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This presentation gives a summation of the fourth generation of maintenance.

This presentation gives a summation of the fourth generation of maintenance.

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    4 Th Gen 4 Th Gen Presentation Transcript

    • FOURTH GENERATION MAINTENANCE 04/13/10 CSDO
    • 04/13/10 CSDO
    • 04/13/10 CSDO
    • 04/13/10 CSDO MAINTAINABILITY ASPECTS OF AIRCRAFT SYSTEMS
    • 04/13/10 CSDO 1940 1950 1970 1990 2010 1st Gen: Fix It when it breaks Focus: Repair Tasks 2 nd Gen: Scheduled O/H Sys for Plng & Controlling work Focus: Improving Maintenance Planning & Scheduling 3 rd Gen: CBM, FMEA, Multi Skilling, Team Work, Rel, Maint, Availb Computers Focus: Predicting, Preventing & Avoiding the Consequences of Equipment Failures 4 th Gen: Focus: Failure Elimination – Pro Active Maintenance, LCC, Lean, CBM+, RCA
    • Scheduled Maintenance vs Reliability-Centered Maintenance
      • Scheduled Maintenance
      • Repair Only What Is Broken
      • Maintenance Is Unplanned if
      • we have on-condition items
      • failing.
      • Maintenance Driven by Lowest Rs / Tender L1
      • (What's Easiest Today)
      • RCM
      • Repair Not Only What Is Broken but What is Likely to Fail Before a Defined Time
      • Focus is Planned Maintenance
      • Facilitates Resource
      • Requirements Predications
      • Maintenance Based on
      • LCC & Value
      • (What's Best for the Long Term)
      04/13/10 CSDO
    • The Fourth Generation of Maintenance
      • Will focus on failure elimination, rather than prediction or prevention
      • Find the Root Cause(s) of “events” or “mishaps”
      • Human Factors Risk Analysis - Human errors account for an alarming rate of failures throughout a broad range of industries worldwide. With high failure rates and the fact that the results of human error can result in enormously costly failures, including the loss of life, the need for human error analysis and safety assessment is crucial.
      04/13/10 CSDO
    • Failure Reporting Analysis and Corrective Action System (FRACAS)
      • An effective FRACAS process provides for gathering and tracking failure data in a central database so that this data can be analyzed to determine underlying causes. Yet, in many organi-zations, the individuals participating in the process are distributed across multiple groups or locations, and are recording information in different sources or databases. As a result, the ability to quickly isolate failure trends is compromised. FRACAS Standard helps organizations to overcome this fragmented approach to reliability.
      04/13/10 CSDO
    • Paradigm Change now 04/13/10 CSDO
    • Maxim 1
      • Old
      • Most equipment becomes more likely to fail as it gets older
      • New
      • Most failures are not more likely to occur as equipment gets older
    • Maxim 2
      • Old
      • Routine maintenance is about preventing failures
      • New
      • Routine maintenance is about avoiding, reducing or eliminating the consequences of failures
      04/13/10 CSDO
    • Maxim 3
      • Old
      • There are three basic types of maintenance:
      • Predictive
      • Preventive
      • Corrective
      04/13/10 CSDO
    • Maxim 3
      • New
      • There are four basic types of maintenance:
      • Predictive – condition based
      • Preventive – overhaul/replace
      • Corrective – after/during failure
      • Detective – proactive
      04/13/10 CSDO
    • 04/13/10 CSDO
    • 04/13/10 CSDO
    • 04/13/10 CSDO
    • The Engineering Paradox
      • Universities teach engineers to build
      • things that never fail--but they fail !
      • Universities teach engineers about
      • entropy--but most engineers cannot
      • calculate maintenance demands to
      • prevent or overcome deterioration.
      • We look busy but no attempt to do
      • Life Cycle Costs (LCC).
      04/13/10 CSDO
    • Breaking The Paradox
      • Reliability problems are entropy driven
      • failures which cost money and require
      • trade-off considerations based on LCC.
      04/13/10 CSDO
    • Maxim 4
      • Old
      • Comprehensive data about failure rates must be available before it is possible to develop a really successful maintenance program
      • New
      • Decisions about the management of aircraft equipment failures will nearly always have to be made with inadequate hard data about failure rates
      04/13/10 CSDO
    • Maxim 5
      • Old
      • If both are technically appropriate, fixed interval overhauls / replacements are usually both cheaper and more effective than condition-based maintenance.
      • New
      • If both are technically appropriate, condition-based maintenance is nearly always both cheaper and more effective than fixed interval overhauls/replacements throughout the life of the asset.
      04/13/10 CSDO
    • Maxim 6
      • OLD
      • The quickest and surest way to improve the performance of an existing "unreliable" asset is to upgrade the design
      • NEW
      • It is nearly always more cost-effective to try to improve the performance of an unreliable asset by improving the way it is operated and maintained, and only to review the design if this cannot deliver the required performance
      04/13/10 CSDO
    • Maxim 7
      • OLD
      • Maint policies should be formulated by managers and maint policies drawn up by suitably qualified specialists or ext agencies (a top-down approach)
      • NEW
      • Maint policies should be formulated by the people closest to the assets. The role of management is to provide the tools to help them make the right decisions, and to ensure that the decisions are sensible and defensible
      04/13/10 CSDO
    • 04/13/10 CSDO
    • 04/13/10 CSDO The Elephant is like …
    • 04/13/10 CSDO AOM
    • Maintenance Program Today
      • The modern aircraft, although extremely complex when compared to its predecessors, requires less and less maint.
      • Nowadays, maint costs represent only a fraction of total operating costs but cost of maint is going up.
      04/13/10 CSDO
    • 04/13/10 CSDO
    • MILITARY AIRCRAFT REQUIREMENTS
      • LOWER MAINTENANCE RELATED COSTS
      • BETTER OPERATIONAL RELIABILITY
      • BETTER AIRCRAFT AVAILABILITY
      04/13/10 CSDO
    • 04/13/10 CSDO
    • MAINTAINABILITY
      • ESSENTIALLY, THE EASE AND SPEED WITH WHICH A FAILED EQUIPMENT CAN BE BROUGHT BACK INTO OPERATING CONDITIONS IS MAINTAINABILITY
      • ALSO CALLED AS MEAN TIME TO REPAIR (MTTR) OF AN ITEM.
      04/13/10 CSDO
    • MEAN TIME TO REPAIR
      • DETECTION OF FAULT
      • ALLOCATION OF MAINTENANCE TEAM
      • DIAGNOSE FAULT
      • OBTAIN SPARE PARTS (LOGISTIC DELAY)
      • REPAIR TIME(MTTR-THIS IS THE MANUFACTURERS INFORMATION)
      • TEST AND ACCEPT REPAIR
      • CLOSING UP THE SYSTEM AND RETURNING TO NORMAL OPERATION.
      • SKILL OF THE MAINTENANCE ENGINEERS AND THE MAINTENANCE STAFF AVAILABLE AT THE BASES
      04/13/10 CSDO
    • OPERATIONAL CONSIDERATIONS
      • MISSION ACCOMPLISHMENT
      • FLIGHT SAFETY
      • SIMULTANEOUS SERVICEABILITY
      • Therefore the effectiveness of a system is defined by Reliability, Maintainability and Availability.
      04/13/10 CSDO
      • To consider pedagogical methodologies other than “conventional ones”
      Memory and learning 04/13/10 CSDO 95% of what we teach 10% of what we read 20% of what we hear 50% of what we see & hear 30% of what we see “ conventional” learning 70% of what we discuss 80% of what we experience active learning
    • GROUND CREW SUPPORT
      • Line mechanics spend 30% of their time trying to access information to diagnose and rectify failures.
      • Human error in the maintenance task has been estimated as contributing to 15% of aircraft accidents.
      04/13/10 CSDO
    • GROUND CREW SUPPORT
      • System-oriented approach to a Process-oriented approach.
      • The right Technical Data and tools necessary to complete those tasks.
      • The Ground crew should have all the support readily at hand rather than searching for it.
      04/13/10 CSDO
    • 04/13/10 CSDO MATURITY
    • GROUND CREW SUPPORT
      • Enable the rapid update of the technical information onboard the aircraft to support the operability driven aircraft approach.
      • Human interface technologies to provide the ground crew with information, data and advice at the point of work.
      04/13/10 CSDO
    • 04/13/10 CSDO
    • GROUND CREW SUPPORT
      • Focus on embedded training technologies - train the ground crew within the operational environment - use the advanced HMI features - evaluate the proficiency of trainees.
      • Diagnostic methods to identify and locate failures and malfunctions and so reduce the incidence of ‘no fault found’ alarms.
      04/13/10 CSDO
    • 04/13/10 CSDO
    • 04/13/10 CSDO F-16 A – A TECH NIGHTMARE EVOLVE A “BETTER – THAN – BEFORE” DESIGN
    • 04/13/10 CSDO BUILD – IN MAINTAINABILITY AT DESIGN STAGE
    • 04/13/10 CSDO EMERGENCY LOWERING OF UNDER CARRIAGE SEEPAGE FROM HYDRAULIC PRESSURISATION POINT
    • TEJAS
      • TO REMOVE THE HYDRAULIC PUMP ENGINE REMOVAL IS REQUIRED
      • THE REFUELLING AND GPU POINT ARE SITUATED CLOSE BY, WHICH CAN LEAD TO A FIRE BY SHORT CIRCUIT
      04/13/10 CSDO LIMIT MAINT PERSONNEL REQMTS AND TO REDUCE THE POTENTIAL FOR MAINT ERROR
    • FIFTH GENERATION AIRCRAFT
      • INTEGRATED VERY LOW OBSERVABLE STEALTH.
      • MTBF OF GREATER THAN 10 8 .
      • MTTR OF 2 HRS .
      • EMPHASIS ON RELIABILITY , MAINTAINABILITY AND SUSTAINABILITY - THE CAPABILITY TO FLY DAYS WITHOUT EXTENSIVE MAINTENANCE
      04/13/10 CSDO
      • ACCESS / MAINTAINABILITY
        • 36 INCHES OFF THE GROUND.
        • SHOULDER HEIGHT TO NEARLY EVERY COMPONENT SUCH AS AVIONICS RACKS, ENGINES, AIRFRAME MOUNTED ACCESSORY DRIVE SYSTEM WITHOUT LADDERS OR WORK STANDS.
      DESIGN FEATURES 04/13/10 CSDO SHARE NEW IDEAS TO REDUCE THE FREQ OF DESIGN DICTATED MAINT ACTIVITIES
    • 04/13/10 CSDO
    • DESIGN FEATURES (CONT’D) AVIONICS
      • Future - Highly Interactive and Distributed Avionics Architectures.
      • "Selective Passivisation" - To enable an avionics computer to continue some part of its functionality even when a hardware or software failure occurs
      • "Disposable Electronics" - Meeting functional performances whilst dramatically decreasing maintenance costs.
      • Maintenance-free avionics that require no scheduled maintenance work.
      04/13/10 CSDO
    • 04/13/10 CSDO On-Board Oxygen Generating System
    • SELF SUFFICIENCY:- 04/13/10 CSDO
      • ON BOARD OXYGEN GENERATING SYSTEM REPLACES GROUND BASED LOX.
      • ON BOARD INERT GAS GENERATING SYSTEM (OBIGGS) USED TO FILL THE FUEL TANKS WITH NITROGEN AND USED FOR APU.
      DESIGN FEATURES (CONT’D)
    • 04/13/10 CSDO PIT STOP IN RACING = ICT
    • INTEGRATED COMBAT TURN 04/13/10 CSDO
        • ICT IS THE MILITARY EQUIVALENT OF A PIT STOP IN
      • AUTO RACING
      • – THE AIRCRAFT IS REFUELED, RE-ARMED, AND SENT BACK INTO COMBAT.
        • SIMULTANEOUS GUN AMMUNITION AND MISSILE RELOADING, A PROCESS THAT NORMALLY GOES IN SEQUENCE ONLY.
        • SINGLE POINT REFUELING AND SINGLE POINT CONSUMABLES (OIL, CHAFF, FLARES ETC), STATUS CHECK POINT.
      DESIGN FEATURES (CONT’D)
    • " T echnologies A nd T echniques for n E w M aintenance concepts "
      • A four-year, €40 million ($50 million) project co-funded by the European Commission under its Framework 6 research programme that aims to cut future generation aircraft maintenance costs by 50% within 20 years.
      • TATEM research and technology project has now identified 19 top-level requirements and is working to apply these principles.
      04/13/10 CSDO SUCCESS STORY OF CIVIL AVIATION MAINTAINABILITY MILITARY - LESS FLYING BUT MORE HARD MANOEUVRES
    • NEW PHILOSOPHY
      • THE QUEST FOR SHORTCUTS
      • IMPROVEMENT IS A JOURNEY, NOT A DESTINATION
      04/13/10 CSDO
    • 04/13/10 CSDO
    • 04/13/10 CSDO
    • Lean is…
      • “ Eliminate all costs which do not add value to a product or process”
      • “ Becoming ‘lean’ is a process of eliminating waste with the goal of creating value”
      04/13/10 CSDO
    • 04/13/10 CSDO
    • 04/13/10 CSDO
    • 04/13/10 CSDO
    • 04/13/10 CSDO
    • 04/13/10 CSDO
    • 04/13/10 CSDO 4% 2% 5% 7% 14% 68%
    • 04/13/10 CSDO
    • 04/13/10 CSDO
    • Current situation: Document-oriented manuals
      • Today, technical documentation is organized in a document-centric approach.
      04/13/10 CSDO
    • Future
      • The objective: provide information according to what, when and how it is needed , instead of how it is printed.
      • In other words, be process-oriented !
      04/13/10 CSDO
    • 04/13/10 CSDO
    • 04/13/10 CSDO
    • 04/13/10 CSDO