DALLAS — KLM Royal Dutch Airlines (KL) is the world’s oldest airline. It operates a fleet of Airbus A321neo, A330, Boeing 737, Boeing 787, and Boeing 777 aircraft, and it has a large maintenance effort to match its extensive fleet.

Our tour started in the Engines Services shop, where multiple lines are present to disassemble, fix, and reassemble jet engines. Around 700 people work here, with skills spanning from (automatic) welding to shot peening.

During our visit, many tasks were simultaneously underway: from replacing components to inspecting turbine blades, the shop was busy taking care of different engines. 

The engine shop handles an aircraft's most expensive component. KL also handles engines and services for several airlines and companies. 

The airline has developed its lines to service the engines on the Boeing 737 (NG) (CFM56-7B), Boeing 787 (GEnx), and Airbus A330 (CF6-80E). It is now adding the capability to service the LEAP-1A and LEAP-1B engines, which power the A321neo and the Boeing 737 MAX. The group can maintain the LEAP engines, the GE90, and the Rolls-Royce Trent XWB in Paris.

Air France-KLM services over 500 engines per year from over 100 different customers. 

KLM has also invested in a new laser sensing machine, the world’s first. Based on laser technology, the machine can model objects and parts with a recorded accuracy and detect imperfections in parts where tolerances are of utmost importance for safety.

The visit continued to Hangar 14, where a Boeing 777-300ER awaited us. The airframe was undergoing its C-check. At the hangar's entrance, a large screen monitors the operation’s progress, and all the tasks and work hours are recorded.

We immediately noticed the missing nose cone to expose the radar and the fact that the aircraft was jacked up. The aircraft is grounded with no electricity. As a result, numerous lights illuminate the cabin, which is dismantled and fixed according to repair needs. 

This Boeing 777-300ER is equipped with KL’s three-class layout. 35 reverse herringbone business class seats occupy the front of the cabin. These are divided into a larger cabin at the front, between the first and the second doors, and a smaller cabin behind door 2, which hosts only eight seats.

KLM’s new product is arranged in a 1-2-1 layout, has privacy doors and features a sleek, modern design.

Behind, the passengers’ favorite “Premium Comfort” is found, with seats arranged in 2-4-2. Each seat comes with improved legroom and reclining over the economy class. It is among the most sold cabins on international flights, thanks to the optimal trade-off between comfort and cost.

At the end, the large economy-class section features 266 Recaro CL3710 seats, all equipped with USB chargers, IFE, adjustable headrests, and reclining seats.

During our visit, the cabin was disassembled, inspected, and fixed. The seats in economy class were grouped to create enough space to work on specific components, and some overhead panels were removed. 

All doors on board were open, including 3L and 3R, from which the Triple Seven’s large wing could be seen. The wings were equipped with safety cables connected to suction cups, an important safety measure for workers.

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Seeing an aircraft cabin like this was unique. According to the display at the entrance, KL was ahead of its C-check routine, meaning that the aircraft could be operated earlier than expected as no complications were found.

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