The document discusses the evolution of aircraft maintenance over four generations. The fourth generation focuses on failure elimination through techniques like root cause analysis and reliability-centered maintenance. It also discusses improving maintainability at the aircraft design stage to reduce maintenance needs and costs. The fifth generation aims for increased reliability, maintainability and sustainability with a focus on designing for ease of maintenance.

1. FOURTH GENERATION MAINTENANCE 04/13/10 CSDO

2. 04/13/10 CSDO

3. 04/13/10 CSDO

4. 04/13/10 CSDO MAINTAINABILITY ASPECTS OF AIRCRAFT SYSTEMS

5. 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

6. 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

7. 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

8. 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

9. Paradigm Change now 04/13/10 CSDO

10. 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

11. 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

12. Maxim 3 Old There are three basic types of maintenance: Predictive Preventive Corrective 04/13/10 CSDO

13. 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

14. 04/13/10 CSDO

15. 04/13/10 CSDO

16. 04/13/10 CSDO

17. 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

18. Breaking The Paradox Reliability problems are entropy driven failures which cost money and require trade-off considerations based on LCC. 04/13/10 CSDO

19. 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

20. 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

21. 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

22. 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

23. 04/13/10 CSDO

24. 04/13/10 CSDO The Elephant is like …

25. 04/13/10 CSDO AOM

26. 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

27. 04/13/10 CSDO

28. MILITARY AIRCRAFT REQUIREMENTS LOWER MAINTENANCE RELATED COSTS BETTER OPERATIONAL RELIABILITY BETTER AIRCRAFT AVAILABILITY 04/13/10 CSDO

29. 04/13/10 CSDO

30. 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

31. 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

32. 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

33. 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

34. 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

35. 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

36. 04/13/10 CSDO MATURITY

37. 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

38. 04/13/10 CSDO

39. 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

40. 04/13/10 CSDO

41. 04/13/10 CSDO F-16 A – A TECH NIGHTMARE EVOLVE A “BETTER – THAN – BEFORE” DESIGN

42. 04/13/10 CSDO BUILD – IN MAINTAINABILITY AT DESIGN STAGE

43. 04/13/10 CSDO EMERGENCY LOWERING OF UNDER CARRIAGE SEEPAGE FROM HYDRAULIC PRESSURISATION POINT

44. 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

45. 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

46. 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

47. 04/13/10 CSDO

48. 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

49. 04/13/10 CSDO On-Board Oxygen Generating System

50. 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)

51. 04/13/10 CSDO PIT STOP IN RACING = ICT

52. 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)

53. " 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

54. NEW PHILOSOPHY THE QUEST FOR SHORTCUTS IMPROVEMENT IS A JOURNEY, NOT A DESTINATION 04/13/10 CSDO

55. 04/13/10 CSDO

56. 04/13/10 CSDO

57. 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

58. 04/13/10 CSDO

59. 04/13/10 CSDO

60. 04/13/10 CSDO

61. 04/13/10 CSDO

62. 04/13/10 CSDO

63. 04/13/10 CSDO 4% 2% 5% 7% 14% 68%

64. 04/13/10 CSDO

65. 04/13/10 CSDO

66. Current situation: Document-oriented manuals Today, technical documentation is organized in a document-centric approach. 04/13/10 CSDO

67. 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

68. 04/13/10 CSDO

69. 04/13/10 CSDO

70. 04/13/10 CSDO