This presentation gives you an overview of what a Predacorr program could do for your aircraft fleet.

1. Because Prevention is Better Than Cure

2. Corrosion Reliability Centred Maintenance Primary Objectives
Implement sustainable, cost wise maintenance
programs based on Corrosion Reliability-
Centered Maintenance (RCM) analytical
techniques.
Provide the ADF with a more stable maintenance
environment, enhancing asset preservation.

3. Current Corrosion and Environmental Degradation Costs
 US DoD is spending $10B USD annually on repairing or
reacting to corrosion and ED.
 USAF is spending close to $1B USD annually across all
aircraft types on repairing corrosion damage.
 ADF (RAAF) corrosion expenditure is fast approaching
$50M AUD annually (DSTO figures).
 Intercept estimates that it can save approx 30% of the
ADF’s expenditure on corrosion rectification within 3 years
and up to 70% within 10 years.
 DMO ROI would be less than 18 months.

4. Typical Aerospace Approach to Corrosion Management
Why corrosion costs so much manage…
Ad-hoc planning and inspection intervals
Reacts to the symptoms instead of the root causes
Reactive maintenance and increased
Carried Forward Un-serviceability
Unpredictable maintenance scheduling
Fluctuating DM servicing times
Unpredictable maintenance budgeting

5. Intercept’s Approach to Corrosion Management
How corrosion costs can be reduced…
Scientifically based planning and inspection intervals
Treat the root causes instead of reacting to symptoms
Delivers Proactive Corrosion Potential Failure
Mode Indicator management strategies
Enabling Predictable maintenance scheduling
Balanced and steady state servicing
times for corrosion damage
Predictable maintenance budgeting

6. Predacorr Program Overview
Intercept’s Predacorr Program is a 7 step process:
1. What corrosion protection functions must be maintained on
the aircraft?
2. What are the corrosion failure modes?
3. What causes the failure modes?
4. What effects do the failure modes have?
5. How can the failure modes be predicted or prevented?
6. What are the maintenance actions of each failure mode?
7. What can we do if there’s no predictive or preventative
maintenance action?

7. Basic Benefits of CRCM
1. Gain an Asset specific Corrosion Control Plan, aligned
with a Environmental Degradation Management System
ensures that:
a) Maintenance programs are tailored to the aircraft
operating environment to preserve the asset.
b) Pre-cursors of corrosion can be monitored and managed
instead of reacting to the symptoms.
c) The risk of deferring preventive maintenance is revealed
by the Failure Modes and Effects Analysis.
2. A proactive maintenance strategy reduces overall
maintenance costs.

8. Aircraft
Structural
Data Criticality
FMEA RCM Analysis
Analysis
Decompose
Aircraft
into Zones Corrosion
Preliminary Analysis Phase – Structural Condition Maintenance
Analysis and Assessment Engineering
Analysis
Select Items
for Analysis
Tertiary Analysis Phase – Ongoing Assessment
Maintain Operate
Extending Aircraft Aircraft
Aircraft Life of
Type
Flight line
and deeper Secondary Analysis Phase –
maintenance Preventative Maintenance Tasks and
defect Data Collection
Annual CRCM Annual EDM analysis
Analysis Analysis
To ‘A’
Annual Fatigue
‘B’
Assessments

9. SQN Personnel
SQN personnel perform
inspections, photograph
and record results
Weapon System Specific
Corrosion manual
CMEA
Photograph
‘A’ Packages
PFMIs
1...N CMEAs issued to
SQN for execution
Log onto Fix camera
Intercept via into PC
SQN DRN PCs
CRCM
improvements
CRCM / EDMS improvements
can be made and adjusted upload
here based on analysis
images to
To ‘B’ results
Intercept
Intercept CRCM database
Real-time CRCM logs and sorts images
analysis of PFMI and assesses PFMIs for
data each ‘R’ servicing, which
develops an ED trend for
the fleet
PFMI Data
input to SCDR
For annual EDMS review and ‘closed loop’ analysis

10. CRCM Program Data Analysis
AIRCRAFT
WINGS FUSELAGE ENGINES EMPENNAGE
CW OW FWD AFT NAC FAIR HOR FIN
COR SEAL PAINT OTHER
Location Groupings
Defect type Determined Environmental Degradation Rate (EDR)
To establish scientifically calculated inspection intervals
Defect date For each CCIZ
Defect date newest…oldest

11. Example of Data Corruption and Purification

12. Reactive Maintenance: Looking for the Symptoms

13. Reactive Corrosion Maintenance Practices
100% P-F Int (x) P-F Int (y)
On set of protective coating breakdown
On set of corrosion Material condition trend
CLIMAT VALUES
Material Condition
Detection Probability
Potentially Failed State
Planned Servicing Schedule Inspections ELIMINATE  MANAGE
R1 R2 R3 R4 R5
Material Removal Limit
Non standard repair
Functionally Failed State > MRL
Aircraft In Service Life (years)

14. Looking for the Symptoms: But Ignoring the Causes

15. Ignoring this type of damage will have cost implications

16. C-130J Pre Predacorr Corrective Maintenance Cost Estimates
Pre CRCM Program Costs
Failure Severity Categories
Critical Marginal Negligible
Cost Category
Corrosion Control Zones 9 13 10
Repair Part costs in $1000 235 220 113
Labour costs in $1000 15.8 18.4 10
Aircraft downtime costs in
$1000 300 350 220
Risk normaliser in $1000 1 0.5 0.2
Total in $1000 $551 $588 $343
Likelihood of Failure, Remote Occasional Probable
i.e. 1 failure in every: (10 – 100 yrs) (1– 10 yr) (40 days – 1 yr)
Failures / Yr 1x 1x 3x
Weighted Repair Costs /
a/c / yr $55,100 $117,600 $240,100
Total Annual Pre Predacorr Corrective Action Maintenance Costs $2,064,000

17. AP-3C Pre Predacorr Corrective Action Cost Estimates
Pre CRCM Program Costs
Failure Severity Categories
Critical Marginal Negligible
Cost Category
Corrosion Control Zones 7 2 3
Repair Part costs in $1000 160 18 32.5
Labour costs in $1000 104 18.4 1.5
Aircraft downtime costs in
$1000 1440 288 372
Risk normaliser in $1000 1 0.5 0.2
Total in $1000 $1705 $324.9 $406.2
Likelihood of Failure, Remote Occasional Probable
i.e. 1 failure in every: (10 – 100 yrs) (1– 10 yr) (40 days – 1 yr)
Failures / Yr 1x 1x 3x
Weighted Costs $170,500 $97,470 $284,340
Total Annual Pre CRCM Corrective Action Maintenance Costs $1,120,990

18. Proactive Corrosion Management
P-F Int (x) P-F Int (y)
On set of protective coating breakdown
100%
Potentially Failed State
Monitor and manage PFMI Steady State Material Condition
Material Condition
Detection Probability
Leads to decreased degradation rate
Scientifically calculated inspection intervals
Material Removal Limit
Functionally Failed State > MRL
Aircraft In Service Life (years)

19. Proactive Maintenance: Looking for the Root Causes

20. A Successful Predictive Potential Failure Mode Indicator
Inspection

21. C-130J Post Predacorr Corrective Action Cost Estimates
Pre CRCM Program Costs
Failure Severity Categories
Critical Marginal Negligible
Cost Category
Corrosion Control Zones 9 13 10
Repair Part costs in $1000 1.1 1.5 1.6
Labour costs in $1000 4.7 6.7 6
Aircraft downtime costs in
$1000 2 1 0.5
Risk normaliser in $1000 1 0.5 0.2
Total in $1000 $8,800 $9,700 $8,300
Likelihood of Failure, Remote Occasional Probable
i.e. 1 failure in every: (10 – 100 yrs) (1– 10 yr) (40 days – 1 yr)
Failures / Yr 1x 1x 3x
Weighted Costs $880 $1,940 $5,810
Total Annual Post CRCM Corrective Action Maintenance Costs $43,150

22. AP-3C Post Predacorr Corrective Action Cost Estimates
Pre CRCM Program Costs
Failure Severity Categories
Critical Marginal Negligible
Cost Category
Corrosion Control Zones 7 2 3
Repair Part costs in $1000 0.5 0.1 0.3
Labour costs in $1000 0.2 0.1 0.1
Aircraft downtime costs in
$1000 2 1 0.5
Risk normaliser in $1000 1 0.5 0.2
Total in $1000 $3,700 $1,200 $1,100
Likelihood of Failure, Remote Occasional Probable
i.e. 1 failure in every: (10 – 100 yrs) (1– 10 yr) (40 days – 1 yr)
Failures / Yr 1x 1x 3x
Weighted Costs $370 $240 $770
Total Annual Post Predacorr Corrective Action Maintenance Costs $2,920.00

23. NAVAIR EA-6B Prowler RCM Results
Corrective Maintenance Man Hours
Pre RCM Post RCM
a/c 1 8409 571
a/c 2 1612 470
a/c 3 2628 914
a/c 4 2054 1194
An Intercept Predacorr Program could realise cost savings of
30 to 70 % of your current reactive maintenance budget.

24. Corrosion Modelling for Pre and Post Deployment Management
Dec
Nov
Defect Groupings (Major Assembly: Sub-Assembly)
Oct
Sep
Aug
r ≥ 0.5
Jul
Jun
May
significant number of defects in wing group sub assembly
Apr
When linked to Intercept’s Corrosion Index significant
Mar improvements to maintenance tasking can be made by the
Predacorr Program.
Feb
Jan
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
Guam = 19 days
Deployment Locations (Exposure in Days)

25. PFMI and Control Point DHT Trending for Asset Preservation
other new technologies, i.e. hydrophobic coatings, near UV, and PHM

26. Why Implement an Intercept CRCM Program?
1. Consider what corrosion and ED is costing the ADF,
based on the current reactive maintenance model,
2. Consider that corrective action tasks can cost around
$ 2,064,000 per yr before CRCM,
3. Post CRCM corrective action task costs could be reduced
to as low as $2,920 per yr.
4. Return on Investment payback is less than 18 months
5. Most importantly, we have to look for corrosion and
ED anyway, why not do it a smarter way?

28. QUESTIONS

29. Intercept Contact Details
Direct Enquires
Sammuel Miah – CEO
Mob: 0406 488 153
E: smiah@interceptrs.com
General Enquires
Ph: 03 5256 2889
E: mail@interceptrs.com
Post: P.O. Box 872, Ocean Grove Vic 3226.