Jigs

n metalworking, a jig is a type of custom-made tool used to control the location and/or motion of
another tool. A jig's primary purpose is to provide repeatability, accuracy, andinterchangeability in
the manufacturing of products.[1] A jig is often confused with a fixture; a fixture holds the work in a
fixed location. A device that does both functions (holding the work and guiding a tool) is called a jig.
[citation needed]

An example of a jig is when a key is duplicated; the original is used as a jig so the new key can have
the same path as the old one. Since the advent of automation and computer numerical
controlled (CNC) machines, jigs are often not required because the tool path is digitally programmed
and stored in memory. Jigs may be made for reforming plastics.
Jigs or templates have been known long before the industrial age. There are many types of jigs, and
each one is custom-tailored to do a specific job. Many jigs are created because there is a necessity
to do so by the tradesmen. Some are made to increase productivity through consistency, to do
repetitive activities or to do a job more precisely. Jigs may be well made for frequent use or may be
improvised from scrap for a single project, depending on the task.
Some types of jigs are also called templates or guides. Jigs include machining jigs, woodworking
jigs (e.g. tapering jig), welders' jigs, jewelers' jigs, and many others.

Fixture
A fixture is a work-holding or support device used in the manufacturing industry.[1][2] Fixtures are used
to securely locate (position in a specific location or orientation) and support the work, ensuring that
all parts produced using the fixture will maintain conformity and interchangeability. Using a fixture
improves the economy of production by allowing smooth operation and quick transition from part to
part, reducing the requirement for skilled labor by simplifying how workpieces are mounted, and
increasing conformity across a production run.[2]
A fixture differs from a jig in that when a fixture is used, the tool must move relative to the workpiece;
a jig moves the piece while the tool

Purpose

A fixture's primary purpose is to create a secure mounting point for a workpiece, allowing for support
during operation and increased accuracy, precision, reliability, and interchangeability in the finished
parts. It also serves to reduce working time by allowing quick set-up, and by smoothing the transition
from part to part.[3] It frequently reduces the complexity of a process, allowing for unskilled workers to
perform it and effectively transferring the skill of the tool maker to the unskilled worker.[2] Fixtures also
allow for a higher degree of operator safety by reducing the concentration and effort required to hold
a piece steady.[3]
Economically speaking the most valuable function of a fixture is to reduce labor costs. Without a
fixture, operating a machine or process may require two or more operators; using a fixture can
eliminate one of the operators by securing the workpiece.

Types of fixtures[edit]
Fixtures are usually classified according to the machine for which they were designed. The most
common two are milling fixtures and drill fixtures.[10]

Milling fixtures[edit]
See also: Milling machine
Milling operations tend to involve large, straight cuts that produce lots of chips and involve varying
force. Locating and supporting areas must usually be large and very sturdy in order to accommodate
milling operations; strong clamps are also a requirement. Due to the vibration of the machine,
positive stops are preferred over friction for securing the workpiece. For high-volume automated
processes, milling fixtures usually involve hydraulic or pneumatic clamps.[11][12]

Drilling fixtures[edit]
See also: Drill
Drilling fixtures cover a wider range of different designs and procedures than milling fixtures. Though
workholding for drills is more often provided by jigs, fixtures are also used for drilling operations.
Two common elements of drilling fixtures are the hole and bushing. Holes are often designed into
drilling fixtures, to allow space for the drill bit itself to continue through the workpiece without
damaging the fixture or drill, or to guide the drill bit to the appropriate point on the
workpiece. Bushings are simple bearing sleeves inserted into these holes to protect them and guide
the drill bit.[13]
Because drills tend to apply force in only one direction, support components for drilling fixtures may
be simpler. If the drill is aligned pointing down, the same support components may compensate for
the forces of both the drill and gravity at once. However, though monodirectional, the force applied
by drills tends to be concentrated on a very small area. Drilling fixtures must be designed carefully to
prevent the workpiece from bending under the force of the drill. [14]

Product Divisions: Maintenance

The technical maintenance of its aircraft plays a critical role in ensuring the safe, punctual and cost-effective
flight operations of an airline. Time lost due to an aircraft being unserviceable is expensive both in monetary
terms and in customer trust: on top of the loss of revenue and the continuing capital costs, there is the risk
of a loss of image as nothing annoys and alarms passengers more than delays and cancellations.
An aircraft consists of several million individual parts. To keep this highly complex system and all its
mechanical and electronic components in the best technical condition at all times, there is an elaborate
system of maintenance work. Lufthansa Technik AG is able to take over all of this important maintenance
and overhaul work for its customers worldwide. The essential difference between maintenance and overhaul
is that a maintenance check is short enough to allow the aircraft to remain available for scheduled service,
whereas an overhaul is much more extensive and involves taking the aircraft out of service temporarily.
The lowest-level maintenance event is the pre-flight check that precedes every flight and involves an
inspection of the aircraft by the cockpit crew and mechanics. This check for visible external damage or leaks
lasts between 15 and 60 minutes, depending on the aircraft type.
The next maintenance event in the hierarchy is the ramp check, in which mechanics test individual functions
of the aircraft, inspect the tires and brakes and replenish the oil and hydraulic fluids. A visual inspection of
the aircraft is also carried out, both externally and in the cabin. Such a check, which is carried out on a daily
basis, requires between six and 35 man-hours.
Next in size is the weekly service check, a combination of the work performed in the ramp check with tasks
such as topping up the water, air and oil and thorough cleaning of the cabin, which takes between ten and
55 man-hours.
Next in size is the weekly service check, a combination of the work performed in the ramp check with tasks
such as topping up the water, air and oil and thorough cleaning of the cabin, which takes between ten and
55 man-hours.
The A- and C-checks are significantly more labor-intensive. The A-check is carried out every 350 to 750
flying hours and, depending on the requirement, will take between 45 and about 260 man-hours. As well as
general inspections of the interior and the aircraft hull, it also covers service checks as well as engine and
function checks. At the same time the technicians replenish consumables such as oil, water and air and
eliminate defects whose rectification has been postponed on the grounds that they did not impair flight
safety. If any extensive seat repairs are required, these are also carried out in this interval inspection.

Even more detailed is the maintenance work carried out in connection with the C-check, the biggest
maintenance event before an overhaul. This entails thorough inspections inside and outside, along with
meticulous examination of structures (load-bearing components on the fuselage and wings) and functions.
For example, the technicians would use ultrasonic techniques to look for cracks in critical components. For
the C-check, which can take between 1,500 and 2,000 man-hours of work, an aircraft will spend up to five
days in the maintenance hangar.
Lufthansa Technik's competence to perform such maintenance work is ensured by the official approvals it
holds from the European Aviation Safety Agency (EASA), the American Federal Aviation Administration (FAA)
and a variety of national aviation authorities. Lufthansa Technik AG was also involved in the development
and further improvement of an IT-based system to optimize the maintenance work required in each case.
Thanks to these Aircraft Engineering Services (AES), highly efficient work packages are put together for
maintenance. As a result it is possible to perform the checks a lot more efficiently and save large sums of
money.
Lufthansa Technik operates maintenance stations with the capability to perform checks on customer aircraft
at over 60 airports in Germany and around the world. Lufthansa Technik's maintenance hub is Frankfurt
airport, where it has three large hangars. Here 4,000 staff maintain aircraft belonging to Lufthansa's and
many other fleets 24 hours a day, 365 days a year. In Germany Lufthansa Technik moreover runs
maintenance stations in Munich, Hamburg and at another 13 airports.
In addition to the permanent stations, Lufthansa Technik has also developed a mobile maintenance service
that is unique in the world, called the Airline Support Teams (AST). These small teams consist of highly
qualified engineers and mechanics. When called on, they are able to repair damage to engines or to the
airframe anywhere in the world within a matter of hours and thus ensure that disruption of a customer's
flying operations is minimized.

Product Divisions: Overhaul

The term overhaul refers to the Intermediate Layover (IL) check and the D-check. The IL-check lasts
between two and four weeks and is carried out every three to five years. It is only required for certain
aircraft types. To obtain easier access to the fuselage and wing structure for inspection purposes, a number
of large assemblies such as the high-lift devices are dismantled. At the same time numerous items of
equipment and systems are tested and repaired as necessary. Cabin components such as seats, galleys and
toilets are also completely overhauled and, if necessary, the aircraft will be repainted.
The D-check is the general overhaul of an aircraft and hence the most extensive of all aircraft-related service
events. This check is carried out every six to ten years and entails 30,000 to 50,000 man-hours of labor
over a period of four to six weeks. Leading up to the overhaul, a widebody aircraft may have clocked up
some 30,000 flying hours and 25 million kilometers.
During a D-check the entire structure is inspected down to the smallest detail. After that, the engines, the
landing gear and the high-lift devices are dismantled, along with the cabin interior and the wall and ceiling
panels. This is followed by removal of the instruments, the electrical systems, electronics and hydraulic and
pneumatic equipment. All equipment dismantled and taken apart is closely scrutinized and any necessary
repair work is carried out.
Every component is given a docket that states when and to where it has to be delivered in a serviceable
condition in order for the aircraft to be finished on time. Once the aircraft has been stripped back to the

"skeleton, the outer skin with tens of thousands of rivets and the load-bearing structure of the aircraft can
be scrutinized for damage and corrosion. Here, non-destructive testing methods such as eddy-current,
ultrasonic and x-raying are used to detect the finest hairline cracks in the aircraft structure or its retaining
elements.
For many aircraft types, Lufthansa Technik is able to test and repair all the components in its own
workshops, in accordance with the philosophy of "better repair than throw away. Accordingly, the engineers
always start by trying to rectify damage on defective parts before buying in and installing new parts. Thanks
to Lufthansa Technik's many decades of experience and its various official approvals from all the main
aviation authorities, the repaired parts are then restored to a virtually brand-new condition. In this way
Lufthansa Technik offers its customers efficient and cost-saving solutions for the overhaul of their aircraft
without having to compromise on the reliability of components.
The repair of aircraft parts made from composite materials, such as radomes, wingtips, high-lift devices,
landing gear doors, engine cowlings and thrust reversers, calls for an extremely high level of experience.
These composite materials are becoming more and more widespread in the construction of modern aircraft
due to their high strength and low weight compared with aluminum, for example. However composite parts
are time-consuming to manufacture, so that new parts are particularly expensive. Lufthansa Technik was
quick to recognize and to adapt this trend and has accordingly developed its own procedures for the repair
of such components.