In a recent interview with MRO Business Today, Thomas Knäpper, Managing Director of RAS SAAR GmbH, ensures high-quality aircraft maintenance through advanced technology, rigorous training, and a commitment to safety and regulatory compliance, supported by a dedicated team and extensive industry expertise. For a deep dive into Knäpper’s vision and strategies, read more about the conversation and discover how RAS SAAR is setting new standards in aircraft maintenance.
Q1. How does RAS SAAR ensure high-quality and professional support in aircraft maintenance and technical matters?
Ans: RAS SAAR ensures high-quality and professional support through sustainable maintenance protocols, cutting-edge technology, and continuous investment in staff training and organizational development. The company utilizes a set of procedures to enhance customer interactions, ensure personalized support, and streamline communication processes. This approach helps in maintaining a detailed record of our client’s requirements and feedback, leading to improved service delivery of RAS SAAR and much higher client satisfaction. Our team of over 100 skilled technicians and engineers in Saarbrücken is dedicated to maintaining the highest operational and safety standards.
Q2. Can you elaborate on the specific services offered by RAS SAAR for regional jet and turboprop aircraft maintenance?
Ans: RAS SAAR GmbH, as part of the Rheinland Air Service (RAS) group, benefits from a network of facilities and expertise that strengthens its service capabilities. We at RAS SAAR offer comprehensive maintenance services for regional jets and turboprop aircraft, including scheduled maintenance, inspections, repairs, modifications, and overhauls. The company’s advanced workshops and facilities include a paint cabin, battery shop, sheet metal shop, wheels shop, composite repairs shop, and avionics shop, enabling us to handle complex maintenance tasks with high precision and efficiency. We specialize in maintenance for ATR42/72, DHC-8, Do328, and since the beginning of 2024 also on Embraer E-Jets.
The RAS group enhances our capability portfolio through its extensive MRO services provided by its Mönchengladbach facility. This site features 12 in-house component shops specializing in flight controls, access panels, floor panels, composite components, de-icer boots, leading edges, and more.
Additionally, RAS’ in-house non-destructive testing (NDT) capabilities provide faster access to crucial inspections, significantly reducing turnaround times (TAT). This capability allows us to offer a comprehensive one-stop-shop approach, enhancing efficiency and ensuring thorough inspections of aircraft and its components. This integration supports the overall safety, reliability, and quick service delivery that RAS SAAR is known for.
Furthermore, RAS Engineering, a design organization within the RAS group, provides specialized engineering support, including major and minor repair schemes, cabin/LOPA reconfigurations, paint schemes, and avionic modifications.
RAS SAAR GmbH, as part of the Rheinland Air Service Group, offers comprehensive maintenance services with advanced workshop facilities, in-house NDT capabilities for faster turnaround times, and support from the group’s Mönchengladbach facility and RAS Engineering, positioning us and the whole group as a leader in aircraft maintenance services.
Q3. What is RAS SAAR’s approach to modification, repair, and transition management for aircraft like the ATR 42/72?
Ans: RAS SAAR GmbH employs a holistic maintenance approach that prioritizes continuous exchange and adaptation to customer needs and requirements for all types of aircraft which are in our capability list. This comprehensive customer-centric strategy involves detailed planning based on customer requirements, allowing a swift execution to ensure every aspect of the aircraft’s maintenance or transition is meticulously managed. We at RAS SAAR leverage our facilities and highly skilled personnel to provide customized solutions tailored to client needs.
The approach integrates various maintenance disciplines, including in-house NDT capability, structural repairs, complex modifications, and comprehensive refurbishment programs, ensuring that all maintenance activities are seamlessly coordinated and executed. By employing a systematic method that includes thorough inspections, precise repairs, and necessary modifications, we ensure compliance with regulatory requirements and industry standards. This holistic maintenance approach not only enhances the reliability and safety of the aircraft but also optimizes turnaround times and operational efficiency, ultimately delivering superior service quality and client satisfaction.
Q4. How does RAS SAAR manage spare parts support to ensure efficient operations for its clients?
Ans: RAS SAAR manages spare parts support through a robust inventory and efficient logistics. We invest in specific consumables and expendables and have a strategic plan for further investments to reduce the pressure on our supply chain. Our logistics department employs experienced purchasers and warehouse clerks to ensure timely provision of high-quality aircraft spare parts and consumables. Of course, we cannot completely escape the global supply problems for aircraft spare parts, but we have a large network of contacts in the aviation supply chain so that we can always find optimized solutions for our customers.
Q5. As an experienced aviation professional, what strategies have you implemented to optimize the quality, safety, and efficiency of technical processes in aircraft maintenance?
Ans: First of all, I would like to take this opportunity to point out that I took over responsibility as Managing Director of RAS SAAR GmbH less than three months ago. I think that in order to get an all-embracing picture and derive changes and initiate the first steps, a good leader must above all observe, talk to employees, listen and in particular understand. I am currently still in the evaluation phase and am working on possible optimization strategies with my team. I would therefore like to take this opportunity to explain my understanding of what the optimization of quality, safety and efficiency of technical processes in aircraft maintenance depends on.
I think optimizing technical processes in aircraft maintenance is driven by a commitment to continuous organisational learning and staff empowerment. The company needs to foster a culture of an ability to ongoing change, continuous education and training to ensure that all team members and the whole organisation stay abreast of the latest industry advancements and best practices. Transparency is a cornerstone of my approach, ensuring that quality, compliance, safety, and strategic goals are communicated and understood at all levels.
By empowering staff with the technical knowledge and tools they need but also on the strategic long-time goals, I try to enhance their ability to execute maintenance tasks efficiently as well as effectively and furthermore have a better understanding of decisions being taken by the management. This transparent and inclusive strategy not only ensures high operational standards but also aligns the entire organization towards achieving its strategic objectives, thereby maintaining the highest levels of service quality and customer satisfaction
Q6. Could you provide an example of a successful organizational change or improvement initiative you’ve led in the aviation maintenance sector?
Ans: As I have only been a member of the RAS for such a short time, I am unfortunately not yet able to give an example of how a change process has been led by me. These will come, but they still need to be specified. I think the best example of such a change process that I was able to accompany in a leadership role was during my time as a Nominated Person Continuing Airworthiness (NPCA) at Discover Airlines, where I helped set up the airline’s Continuing Airworthiness Management Organization (CAMO). Discover Airlines was founded as a new airline within the Lufthansa Group with no organizational structure or shell to fall back on. The entire operational and organizational structure had to be defined from scratch and integrated into the Lufthansa Group.
All technical processes had to be designed, tested and established, from the selection of personnel and approval under EASA aviation legislation by the LBA to the budget process, the first flight and the start of flight operations. We successfully started operations at Discover with wet lease flights for Air Dolomiti before we operated our inaugural flight as an airline to our first own destination in Mombasa. We then successively added further routes to our network, for which we as CAMO contracted maintenance providers. In the first six months, the CAMO expanded its capability list from A330-200 over A330-300 to A320 with the associated regulatory audits. We successfully carried out an IOSA initial audit and accompanied the first C-Checks at LTP in Manila. I think we started work very successfully as a CAMO team at that time and have continued to develop steadily. Even though the role of the NPCA is an operational role in flight operations, it manages the entire maintenance of its own fleet. I hope you will accept this answer at this point.
Q7. What role does innovation play in your approach to solving challenges in aircraft maintenance and repair?
Ans: Aircraft maintenance is a complex and critical field, facing several challenges that impact efficiency, safety, and cost-effectiveness. Some of the challenges are technological advancement, regulatory compliance, skill shortages, supply chain management, environmental concerns, aging aircraft fleets to name just a few. Innovation plays a crucial role in overcoming these challenges by introducing advanced technologies and methodologies that enhance operational readiness, solve obsolescence issues, reduce maintenance-related costs and strengthen supply chains. At the RAS Group, we need to take a closer look at some innovative solutions and evaluate how they can increase efficiency, improve quality and reduce costs.
Such innovative solutions could be Augmented and Virtual Reality (AR & VR). AR and VR can be used for training maintenance personnel or providing real-time assistance during maintenance tasks. These tools can enhance the learning experience, improve skill levels, and ensure that complex procedures are followed accurately. Another development relates to the technical documentation of the aircraft that we look after and whose data we have to archive securely, verifiably and unambiguously.
We need to assess how blockchain technology can be used for compliance and record-keeping. This technology ensures secure and immutable record-keeping of maintenance activities, enhancing transparency and traceability. This is crucial for regulatory compliance and maintaining the integrity of maintenance records. These are just two examples from a large number of possible innovations. RAS SAAR does not act alone, but we work together in the RAS Group to develop sustainable solutions. This is the strength of our group.
Q8. How does RAS SAAR stay current with advancements in aviation technology and best practices in maintenance and overhaul?
Ans: RAS SAAR GmbH stays updated with advancements in aviation technology and best practices through continuous exchange within the industry, cooperation with European aviation training facilities, and partnerships with universities. This proactive approach includes participating in industry conferences, engaging in collaborative research projects, and leveraging the expertise of academic institutions. By fostering these relationships, we ensure that our staff are continuously trained and aware of the latest technological innovations and regulatory changes.
This commitment to ongoing education and industry engagement enables RAS SAAR to maintain high standards in maintenance and overhaul, ensuring that our practices are always at the forefront of the aviation industry. We also employ RAS’ PART21J Design Organisation (DOA) by participating in programs with a research component.
Q9. Can you discuss the importance of regulatory compliance in aircraft maintenance and how RAS SAAR ensures adherence to aviation laws and standards?
Ans: Compliance and safety management are critical in the aviation industry as they ensure the highest standards of operational integrity, prevent accidents, and safeguard lives. For us at RAS SAAR, maintaining rigorous compliance and safety protocols is essential to uphold our reputation, meet regulatory requirements, and provide reliable, high-quality maintenance services to our clients. The regulatory compliance at RAS SAAR is ensured through rigorous internal and external audits, continuous training, and obtaining necessary certifications.
Internal and external audits are crucial as they provide an objective assessment of compliance with aviation standards and identify areas for improvement. External audits are used to ensure that we do not lose sight of external perspectives or become blind to our operations. We use external experts to audit our processes as well as competent personnel from the entire RAS Group. The exchange of compliance personnel between the different facilitates the sharing of objective views and best practices, ensuring alignment within the RAS Group and fostering continuous improvement in regulatory adherence and safety management.
Additionally, continuous training ensures that staff are up-to-date with the latest regulations and best practices, maintaining high safety and quality standards. Cooperation within the RAS Group further enhances compliance by sharing knowledge, resources, and expertise across different facilities, ensuring a unified and thorough approach to regulatory adherence. RAS SAAR adheres to guidelines set by aviation authorities such as EASA, CAA (UK), and FAA to maintain compliance. Here too, in the important area of compliance and safety management, RAS SAAR GmbH benefits from the diversity of the entire RAS group.
Q10. What are the key factors you consider when developing and implementing maintenance schedules for regional jet and turboprop aircraft?
Ans: First of all, I would like to state that RAS SAAR GmbH does not have its own CAMO and is not affiliated with the technical department of an airline. Therefore, we do not develop maintenance schedules, we can only contribute to them. However, a maintenance organization has a great responsibility in this contribution. Every CAMO’s reliability program needs reliable data. This data is recorded by us as RAS SAAR, be it in the form of measured values, execution of operational tests or consumption of operating fluids such as engine and hydraulic oil. The drivers for a maintenance program are ground times, the airline’s operating model and maintenance capacity in the flight plan.
When supporting maintenance schedules, RAS SAAR considers factors such as manufacturer recommendations, aircraft usage patterns, historical maintenance data, and regulatory requirements. They aim to balance optimal aircraft performance with minimal operational disruption. Therefore, we recommend the adoption of predictive maintenance technologies, such as advanced sensors and data analytics. These allow maintenance teams to monitor the health of aircraft components in real-time. This helps in predicting failures before they occur, reducing unplanned maintenance and downtime, and optimizing the maintenance schedule.
