Kenya Airways has strengthened its aircraft maintenance capabilities after successfully completing its first landing gear replacement on a Boeing 787-8 Dreamliner, marking a major step in the national carrier’s ambition to become a leading Maintenance, Repair and Overhaul (MRO) provider in Africa.
The complex maintenance operation was completed on Monday, August 10, at the airline’s MRO facility at Jomo Kenyatta International Airport (JKIA) in Nairobi.
The milestone followed six years of planning, technical preparation, specialised training and procurement by Kenya Airways’ engineering teams.
The national carrier said its engineers successfully replaced the landing gear on one of its Boeing 787-8 Dreamliners, a major maintenance procedure requiring specialised equipment, technical expertise and close coordination between different engineering teams.
Kenya Airways currently operates nine Boeing 787-8 Dreamliners, which form a key part of its long-haul fleet.
The procedure involved lifting the aircraft using specialised jacking equipment before removing the existing landing gear and installing its replacement.
Engineers then integrated the various aircraft systems before conducting a series of tests and inspections required before the aircraft could be certified for service.
“This complex maintenance activity brought together meticulous planning, specialised expertise and the skill of our engineering teams, from aircraft jacking and landing gear replacement to systems integration, testing and certification,” KQ said.
Gilbert Bett, Kenya Airways’ Director of Technical, explained that preparations for the operation began six years ago as the airline assessed the technical requirements and worked on developing the necessary expertise among its engineering teams.
The preparations included reviewing the maintenance requirements, sourcing the materials and equipment required for the job, and ensuring engineers received the appropriate training.
“So we've taken time to really review all the requirements starting from six years ago, making sure that the suppliers who are going to support us in this process,” Bett said.
The operation required engineers to follow a carefully coordinated sequence because of the weight and complexity of the aircraft’s landing gear system.
Benson Ndirangu, Head of Technical Materials, said the first stage involved disconnecting and removing components linked to the landing gear. These included harnesses, electrical connectors, hydraulic tubes and brakes before the landing gear could be detached from the aircraft.
The component was then lowered using specialised equipment capable of handling its considerable weight.
Ndirangu noted that the equipment used in the process weighs approximately six tonnes, underscoring the level of precision required when carrying out the procedure.
The latest achievement adds to a series of increasingly complex maintenance activities that Kenya Airways has brought in-house. Barely a year ago, KQ engineers completed a full 12-year 6C heavy maintenance check internally, demonstrating the airline’s growing ability to undertake major maintenance work without relying entirely on external facilities.
Kenya Airways has increasingly positioned its MRO division as an important part of its strategy to diversify its revenue streams beyond passenger and cargo operations.
The airline is seeking to use its engineering expertise and facilities at JKIA to attract maintenance work from other airlines operating in Africa and beyond.
The completion of the Boeing 787-8 landing gear replacement therefore represents more than an internal maintenance achievement, as the airline seeks to build a commercially viable MRO business around its technical capabilities.
Kenya Airways said the latest milestone brings it closer to its goal of becoming the MRO provider of choice in Africa and beyond.
The development also comes as African airlines continue to face challenges in accessing specialised aircraft maintenance services locally, with some carriers having to send aircraft abroad for major maintenance work.
By expanding the range of procedures it can perform internally, Kenya Airways is positioning its Nairobi facility to handle more sophisticated aircraft maintenance requirements while potentially creating an additional source of revenue for the airline.
