges)

Note: Wording subject to commercial review. Specific inclusions vary per contract.

Rework Level Definitions

Engine and module rework level definitions (Check & Repair, Refurbishment, Overhaul, and Levels 1–4 module work packages) are defined in the relevant Engine Management Programme (EMP) and TotalCare Agreement.

Refer to the EMP on the Rolls-Royce Portal for current rework level definitions applicable to your engine type.

OHB Responsibilities

1
Engine Arrival and Inventory

Inspect the engine for inventory and inform RR AST of any missing or damaged items, transportation equipment, or parts required

2
Engine Induction

Commence the induction and repair process

3
Engine Work

Carry out work in accordance with the agreed work scope; provide status and workscope updates as required to Rolls-Royce and the Customer

4
Engine Testing

Conduct engine testing to verify serviceability

5
Dispatch Preparation

Ensure engine is installed in a serviceable transportation stand and prepared for transportation in accordance with the Transportation Standard

6
Dispatch Notification

Advise RR AST and Customer that the engine has passed test and is ready for dispatch

7
Documentation

Provide all required dispatch paperwork (see Documents at Dispatch section)

OHB Sequence

The following sequence describes the activities from engine arrival at the Overhaul Base through to dispatch.

1
Engine Arrival
OHB

Engine delivered to Overhaul Base facility

2
Engine Inventory
OHB

Overhaul Base inspects the engine for inventory and informs RR AST of any missing or damaged items, transportation equipment, or parts required

3
Shortages & Damage Notification
Rolls-Royce

RR AST notifies Customer of any shortages or damages and will review

4
Customer Resolution
Customer

Customer to deliver shortage parts if available. For damage, Customer and RR AST investigate and decide whether repairs are Additional Services.

5
Engine Induction
OHB

Induction and repair process begins at the Overhaul Base

6
Engine Worked
OHB

Overhaul Base carries out work in accordance with the agreed work scope. Status and shortage updates provided as required.

7
Dispatch
OHB

Overhaul Base advises RR AST and Customer that the engine has passed test and is ready for dispatch

Customer
Rolls-Royce
Overhaul Base

Shop Visit Reports & Dispatch Documents

After concluding the work on an engine, Rolls-Royce will provide the Customer with one copy of the documents detailed below. Documents are available through TRES and OB SharePoint Portal.

Dispatch Documentation (provided within 5 working days of Form 1 provision)

  • Airworthiness certificates as defined on the workscope
  • Life Limited Part summary and integral parts list (part number, serial number, TSN hours/cycles, life remaining)
  • Airworthiness Directive Compliance Status
  • Parts shortage list
  • Module Log
  • Accessory on-off log
  • Carry forward items and in-service inspection requirements
  • Any applicable TVs with short interval maintenance requirement
  • SB, RTV/TV compliance status
  • Engine test log / performance reports
  • Pre-induction BSI reports
  • PMA/DER statements (only if applicable)

Engine Shop Visit Report

Provided within 30 days of redelivery. Includes:

  • Summary of work accomplished
  • Workscope level per module
  • Service Bulletins incorporated
  • Applicable TVs

Parts Shortage Management

During Shop Visits

  • The OHB will aim to return the same unit to the Engine from which it was removed
  • If a part/LRU is not available at kitting, the OHB will seek assistance via the Rolls-Royce OBM
  • The RR OBM will review options with AST, Customer, and LRU Management team
  • Shortage updates are provided as required by the OHB during shop visits

Shortages at Engine Arrival

  • RR AST notifies the Customer of any shortages or damages
  • Customer to deliver shortage parts if spares are available
  • Damage is investigated jointly by Customer and RR AST

Parts Beyond Economic Repair

If a part/LRU is deemed beyond economic repair, the Rolls-Royce OBM will agree replacement options with the Rolls-Royce AST, Customer, and the LRU Management team as appropriate.

Turn-Around Time

Rolls-Royce will be responsible for monitoring turn round time in shop and will advise the customer on the expected time period.

Key Timelines

Status Updates

As required

Shortage Reports

As required

Shop Visit Report

30 days post-redelivery

Reference

For Rolls-Royce and Customer obligations in respect to the Engine and Overhaul Service, refer to Part 1 of Schedule 4 of the TotalCare Agreement.

Abbreviations

OHBOverhaul Base
OBMOverhaul Base Manager
ASTAirline Support Team
EMPEngine Management Programme
TVTechnical Variation
SBService Bulletin
TRESTechnical Records

Pro Tip

Ensure the workscope is fully agreed before the shop visit begins to avoid delays and additional cost discussions during the process.