4 Th Gen

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FOURTHFOURTHGENERATION GENERATION MAINTENANCEMAINTENANCE

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MAINTAINABILITY ASPECTS OF AIRCRAFT SYSTEMS

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1940 1950 1970 1990 2010

1st Gen:Fix It when it breaks

Focus: Repair Tasks

2nd Gen:

Scheduled O/H

Sys for Plng &

Controlling work

Focus: Improving Maintenance Planning & Scheduling

3rd Gen:

CBM, FMEA, Multi

Skilling, Team Work,

Rel, Maint, Availb

ComputersFocus: Predicting, Preventing & Avoiding the Consequences of Equipment Failures

4th Gen: Focus: Failure Elimination – Pro Active Maintenance, LCC, Lean, CBM+, RCA

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Scheduled Maintenance vsScheduled Maintenance vsReliability-Centered MaintenanceReliability-Centered Maintenance

Scheduled MaintenanceScheduled Maintenance Repair Only What Is BrokenRepair Only What Is Broken

Maintenance Is Unplanned if Maintenance Is Unplanned if we have on-condition itemswe have on-condition items failing.failing.

Maintenance Driven by Maintenance Driven by Lowest Rs / Tender L1Lowest Rs / Tender L1

(What's Easiest Today)(What's Easiest Today)

RCMRCM

Repair Not Only What Is Repair Not Only What Is Broken but What is Likely to Broken but What is Likely to Fail Before a Defined TimeFail Before a Defined Time

Focus is Planned Focus is Planned MaintenanceMaintenance

Facilitates Resource Facilitates Resource Requirements PredicationsRequirements Predications

Maintenance Based on Maintenance Based on LCC & ValueLCC & Value(What's Best for the Long (What's Best for the Long

Term)Term)

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The Fourth Generation of The Fourth Generation of MaintenanceMaintenance

Will focus on failure elimination, rather Will focus on failure elimination, rather than prediction or preventionthan prediction or prevention

Find the Root Cause(s) of “events” or Find the Root Cause(s) of “events” or “mishaps”“mishaps”

Human Factors Risk Analysis - Human Factors Risk Analysis - Human Human

errors account for an alarming rate of failures throughout a broad errors account for an alarming rate of failures throughout a broad range of industries worldwide. With high failure rates and the fact range of industries worldwide. With high failure rates and the fact that the results of human error can result in enormously costly that the results of human error can result in enormously costly failures, including the loss of life, the need for human error analysis failures, including the loss of life, the need for human error analysis and safety assessment is crucial.and safety assessment is crucial.

Failure Reporting Analysis and Failure Reporting Analysis and Corrective Action System (FRACAS) Corrective Action System (FRACAS) An effective FRACAS process provides for An effective FRACAS process provides for

gathering and tracking failure data in a central gathering and tracking failure data in a central database so that this data can be analyzed to database so that this data can be analyzed to determine underlying causes. Yet, in many organi-determine underlying causes. Yet, in many organi-zations, the individuals participating in the process zations, the individuals participating in the process are distributed across multiple groups or locations, are distributed across multiple groups or locations, and are recording information in different sources or and are recording information in different sources or databases. As a result, the ability to quickly isolate databases. As a result, the ability to quickly isolate failure trends is compromised. FRACAS Standard failure trends is compromised. FRACAS Standard helps organizations to overcome this fragmented helps organizations to overcome this fragmented approach to reliability. approach to reliability.

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ParadigmParadigmChangeChange

nownow

Maxim 1Maxim 1

OldOld

Most equipment becomes more likely Most equipment becomes more likely to fail as it gets to fail as it gets older

NewNew

Most failures are not more Most failures are not more likely to occur as equipment gets olderas equipment gets older

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Maxim 2Maxim 2

OldOld

Routine maintenance is about Routine maintenance is about preventing failurespreventing failures

NewNew

Routine maintenance is about avoiding, Routine maintenance is about avoiding, reducing or eliminating the reducing or eliminating the consequences of failuresconsequences of failures

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Maxim 3Maxim 3

OldOld

There are three basic types of There are three basic types of maintenance:maintenance:

Predictive Predictive Preventive Preventive CorrectiveCorrective

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Maxim 3Maxim 3

NewNew

There are four basic types of There are four basic types of maintenance:maintenance:

Predictive – condition basedPredictive – condition based Preventive – overhaul/replacePreventive – overhaul/replace Corrective – after/during failureCorrective – after/during failure Detective – proactiveDetective – proactive

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The Engineering ParadoxThe Engineering Paradox

Universities teach engineers to buildUniversities teach engineers to buildthings that never fail--but they fail !things that never fail--but they fail ! Universities teach engineers aboutUniversities teach engineers aboutentropy--but most engineers cannotentropy--but most engineers cannotcalculate maintenance demands tocalculate maintenance demands toprevent or overcome deterioration.prevent or overcome deterioration. We look busy but no attempt to do We look busy but no attempt to do Life Cycle Costs (LCC).Life Cycle Costs (LCC).

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Breaking The ParadoxBreaking The Paradox

Reliability problems are entropy drivenReliability problems are entropy driven

failures which cost money and requirefailures which cost money and require

trade-off considerations based on LCC.trade-off considerations based on LCC.

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Maxim 4Maxim 4 OldOld

Comprehensive data about failure rates must Comprehensive data about failure rates must be available before it is possible to develop a be available before it is possible to develop a really successful maintenance programreally successful maintenance program

NewNew

Decisions about the management of aircraft Decisions about the management of aircraft equipment failures will nearly always have to equipment failures will nearly always have to be made with inadequate hard data about be made with inadequate hard data about failure ratesfailure rates

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Maxim 5Maxim 5 OldOld If both are technically appropriate, fixed If both are technically appropriate, fixed

interval overhauls / replacements are usually interval overhauls / replacements are usually both cheaper and more effective than both cheaper and more effective than condition-based maintenance.condition-based maintenance.

NewNew If both are technically appropriate, condition-If both are technically appropriate, condition-

based maintenance is nearly always both based maintenance is nearly always both cheaper and more effective than fixed cheaper and more effective than fixed interval overhauls/replacements throughout interval overhauls/replacements throughout the life of the asset.the life of the asset.

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Maxim 6Maxim 6

OLDOLD The quickest and surest way to improve the The quickest and surest way to improve the

performance of an existing "unreliable" asset performance of an existing "unreliable" asset is to upgrade the designis to upgrade the design

NEWNEW It is nearly always more cost-effective to try It is nearly always more cost-effective to try

to improve the performance of an unreliable to improve the performance of an unreliable asset by improving the way it is operated and asset by improving the way it is operated and maintained, and only to review the design if maintained, and only to review the design if this cannot deliver the required performancethis cannot deliver the required performance

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Maxim 7Maxim 7 OLDOLD

Maint policies should be formulated by Maint policies should be formulated by managers and maint policies drawn up by managers and maint policies drawn up by suitably qualified specialists or ext agencies suitably qualified specialists or ext agencies (a top-down approach)(a top-down approach)

NEWNEW

Maint policies should be formulated by the Maint policies should be formulated by the people closest to the assets. The role of people closest to the assets. The role of management is to provide the tools to help management is to provide the tools to help them make the right decisions, and to them make the right decisions, and to ensure that the decisions are sensible and ensure that the decisions are sensible and defensibledefensible

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The Elephant is like …

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AOM

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Maintenance Program Today

The modern aircraft, although The modern aircraft, although extremely complex when compared to extremely complex when compared to its predecessors, requires less and its predecessors, requires less and less maint. less maint.

Nowadays, maint costs represent Nowadays, maint costs represent only a fraction of total operating costs only a fraction of total operating costs but cost of maint is going up.but cost of maint is going up.

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MILITARY AIRCRAFT MILITARY AIRCRAFT REQUIREMENTSREQUIREMENTS

LOWER MAINTENANCE RELATED LOWER MAINTENANCE RELATED COSTSCOSTS

BETTER OPERATIONAL BETTER OPERATIONAL RELIABILITYRELIABILITY

BETTER AIRCRAFT AVAILABILITYBETTER AIRCRAFT AVAILABILITY

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MAINTAINABILITYMAINTAINABILITY

ESSENTIALLY, THE EASE AND SPEED ESSENTIALLY, THE EASE AND SPEED WITH WHICH A FAILED EQUIPMENT WITH WHICH A FAILED EQUIPMENT CAN BE BROUGHT BACK INTO CAN BE BROUGHT BACK INTO OPERATING CONDITIONS IS OPERATING CONDITIONS IS MAINTAINABILITY MAINTAINABILITY

ALSO CALLED AS MEAN TIME TO ALSO CALLED AS MEAN TIME TO REPAIR (MTTR) OF AN ITEM. REPAIR (MTTR) OF AN ITEM.

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MEAN TIME TO REPAIRMEAN TIME TO REPAIR DETECTION OF FAULTDETECTION OF FAULT ALLOCATION OF MAINTENANCE TEAMALLOCATION OF MAINTENANCE TEAM DIAGNOSE FAULT DIAGNOSE FAULT OBTAIN SPARE PARTS (LOGISTIC DELAY)OBTAIN SPARE PARTS (LOGISTIC DELAY) REPAIR TIME(MTTR-THIS IS THE MANUFACTURERS REPAIR TIME(MTTR-THIS IS THE MANUFACTURERS

INFORMATION)INFORMATION) TEST AND ACCEPT REPAIR TEST AND ACCEPT REPAIR CLOSING UP THE SYSTEM AND RETURNING TO CLOSING UP THE SYSTEM AND RETURNING TO

NORMAL OPERATION.NORMAL OPERATION. SKILL OF THE MAINTENANCE ENGINEERS AND THE SKILL OF THE MAINTENANCE ENGINEERS AND THE

MAINTENANCE STAFF AVAILABLE AT THE BASESMAINTENANCE STAFF AVAILABLE AT THE BASES

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OPERATIONAL OPERATIONAL CONSIDERATIONSCONSIDERATIONS

MISSION ACCOMPLISHMENTMISSION ACCOMPLISHMENT FLIGHT SAFETYFLIGHT SAFETY SIMULTANEOUS SERVICEABILITYSIMULTANEOUS SERVICEABILITY

Therefore the effectiveness of a Therefore the effectiveness of a system is defined bysystem is defined by Reliability,Reliability, MaintainabilityMaintainability and and Availability.Availability.

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To consider To consider pedagogical methodologiespedagogical methodologies other other than “conventional ones”than “conventional ones”

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

activelearning

Memory and learning

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GROUND CREW SUPPORTGROUND CREW SUPPORT

Line mechanics spend 30% of their Line mechanics spend 30% of their time trying to access information to time trying to access information to diagnose and rectify failures.diagnose and rectify failures.

Human error in the maintenance task Human error in the maintenance task has been estimated as contributing to has been estimated as contributing to 15% of aircraft accidents.15% of aircraft accidents.

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System-oriented approach to a System-oriented approach to a Process-oriented approach.Process-oriented approach.

The right Technical Data and tools The right Technical Data and tools necessary to complete those tasks.necessary to complete those tasks.

The Ground crew should have all the The Ground crew should have all the support readily at hand rather than support readily at hand rather than searching for it. searching for it.

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MATURITY

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Enable the rapid update of the Enable the rapid update of the technical information onboard the technical information onboard the aircraft to support the operability aircraft to support the operability driven aircraft approach.driven aircraft approach.

Human interface technologies to Human interface technologies to provide the ground crew with provide the ground crew with information, data and advice at the information, data and advice at the point of work.point of work.

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Focus on embedded training Focus on embedded training technologies - train the ground crew technologies - train the ground crew within the operational environment - within the operational environment - use the advanced HMI features - use the advanced HMI features - evaluate the proficiency of trainees. evaluate the proficiency of trainees.

Diagnostic methods to identify and Diagnostic methods to identify and locate failures and malfunctions and locate failures and malfunctions and so reduce the incidence of ‘no fault so reduce the incidence of ‘no fault found’ alarms.found’ alarms.

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F-16 A – A TECH NIGHTMARE

EVOLVE A “BETTER – THAN – BEFORE” DESIGN

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BUILD – IN MAINTAINABILITY AT DESIGN STAGE

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EMERGENCY LOWERING OF UNDER CARRIAGE

SEEPAGE FROM HYDRAULIC PRESSURISATION POINT

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TEJASTEJAS TO REMOVE THE HYDRAULIC TO REMOVE THE HYDRAULIC

PUMP ENGINE REMOVAL IS PUMP ENGINE REMOVAL IS REQUIRED REQUIRED

THE REFUELLING AND GPU POINT THE REFUELLING AND GPU POINT ARE SITUATED CLOSE BY, WHICH ARE SITUATED CLOSE BY, WHICH CAN LEAD TO A FIRE BY SHORT CAN LEAD TO A FIRE BY SHORT CIRCUITCIRCUIT

LIMIT MAINT PERSONNEL REQMTS AND TO REDUCE THE POTENTIAL FOR MAINT ERROR

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FIFTH GENERATION FIFTH GENERATION AIRCRAFTAIRCRAFT

INTEGRATED VERY LOW OBSERVABLE INTEGRATED VERY LOW OBSERVABLE STEALTH.STEALTH.

MTBF OF GREATER THAN 10MTBF OF GREATER THAN 1088 . .

MTTR OF 2 HRS .MTTR OF 2 HRS .

EMPHASIS ON RELIABILITY , MAINTAINABILITY EMPHASIS ON RELIABILITY , MAINTAINABILITY AND SUSTAINABILITY - THE CAPABILITY TO FLY AND SUSTAINABILITY - THE CAPABILITY TO FLY DAYS WITHOUT EXTENSIVE MAINTENANCEDAYS WITHOUT EXTENSIVE MAINTENANCE

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ACCESS / MAINTAINABILITYACCESS / MAINTAINABILITY 36 INCHES OFF THE GROUND.36 INCHES OFF THE GROUND. SHOULDER HEIGHT TO NEARLY SHOULDER HEIGHT TO NEARLY

EVERY COMPONENT SUCH AS EVERY COMPONENT SUCH AS AVIONICS RACKS, ENGINES, AVIONICS RACKS, ENGINES, AIRFRAME MOUNTED ACCESSORY AIRFRAME MOUNTED ACCESSORY DRIVE SYSTEM WITHOUT LADDERS DRIVE SYSTEM WITHOUT LADDERS OR WORK STANDS.OR WORK STANDS.

DESIGN FEATURES DESIGN FEATURES

SHARE NEW IDEAS TO REDUCE THE FREQ OF DESIGN DICTATED MAINT ACTIVITIES

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DESIGN FEATURES (CONT’D)DESIGN FEATURES (CONT’D) AVIONICSAVIONICS

Future - Highly Interactive and Distributed Future - Highly Interactive and Distributed Avionics Architectures.Avionics Architectures.

"Selective Passivisation" - To enable an avionics "Selective Passivisation" - To enable an avionics computer to continue some part of its functionality computer to continue some part of its functionality even when a hardware or software failure occurs even when a hardware or software failure occurs

"Disposable Electronics" - Meeting functional "Disposable Electronics" - Meeting functional performances whilst dramatically decreasing performances whilst dramatically decreasing maintenance costs. maintenance costs.

Maintenance-free avionics that require no Maintenance-free avionics that require no scheduled maintenance work. scheduled maintenance work.

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On-Board Oxygen Generating System

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SELF SUFFICIENCY:-SELF SUFFICIENCY:-

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)DESIGN FEATURES (CONT’D)

04/10/2304/10/23 CSDOCSDO 5151PIT STOP IN RACING = ICT

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INTEGRATED COMBAT TURNINTEGRATED COMBAT TURN

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)DESIGN FEATURES (CONT’D)

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""TTechnologies echnologies AAnd nd TTechniques for echniques for nnEEw w MMaintenance conceptsaintenance concepts""

A four-year, €40 million ($50 million) project co-A four-year, €40 million ($50 million) project co-funded by the European Commission under its funded by the European Commission under its Framework 6 research programme that aims to Framework 6 research programme that aims to cut future generation aircraft maintenance costs cut future generation aircraft maintenance costs by 50% within 20 years.by 50% within 20 years.

TATEM research and technology project has TATEM research and technology project has now identified 19 top-level requirements and is now identified 19 top-level requirements and is working to apply these principles.working to apply these principles.

SUCCESS STORY OF CIVIL AVIATION MAINTAINABILITY

MILITARY - LESS FLYING BUT MORE HARD MANOEUVRES

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NEW PHILOSOPHYNEW PHILOSOPHY

THE QUEST FOR SHORTCUTSTHE QUEST FOR SHORTCUTS IMPROVEMENT IS A JOURNEY, IMPROVEMENT IS A JOURNEY,

NOT A DESTINATIONNOT A DESTINATION

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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”

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4%

2%

5%

7%

14%

68%

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Current situation:Document-oriented manuals

Today, technical documentation is organized in a document-centric approach.

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FutureFuture

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 !

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4 Th Gen

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