A Tremendous Achievement
The arrival back to New Zealand of the second modified Boeing 757, NZ7572, marks an important milestone in the B757 Modification Project. With the issuance of the new NZDF Special Type Certificate (STC) in November 2008, both 757 aircraft are now available for operational service. Over the coming months, the aircraft’s new capabilities will be exercised in various roles. NZ7572 was immediately pressed into service with a SATS task and ferrying fire fighters to Australia all in the same day.
WGCDR Mark Brunton sums up the project’s progress...
The new Multi-Role Aircraft
Formal delivery of the NZ7572
The capability and flexibility of the modified RNZAF Boeing 757 aircraft now provides the NZDF a unique and potent platform unmatched in the family of 757 and other narrow body airliners. The Project deliverable was to integrate in a single programme, numerous individual modifications. Many of the various modifications had previously been accomplished on other 757 aircraft as individual packages but no organisation or operator has attempted to achieve so many changes in one package. In addition to the modification package, scheduled heavy maintenance (C Check), engine strut modifications, new Electronic Flight Bag and cabin interior refurbishment were included. The complete package was always going to be a challenge to achieve and this proved to be the case and more.
Modification deliverables:
- Install a cargo door;
- Reconfigure the cabin interior for an 11 freight pallet capability;
- Install a cargo handling system able to accommodate numerous cabin configurations;
- Provide a VIP and AME capability;
- Install air stairs and crew access ladder;
- Upgrade aircraft communications and navigation systems;
- Install a package of military communications and cabin LAN equipment;
- Install a package of cabin noise-reduction features;
- Engine thrust upgrade.
Achieving Integration
NZ, MAE and Boeing personnel
The Project required numerous inputs from many organisations and contractors. There were three primary contractors for the modifications, Mobile Aerospace Engineering (MAE), Boeing Commercial and Boeing Integrated Defense Systems. Many other sub-contractors were contracted to deliver various elements of the Project including the cargo handling system, air stairs/crew access ladder, noise-reduction package, VIP package, interior reconfiguration and interior monuments. Each of these inputs presented crossover to the other modification packages so detailed engineering integration and communication lines were required to achieve successful accomplishment.
Working Together
NZ7572 lands at Whenuapai
All the contractors were on-site at various times to provide technical assistance to MAE for the various elements of the programme. The complexities and challenges experienced with the integration required numerous extensions to on-site attendance. The contractors associated with the Project had excellent ownership of the overall Project and its potential capability. They readily offered to extend their time on-site and went out of their way to make sure the final deliverable met all expectations. Ownership extended to providing additional features and services that were not strictly contract deliverables. At times integration conflicts required the contractors to negotiate solutions that expended resources beyond any contractual obligations. An overwhelming and united focus amongst all contractors was ‘let’s make it work’. They all enjoyed being associated with the NZ Project, the ‘Kiwis’ and the potential to deliver such a capable platform. All main contractors and sub-contractors attended the First Aircraft Delivery Ceremony and were recognized by the MoD and MAE for their assistance.
RNZAF Base Mobile, Alabama
The final phase of completing the aircraft required extensive assistance from RNZAF Units. This assistance was provided by No. 40 Squadron, ATSU (TS BOE), DLC, IIS Team, AMPU, FPU, NZDF TTU, CIS Branch and SCMS to name a few. No. 40 Squadron personnel in particular, were on-site for extensive periods to facilitate the completion activities, accomplishment of AT&E and deliver the aircraft. The periods spent in Mobile, Alabama and Wichita, Kansas were considerably longer than planned and this affected numerous personal and family plans. For some No. 40 Squadron personnel, two Christmas/New Year periods were affected by requirements to be on-site at MAE.
SQNLDR Dicko Beaton
Getting the Job Done
Despite the extended periods away from home and seemingly endless number of extensions, No. 40 Squadron personnel remained upbeat and focused on working with the RPT to deliver the highest quality and most capable platform. Throughout all activities, the ‘Team’ approach was evident with the RPT and RNZAF personnel working as a cohesive Unit with total ownership of the requirements to complete the aircraft with the contractors. In the completion phases of both aircraft, MAE worked 24/7 on the aircraft in an attempt to meet delivery deadlines. As the Crown was required to have on-site representation at all times work was conducted, RNZAF and RPT personnel worked extended periods providing the necessary coverage.
The completion of both aircraft, despite the challenges, represents a tremendous achievement for everyone associated with the Project.
Now it’s time to put the aircraft to work.