The Duncan Download Blog: Business Aviation Advice & Observations

Contributed by Interior Modification Reps. Nate Darlington and Matthew Schepers

Maintaining an aircraft interior involves much more than keeping the carpets and seats clean. Functional interior items also require regular adjustment, and if done regularly can help an interior modification last longer.

Articulating chairs, executive tables, doors and cabinets will break or damage surrounding materials if they aren’t maintained. It takes very little time to make sure doors and drawers are properly adjusted and won’t puncture the cabinet veneer. Otherwise it takes multiple hours to repair and refinish the veneer.

When interior items become a nuisance, scheduling can become a last-minute addition to the workscope, which can extend downtime and increase costs beyond the budgeted expenses. Aircraft availability can also be affected if last-minute additions cause scheduling conflicts, or when there isn’t enough lead time to order necessary materials. As a general rule, larger aircraft should have interior projects planned at least six to eight weeks in advance. Smaller aircraft can be done with less lead time, about four to six weeks.

Operators tend to consider the condition of an interior about every six years or so (the typical lifespan of an interior). However, not all materials last that long without regular maintenance. The ideal way to schedule interior maintenance is to coordinate it with phased airframe maintenance events of similar downtimes. At Duncan Aviation, we call this approach “Phased Interior Maintenance.”

For example, maintenance events that require the removal and reinstallation of seats and floorboards are a prime opportunity to install carpet and replace softgoods. Nearly all aspects of an interior refurbishment can be divided among multiple maintenance events, which helps improve aircraft availability and keeps an interior looking new through the end of its functional lifespan.

Duncan Aviation works with operators to create custom interior maintenance schedules for Directors of Maintenance (DOMs) and their aircraft, free of cost or obligation. For advice on how to keep your aircraft interior looking new without the expense and downtime of a complete interior refurbishment, request a phased interior maintenance schedule at www.DuncanAviation.aero/interior.

Nate Darlington serves as an Interior Modifications Rep. at Duncan Aviation’s Battle Creek, Michigan facility, and began working in aviation in 2001. Matthew Schepers also serves as an Interior Modifications Rep. at Duncan Aviation’s Lincoln, Nebraska facility, and began working in aviation in 2005. Nate and Matthew both work with operators to plan phased interior maintenance schedules for their aircraft.

In March of 2010, the first blog post for the Duncan Download was published. Today, in honor of our 100^th blog post and the success of all of Duncan Aviation, we are sharing with you a list of 100 achievements, milestones and down-right cool things to brag about that have occurred at Duncan Aviation since the first post.

Celebrate with us.

Company

1. 55^th anniversary of company founding observed
2. 168,377 square feet of leather goods purchased for new aircraft interiors at BTL and LNK
3. 5,457 Component Solutions customers served worldwide
4. 7,259,089 gallons of Jet A fuel sold at Kalamazoo, MI (AZO), Battle Creek, MI (BTL) and Lincoln, NE (LNK)
5. 133,864 gallons of Avgas sold at AZO, BTL and LNK
6. 1,652 aircraft delivered out of maintenance at BTL, LNK and Provo, UT (PVU)
7. 615 business aircraft maintenance road trips to seven countries from all locations
8. 160 business aviation conventions and events attended by Duncan Aviation
9. 1,342 AOG engines returned to service in the field by Engine Rapid Response
10. 1,810 engines returned to service out of BTL and LNK
11. 204 TFE731 MPIs performed in LNK
12. 22 Pratt & Whitney Hot Sections performed in BTL
13. 126,077 Fed Ex packages shipped and received totaling 3,709,389 pounds
14. 258 aircraft interior refurbishments performed in BTL and LNK
15. 93 business aircraft painted at BTL
16. 141 aircraft Wi-Fi solutions installed per a STC at all locations; majority under a Duncan Aviation STC
17. 157 in-flight internet solutions installed. Duncan Aviation is the market leader
18. 30 WAAS/LPV systems installed at all locations
19. 25 Falcon winglets installed at BTL and LNK
20. 52 Falcon dry bay mods completed at BTL and LNK
21. 24 Gulfstream water line ribbon heaters upgrades (ASC 469/173) performed
22. 63 business aircraft prebuy evaluations performed in BTL, LNK and PVU
23. 624 aircraft landing gear legs overhauled
24. 1,851 aircraft batteries overhauled or reblocked
25. 13,710,410 aviation parts sold
26. 345,000 Component Solutions customer service calls
27. 11,360 aviation tools calibrated
28. 2,355 NDT inspections performed
29. Secured full contractual logistic support for the Mexican Navy Lear program 
30. 4 year F20 contract renewed with Royal Norwegian Air Force
31. 13,800 additional labor hours contracted with Offutt AFB in OMA
32. 1 year contract renewed with Egyptian Air Force
33. 2 L60 Flight Inspection Aircraft delivered to the Malaysian Department of Civil Aviation
34. Signed contract for Egyptian Air Force G3 Hush Kit installation
35. 62 customer dinners at BTL and LNK
36. 10 customers serving on Duncan Aviation’s Customer Advisory Board
37. 10 members of Duncan Aviation’s Board of Advisors
38. 10 customers to serve on the new Duncan Aviation European Customer Advisory Board

Facilities

39. 25^th anniversary of Avionics Satellite Network observed
40. 10^th engine Rapid Response location opened in Seattle, WA
41. 4 new Satellite Avionics locations opened
42. 3^rd aircraft maintenance facility opened in Provo, UT, with Bombardier (Challenger/Learjet) Authorization
43. 1 new paint hangar construction project breaks ground at LNK
44. AHA Fit Friendly Platinum awarded to BTL and LNK
45. Regional Health Alliance Workplace Wellness Award presented to BTL
46. 2010 United Way Corporate Volunteer Company of the Year presented to BTL

Authorizations & Certifications

47. 30th anniversary of Honeywell Authorized TFE731 Major Service Center
48. 51 revisions approved for existing STCs
49. 8 type design amendments approved for existing STCs
50. 16 new STCs issued
51. 7 Wi-Fi STCs issued in seven airframes, including the first Wi-Fi STC in the Citation 750
52. 6 WAAS/LPV STCs issued, including the first Learjet 31A, the first Honeywell NZ-2000 FMS in a Falcon 900B and Challenger 601-3A
53. 6 foreign certificates renewed by audit
54. 5 PMA supplements added
55. 4 interior alteration STCs issued
56. 1 FIS STC issued
57. First iPad integration for Cabin Control in Falcon 900 certified, iCabin service mark earned
58. PVU named Embraer Authorized Service Facility for Phenom 100, 300
59. New authorizations added to China CAAC Repair Station Certificate
60. Named exclusive repair service provider for Avidyne Legacy Display System

Private Flight Services

61. Launched Safety Management System
62. 11 aircraft owned, managed and operated
63. 2,800 flight hours flown by 13 Duncan Aviation pilots
64. 1,000,000 miles flown by 13 Duncan Aviation pilot

Team members

65. 20^th anniversary of Duncan Aviation Project Manager Services
66. 10^th anniversary of Engine Rapid Response AOG Services
67. 475 military veterans serving at Duncan Aviation
68. 312 new Duncan Aviation employees hired
69. 230 technicians attended OEM factory training for 14 airframe or engine types
70. 12 Duncan Aviation employees retired
71. 217 employees volunteered for the 2010 National Special Olympic Games in Lincoln, NE
72. 35 Duncan Aviation employees employed at least 25 years inducted into Silver Wings Club
73. 77 babies born to Duncan Aviation families
74. 15 employees serving on business aviation industry boards
75. 13 employees qualified in or expanded responsibilities as Unit Members under ODA designation
76. 20 multilingual representatives located in 14 countries
77. 1 new European Regional Manager
78. 2,746 vacation hours donated to fellow coworkers in need
79. 2,327 items of food donated to local food programs
80. United Way Corporate Volunteer Company of the year for 2010 (BTL)
81. $177,981 raised for United Way at LNK, BTL and AZO
82. Generously supported many other local charities in every community  

Informational Resources

83. Job status tracking launched for myDuncan.aero
84. ADS-B Straight Talk book published.
85. Field Guides published about business aircraft Issues
86. The Duncan Download Blog launched
87. “Understanding WAAS/LPV” Video Series launched
88. 73 Duncan Intelligence articles published
89. 72% increase in new visits to www.DuncanAviation.aero
90. Updated company logo designed and introduced
91. Company video, websites and brochure launched in five languages
92. Web directory expanded to include profiles of customer contacts
93. WAAS/LPV calculator launched to demonstrate technology value
94. Inflight internet system selection tool launched

Additional Service Offerings

95. Bombardier Global Service capabilities expanded
96. Phased Interior Maintenance program launched
97. Interior Program with 14-Day Downtime Guarantee launched for Learjet and Citation models
98. Chrome-free paint process launched
99. New avionics capabilities for Avidyne Flightmax indicators, ELTA and Socata ELTs
100. Earth-friendly interior materials selected for interior refurbishments

Contributed by Interior Modification Reps. Nate Darlington and Matthew Schepers

It takes very little time to make sure doors and drawers are properly adjusted and won’t puncture the cabinet veneer.

Interior modifications are trending away from complete refurbishments and moving toward partial interior work. Most DOMs are keeping costs down by fixing only what they must to help their interiors look and feel less worn. It’s easier on the balance sheets, but leaves something to be desired in passenger comfort and peace of mind.

With proper planning, a complete interior modification can be effectively phased over several years of regularly scheduled maintenance events. Doing so can extend the “like-new” quality of an interior through to the end of its functional lifespan. More importantly, regular interior maintenance can also help materials last longer, prevent damage, lower costs and increase aircraft availability.

We call this approach “phased interior maintenance.” Here are four ways to get started.

1. Maintain functional items to prevent damage.

Ongoing maintenance of big ticket items extends their lifespan and makes an interior investment last longer, says Matthew. Functional items can break or damage surrounding materials if they aren’t maintained.

It takes very little time to make sure doors and drawers are properly adjusted and won’t puncture the cabinet veneer, says Nate. Otherwise it takes multiple hours to repair and refinish the veneer.

2. Schedule interior items with related maintenance events.

Pairing inspections that require removal and reinstallation of interior items with maintenance for those same items can save weeks of downtime, says Matthew. Inspections that require the removal of seats and floorboards are a prime opportunity to replace carpet and recover seats without extending the service schedule.

3. Anticipate scheduling and budget considerations.

Aircraft availability can be affected if last-minute additions cause scheduling conflicts, or if there isn’t enough lead time to order necessary materials. As a general rule, larger aircraft should have interior projects planned at least six to eight weeks in advance, says Matthew. Smaller aircraft can be done with less lead time, about four to six weeks.

4. Create an interior maintenance schedule.

Estimating downtimes and determining what interior modification services can, or should, be scheduled with maintenance events can get complicated quickly. An interior maintenance plan helps operators perform annual evaluations, anticipate interior repairs, and budget more effectively, says Nate. If the plan is followed, it also helps soften the blow to the balance sheets by spreading interior costs over several years.

Duncan Aviation works with operators to create custom interior maintenance schedules for Directors of Maintenance (DOMs) and their aircraft, free of cost or obligation. For more information, or to request a phased interior maintenance schedule, please visit www.DuncanAviation.aero/interior.

Nate Darlington serves as an Interior Modifications Rep. at Duncan Aviation’s Battle Creek, Michigan facility, and began working in aviation in 2001. Matthew Schepers also serves as an Interior Modifications Rep. at Duncan Aviation’s Lincoln, Nebraska facility, and began working in aviation in 2005. Nate and Matthew both work with operators to plan phased interior maintenance schedules for their aircraft.

Whether or not you have an in-house flight department capable of minor inspections and maintenance on your aircraft, occasionally, you will need to visit a Maintenance Repair Organization (MRO) for larger inspections requiring specialized tooling, more available trained technicians and the hangar space to efficiently perform all required maintenance.

Whether the workscope is large or small, the planning should be done well in advance in a well organized and methodical manner. The result will be a better experience and a united service expectation for both you and your chosen MRO.

Preplanning helps both the operator and the service facility get what they want—a quality job done efficiently and on time.

How preplanning benefits you:

1. You are in control.
2. Freedom to choose a convenient downtime.
3. Choice of service providers.
4. High-quality job, delivered on time, for the best value.

How preplanning helps the service provider:

1. Time to dedicate the best technicians to your aircraft.
2. Schedule the correct amount of resources.
3. Better coordination, scheduling and parts provisioning.
4. Time to perform at peak efficiency and quality.

Every maintenance event is an opportunity to achieve maximum results with minimum downtime. Learn how to leverage scheduled and unscheduled events to your advantage through preplanning and compare key points when selecting an MRO and planning maintenance events.

If you have questions about maintenance event planning, call a Duncan Aviation Sales Representative for your airframe.

As a business aircraft owner/operator, Chief Pilot or DOM, you have orders to cut expenses and come in under budget. That makes it very tempting to go with the maintenance facility offering the lowest bid. However, without fully understanding exactly what each bid includes—or more importantly does not include—going with the lowest number may have the highest cost when the final bill arrives.

After weighing the hard costs of the project and making sure the quotes provided are comparing like products and services, go beyond the bid number and properly compare each MRO.

Identify your priorities and get the answers to these questions.

1. What is their plan to meet your downtime requirement?
2. How much experience do they have performing your required maintenance or modification?
3. What is their stated warranty and what does it include?
4. What are the hidden charges? engineering services, interior R&R, consumables?
5. Are they an Authorized Service Facility / Authorized Dealer?
6. How are unexpected squawks and discrepancies communicated?
7. Will factory-trained technicians be working on your aircraft?
8. Do they have an FAA approved drug and alcohol prevention program?
9. How much insurance will be protecting your aircraft while in their hangar?
10. How will you approve squawks and discrepancies if not on-site?

Use this MRO Comparison Worksheet as a tool to compare your top service provider candidates side-by-side. Key points are identified to more easily find and compare the strengths and weaknesses of each organization.

Compare up to three MROs using the MRO Comparison Worksheet.

Contributed by Lori Browning, Aircraft Interior Designer

In my previous post, Exploring "Green" Materials for Aircraft Interiors, I discussed how I was inspired by some recent eco-friendly fabric collections, and I found that the properties that make them green also make them suitable for aviation burn regulations.

I went beyond fabrics and started looking into carpets, veneers, and other materials used in corporate aircraft to find the most sustainable products available. Here are 12 of my favorite materials and how they might be used to design an eco-friendly aircraft interior:

• 1A - Seats: Green Hides Leather, processed using environmentally-friendly, low-emission mineral tanning formulas and finished with water-based products.
• 1B - Cabinet interior: LEED-certified material for recycled content, indoor air quality and rapidly renewable resources.
• Carpet option: 100% rapidly renewable, Leadership in Energy and Environmental Design (LEED)-certified wool.
• 1C - Carpet option: 100% rapidly renewable, LEED-certified wool.
• 1D - Divan: Bamboo fiber material.
• 2A - Carpet option: 100% rapidly renewable, LEED-certified wool.
• 2B - Sidewalls: 100% natural silk.
• 2C - Countertops: quartz surface made from 93% quartz, an abundant natural resource with low levels of Volatile Organic Compound (VOC) emissions.
• 2D - Lower side wall: 100% natural silk.
• 3A - Divan pillows: bamboo and organic cotton.
• 3B - Lavatory panel and seat pillows: 100% natural silk.
• 3C - Cabinetry: rapidly-renewable wood veneer.
• 3D - Baggage compartment: natural wool and cotton, 100% compostable yarns.

Lori Browning is a Designer at Duncan Aviation’s Battle Creek, Mich. (BTL) facility, specializing in business aircraft modifications, completions and refurbishments. She began working in aviation in 2006.

Contributed by Lori Browning, Aircraft Interior Designer

Eco-friendly fabric collections inspired Duncan Designer Lori Browning to explore other  products available for "green" aircraft interiors.

Many textile companies are creating new fabric lines to meet the “green” demands of the commercial industry. I was inspired by some recent eco-friendly fabric collections, and I found that the properties that make them green also make them suitable for aviation burn regulations. I decided to explore options for a green aircraft interior.

What Makes a Material “Green”?

Materials are considered green when they are made of renewable, recycled or natural resources. In general, the fewer natural resources and energy that are consumed the better. For example, using a local carpet vendor reduces fuel consumption without compromising the quality of the carpet. Eco-friendly materials aren’t hard to find, and new products are coming out all the time.

Toxicity & Burn Testing

Fabrics that are treated with stain-resistant chemicals or made of synthetic fibers are more toxic and tend to have more issues passing the burn tests for aviation. More natural materials are less toxic by comparison, and more suitable for use in aircraft interiors. Plus, natural fibers won’t off-gas like synthetic fabrics and carpets, which improves the cabin’s air quality.

National organizations such as the U.S. Green Build Council (USGBC), Greenguard, the Carpet and Rug Institute (CRI) and the National Science Foundation (NSF) certify many of the materials presented for use in aviation.

Durability

How a fabric is made determines durability more than what materials are used to make it. With this in mind, eco-friendly materials can be just as durable as standard fabrics. Like synthetic materials, they can also be treated with Scotch-guard for stain resistance.

Cost

Do eco-friendly materials improve a client’s bottom line? Prices can vary widely, so yes and no. Some fabric prices are higher while others are very economical. Rapidly-renewable wood veneers are less expensive because they grow more quickly. For those who believe in corporate responsibility, this is an opportunity to lead by example.

Design Trends

There are a wide range of colors, designs and options available for eco-friendly materials.  Most tend to follow the natural palettes current for commercial and residential design, but the neutral hues work well for corporate aircraft interiors as well. Carpet options are endless, and new fibers such as bamboo are really opening the doors for creative design.

You never have to sacrifice quality or aesthetics to go green. Eco-friendly materials can be just as luxurious and beautiful as conventional materials, and the quality is certainly as good or better.

To view the latest Duncan Aviation interior refurbishments, visit our recent galleries.

Lori Browning is a Designer at Duncan Aviation’s Battle Creek, Mich. (BTL) facility, specializing in business aircraft modifications, completions and refurbishments. She began working in aviation in 2006.

Contributed by George Bajo, Completions Sales Rep.

In six years, this Falcon 900 interior refurbishment will be reaching the end of its lifespan. Maintaining the seat coverings, replacing carpet and recovering the lower sidewall panels can give it a new look on a smaller budget.

Over the past two years, interior trends have shifted away from complete aircraft refurbishments to partial, more budget-friendly updates. However, identifying what needs to be done and when can be a challenge, especially for owners and operators seeking a new look with a smaller budget.

Required maintenance events are an ideal time for interior updates, particularly if finishes are reaching the end of their lifespan and are due for replacement. I strongly recommend keeping in mind when the next required downtime is scheduled, what parts of the interior can be addressed during that downtime and where the largest costs are involved.

With proper planning, an interior can be given a fresh look on a smaller budget without extending downtime.

1. Maintain seat leather/upholstery.

If the seat material is in serviceable condition, it can be cleaned. Leather can also be redyed. This improves the seat appearance at a fraction of the cost of replacement.

2. Replace carpet.

Floor coverings are independent from most interior items, making it quick and easy to replace. With the help of a professional designer, carpet can complement future softgood replacements.

3. Recover lower sidewall (dado) panels.

Updating the panel material is also a straightforward process, and when combined with seats and carpet it can go a long way to achieving a fresh, new look.

An aircraft interior can also be updated over the course of several maintenance events, spreading the cost over multiple years and reducing the total downtime.

George Bajo is a Completions Sales Representative at Duncan Aviation-Battle Creek,  specializing in interior and paint refurbishments for Challenger, Embraer, Gulfstream, Learjet and Astra / Westwind aircraft. He began working in aviation in 1984.