April, 2008

April, 2008April, 2008

Saudi Aramco Saudi Aramco

Aviation System Aviation System

for Aircraftfor Aircraft

MaintenanceMaintenance

AgendaAgenda

• Introduction to SAP ERPIntroduction to SAP ERP

• Key SAP Processes Key SAP Processes

• SAP Maintenance TrackingSAP Maintenance Tracking

SAP Implementations for Saudi AramcoSAP Implementations for Saudi Aramco

•2007 - Aramco Aviation upgraded to latest SAP version:

• SAP Aerospace & Defense Version ECC 6.0

•400 users across 3 Maintenance Bases

4Q99

HR

3Q00

IS Oil,Sales

PS

3Q024Q01

SAP Core,SCM/PMBig Bang FI/CO

2Q02

TSW&APO, Payroll

4Q02

IS-A&D 4.6C

2Q04 2Q05

IS Healthcare

SAP Aerospace & Defense (IS A&D)SAP Aerospace & Defense (IS A&D)

•Aerospace & Defense Solution has specific Aerospace & Defense Solution has specific enhancements developed to meet the needs of Major enhancements developed to meet the needs of Major Aerospace Operators, Manufacturers and Defense Aerospace Operators, Manufacturers and Defense IndustryIndustry

•Aramco Aviation is using SAP Aerospace & Defense Aramco Aviation is using SAP Aerospace & Defense Solution as the basis of their Maintenance and Solution as the basis of their Maintenance and Materials Management System Materials Management System

•Aerospace & Defense Solution has specific Aerospace & Defense Solution has specific enhancements developed to meet the needs of Major enhancements developed to meet the needs of Major Aerospace Operators, Manufacturers and Defense Aerospace Operators, Manufacturers and Defense IndustryIndustry

•Aramco Aviation is using SAP Aerospace & Defense Aramco Aviation is using SAP Aerospace & Defense Solution as the basis of their Maintenance and Solution as the basis of their Maintenance and Materials Management System Materials Management System

SAP Aerospace & Defense - Solution MapSAP Aerospace & Defense - Solution Map

Best Practice - Full Business Suite for IS Aerospace & Defense Best Practice - Full Business Suite for IS Aerospace & Defense

Enterprise Management

Strategic Enterprise Management

Management Accounting

Financial Accounting

Corporate Governance

Financial Supply Chain Management

Business Analytics

Sales & Marketing Marketing Service Sales Spare Part SalesBilling & Credit Management

Analytics

Engineering & Configuration Management

Technical Document Management

Maintenance Program Management

Configuration & Compliance Management

Asset Induction & Retirement

Asset Health & Predictive Maintenance

Reliability & Performance Analytics

Maintenance PlanningAdvanced Maintenance & Service Planning

Visit PlanningLine Maintenance Planning

Shop Planning Workforce Planning

Spare Parts & Tools Management

Forecasting & Requirements Planning

Sourcing & Procurement

Inventory & Warehouse Management

Rotables Management

Warranty Management

Tools & Equipment Management

Dangerous Goods Management

Airframe MaintenanceElectronic Logbook

Production ControlWork Execution & Record Keeping

Work Closure

Engine & Component Maintenance

Engine Shop ControlComponent Shop Control

Work Execution Subcontracting Work Closure

Human Capital Management

Employee Life-Cycle Management

Employee Transaction Management

HCM Service Delivery Workforce Deployment

Business Support ProcurementEnvironment, Health & Safety

Travel ManagementIncentive & Commission Management

Fixed Asset Management

Discrepancy Handling










Business Analytics


Analytics















Rotables Management

Warranty Management





Work Closure















Business Analytics


Analytics















Rotables Management

Warranty Management





Work Closure


















Business Analytics


Analytics















Rotables Management

Warranty Management





Work Closure












Aviation SAP - Solution MapAviation SAP - Solution Map

Project

Execution

Materials

Management

Aircraft Master

Data

Maintenance

Program

Management

Alteration &

Configuration

Control

Work Packaging

& Scheduling

Update Counters

Hangar & Line

Maintenance

Warranty

Management

Reliability

Management

Refurbishment

Project Planning

Deferred Work

Management

Cost

Controlling

Financial

Reporting

Equipment

Master Data

Asset InductionAircraft/Parts/

Equipment

Engineering & Planning

Work ExecutionReliability & Warranty

Corporate Finance

Surplus/

Disposal

Aviation Key SAP Aviation Key SAP Process OverviewProcess Overview

Key SAP ProcessesKey SAP Processes•Manufacturer & Regulatory Service Info & Manufacturer & Regulatory Service Info &

Directives ManagementDirectives Management

•Aircraft Maintenance Item (AMI)Aircraft Maintenance Item (AMI)

•Aviation MaintenanceAviation Maintenance

•Configuration ControlConfiguration Control

•Line MaintenanceLine Maintenance

•Component RepairComponent Repair

•Parts ManagementParts Management

•Tools ManagementTools Management

•ReportsReports

•Quality ControlQuality Control

•Manufacturer & Regulatory Service Info & Manufacturer & Regulatory Service Info &









•ReportsReports


Manufacturer & Regulatory Service Info & Manufacturer & Regulatory Service Info & Directives ManagementDirectives ManagementManufacturer & Regulatory Service Info & Manufacturer & Regulatory Service Info & Directives ManagementDirectives Management

SAP is used for recording all applicable:

• Service Bulletins/ Service Letters/ Service Changes etc.Service Bulletins/ Service Letters/ Service Changes etc.

• Airworthiness DirectivesAirworthiness Directives

• Creation of Routine/Non Routine Work FormsCreation of Routine/Non Routine Work Forms

• Integration to Maintenance PlanningIntegration to Maintenance Planning

SAP is used for recording all applicable:

• Service Bulletins/ Service Letters/ Service Changes etc.Service Bulletins/ Service Letters/ Service Changes etc.

• Airworthiness DirectivesAirworthiness Directives

• Creation of Routine/Non Routine Work FormsCreation of Routine/Non Routine Work Forms

• Integration to Maintenance PlanningIntegration to Maintenance Planning

Aircraft Maintenance Item (AMI)Aircraft Maintenance Item (AMI)

• AMI is the SAP representation of the Planned Aircraft Maintenance task.

• It Defines:• Applicability - Links task to Aircraft Fleet/TailApplicability - Links task to Aircraft Fleet/Tail• Intervals/Frequencies:Intervals/Frequencies:

Threshold & Repeat Threshold & Repeat Days/Flight Hours/Cycles/APU/RINs etc.Days/Flight Hours/Cycles/APU/RINs etc.

• Communicates to Maintenance Planning to schedule a task

Regulatory Directives & MFG ServiceRegulatory Directives & MFG ServiceDocuments AMI’sDocuments AMI’s

Regulatory Directives & MFG ServiceRegulatory Directives & MFG ServiceDocuments AMI’sDocuments AMI’s

SB/SL/etc.

Manufacturer Regulator

AMI

Non-Non-ApplicableApplicableNon-Non-ApplicableApplicable

HardcopyFilingTech Library

AD

SAP Maintenance Planning

SAPTDR

SAPAMI

TDR

EngineeringEngineering

ApplicableApplicableApplicableApplicable AllAllAllAll

ApplicableApplicableApplicableApplicable

FAA Inspection Programs AMI’sFAA Inspection Programs AMI’sFAA Inspection Programs AMI’sFAA Inspection Programs AMI’s

Task Card

QC-Tech AdvisoryGroup

Non-ApplicableNon-ApplicableHardcopyFiling

SAPAMI

Free Running/Out of Phase

Package


AMI

SAP (PRT)Document

ApplicablApplicablee

MFG Tasks &Intervals

ManufacturerRegulator

FAR&AWL Tasks &Intervals

Operator

ServiceExperience


AMI SAPAMI

MFG Inspection Programs AMI’sMFG Inspection Programs AMI’sManufacturerRegulator Operator

MFG Tasks &Intervals

FAR&AWL Tasks &Intervals

ServiceExperience

Planning

Task Card & Inspection forms

Non-ApplicableNon-ApplicableNon-ApplicableNon-ApplicableHardcopyFiling

SAPPRT

ApplicableApplicableApplicableApplicable

Free Running/Out of Phase

Package

Aviation MaintenanceAviation Maintenance

Planned Maintenance (Mx)Planned Maintenance (Mx)• Aircraft Maintenance Item (AMI)Aircraft Maintenance Item (AMI)

(Represents a Task in SAP)

• Maintenance Task List (Task Card) Maintenance Task List (Task Card) • Hierarchical Task List (Tasks for Check Interval)Hierarchical Task List (Tasks for Check Interval)• Maintenance Plan (MP) Maintenance Plan (MP) • Routine/Non Routine Workcard:Routine/Non Routine Workcard:

• Notification (Workcard Issuance)• Work Packaging • Work Order (Workcard Completion)

Unplanned Maintenance (Mx)Unplanned Maintenance (Mx)

• Unplanned Mx - Squawks/Work ArisingUnplanned Mx - Squawks/Work Arising • Log Entry/Routine/Non Routine Workcard:Log Entry/Routine/Non Routine Workcard:

Notification (Workcard Issuance) Work Order (Workcard Completion)

• Unplanned Mx - Squawks/Work ArisingUnplanned Mx - Squawks/Work Arising • Log Entry/Routine/Non Routine Workcard:Log Entry/Routine/Non Routine Workcard:

Notification (Workcard Issuance) Work Order (Workcard Completion)

Configuration Control Configuration Control Configuration Control Configuration Control

•Identification of Technical ObjectsIdentification of Technical Objects

•View of Current Aircraft StructureView of Current Aircraft Structure

•Fit/Remove/Swap with Integration to Fit/Remove/Swap with Integration to Materials Management and Maintenance Materials Management and Maintenance PlanningPlanning

•Traceability/History RecordingTraceability/History Recording

•Identification of Technical ObjectsIdentification of Technical Objects

•View of Current Aircraft StructureView of Current Aircraft Structure

•Fit/Remove/Swap with Integration to Fit/Remove/Swap with Integration to Materials Management and Maintenance Materials Management and Maintenance PlanningPlanning

•Traceability/History RecordingTraceability/History Recording

Configuration Control Configuration Control

N737A

N737A-71

Aircraft Registration N737A Serial number 30181

Air Conditioning

Engine Location

Engine

Functional LocationsFunctional Locations

EquipmentEquipmentFan Inlet

LP Interm. Comp

Diffuser

HP Drive Turbine

LP Drive Turbine

N737A-21-20

N737A-21

Actuator

MaterialMaterial•All Aircrafts and AssembliesFully represented in SAP as Technical Objects

•All Aircrafts and AssembliesFully represented in SAP as Technical Objects

Current Aircraft ConfigurationCurrent Aircraft ConfigurationCurrent Aircraft ConfigurationCurrent Aircraft Configuration

Usage list

N737AN737A

Installation 01.01.07Removal 03.20.08

01.01. - 03.20.08 N737A01.01. - 03.20.08 N737A

05.06. - 03.20.06 N738A05.06. - 03.20.06 N738A

Configuration Control Configuration Control

•Scheduling of Maintenance Scheduling of Maintenance Plans Stopped/Started by Fit/Remove Plans Stopped/Started by Fit/Remove Transactions for Time Controlled Transactions for Time Controlled ItemsItems

•Scheduling of Maintenance Scheduling of Maintenance Plans Stopped/Started by Fit/Remove Plans Stopped/Started by Fit/Remove Transactions for Time Controlled Transactions for Time Controlled ItemsItems

SAP has Full Traceability of RotablesSAP has Full Traceability of RotablesSAP has Full Traceability of RotablesSAP has Full Traceability of Rotables

•Defect Capturing – capture all defects in the form of SAP Notifications

•Planning and Execution of all Line Maintenance Tasks

•Defect Capturing – capture all defects in the form of SAP Notifications

•Planning and Execution of all Line Maintenance Tasks

Line MaintenanceLine MaintenanceLine MaintenanceLine Maintenance

Defect capturing

Planning ExecutionPlanning

Execution

Defect AnalysisRoutine Maintenance

Spare Parts Provisioning

Material requirements

Analyzed defects Certification

Release to

ServiceDefer

defects

Key SAP ProcessesKey SAP Processes















Component Repair Component Repair

•Management of Rotables Repair

•Management of Serviceable/ Unserviceable status

•Integration to Materials Management for key processes of:• Stock ManagementStock Management• ExchangeExchange• RefurbishmentRefurbishment• SubcontractingSubcontracting

•Management of Rotables Repair

•Management of Serviceable/ Unserviceable status

•Integration to Materials Management for key processes of:• Stock ManagementStock Management• ExchangeExchange• RefurbishmentRefurbishment• SubcontractingSubcontracting

Stock

ServiceableServiceable UnserviceableUnserviceable

Procurement Scrap

In-house Repair

Aircraft

External Repair

DismantleDismantleInstallInstall

Component Repair Component Repair

Notification

Planning

Scheduling

Execution

Completion

History Material usage, orders, notifications, usage list

4

5

2

3

1 Part No. Serial No. Date

Description Malfunction

Operations Material

Internal/external resources Tools

Order release Capacity leveling

Shop Papers Availability check

Planned/unplanned material withdrawal

External procurement

Time confirmation Order settlement

Technical completion Business Completion

Complete work order cycle recorded in SAPComplete work order cycle recorded in SAPComplete work order cycle recorded in SAPComplete work order cycle recorded in SAP

Parts ManagementParts Management Serial number tracking/history (Equipments)Serial number tracking/history (Equipments) Manufacturer part number - Interchangeable Parts: Manufacturer part number - Interchangeable Parts:

1-Way/Restricted/Full Interchangeability1-Way/Restricted/Full Interchangeability

Selection

Actual

Configuration

Allowed Configuration

IPC

Valid

Configuration

Configuration Interchangeability

Maintenance engineer

Procurement

FFF-Class

Consignment

Sales

Stock

FFF-Class

Supplier

ProcurementInterchangeability

Material planner

Planning/MRP Interchangeability

MPN MRP Set

1

Leading parts

MPN MRP Set 2

FFF-Class

PART-BPART-C

PART-A PART-DPART-E

Parts ManagementParts Management

MaintenceWork Order

Creation

Order processing

Order completion

Maintenance

Material reservatn.

Material provision

Material issue

MRP flag

Material requirmnt.planning

Planned MaterialOrder

Direct Charge/Service requests

Purchase requisition

Purchase order

Goods receipt

Invoice receipt

ProcurementStores / stock Material require-ments planning

•Full Integration from Maintenace Processing to Full Integration from Maintenace Processing to •Materials Management in SAPMaterials Management in SAP•Full Integration from Maintenace Processing to Full Integration from Maintenace Processing to •Materials Management in SAPMaterials Management in SAP

Shelf Life Cont.

Tools ManagementTools Management

• Special Tools Managed in SAP via Maintenance Plans:

• Scheduling of Maintenance RequirementsScheduling of Maintenance Requirements• CalibrationCalibration• ScrappingScrapping










•ReportsReports










•ReportsReports

Information Systems

Progress Analysis

Compliance

SAP ReportsSAP Reports

Structures

Fully CustomizeableReports

)

Order ReportsReservations

Purchase RequisitionsPurchase Orders

Stock/Requirements List

Cost Controlling

List Edit Goto View Extras Settings System Help

WBS-Element Act. Network CCenter Cost Element

600405610 1000 400000

600784320 1000 420000

600997730 1000 450000

10

600343320 1200 600000

600567830 1200 240000

1200 620000

10 1200 24,000.00

COPC-FINI-210 1200 40,000.00

COPC-CONFIG-110

P.1234.1000

P.1234.1000

P.1234.1000

*1000

P.1234.1000

P.1234.1000

*1200

**P.1234.1000

4731

4745

1000

Actual Costs

10,000.00

12,000.00

23,000.00

45,000.00

30,000.00

36.000,00

66,000.00

111,000.00

20,000.00

36,000.00

36,000.00

ALV

MaintenanceDue Dates










•ReportsReports











•ReportsReports


Quality Control Quality Control

• Role:

• InspectorInspector• Activities:

• Review task completionReview task completion• Perform quality checksPerform quality checks• Certify airworthiness / Certify airworthiness /

release aircraft to servicerelease aircraft to service

• Objectives:• Meet regulatory Meet regulatory

requirementsrequirements• Duties:

• Review task completionReview task completion• Perform quality checksPerform quality checks• Aircraft WorkAircraft Work

InspectorInspector

Configuration Configuration ControlControl

Closing and Sign Closing and Sign off for Work Orderoff for Work Order

CertificationCertificationCertificationCertification

Quality ControlQuality Control

Set completion Set completion statusstatus• NotificationNotification• OrderOrder• RevisionRevision

User status for User status for ServiceabilityServiceability• Functional Functional

LocationLocation• EquipmentEquipment

Release to Service for Aircraft/ComponentsRelease to Service for Aircraft/ComponentsRelease to Service for Aircraft/ComponentsRelease to Service for Aircraft/Components

SAP Aviation SAP Aviation Maintenance PlanningMaintenance Planning

Maintenance Plans Maintenance Plans

• A maintenance plan contains the information for maintenance tasks to be performed on a regular basis and for automatically creating maintenance notifications.

It consists of:

• One or several maintenance items:• Technical objects to be serviced (e.g. Tail Technical objects to be serviced (e.g. Tail

number, Equipment)number, Equipment)

• Maintenance schedule• Frequency/OffsetFrequency/Offset

• Maintenance tasks to be performed • Task ListTask List

MaintenanceMaintenance PlansPlans MaintenanceMaintenance PlansPlans

•SAP has an enhanced scheduling program

• Forecasting of Future Maintenance DatesForecasting of Future Maintenance Dates

• Adjustment of Future Maintenance Dates Adjustment of Future Maintenance Dates

•Change Log

• Change documents created for all changes to Change documents created for all changes to

maintenance plans/items/schedulesmaintenance plans/items/schedules

•SAP has an enhanced scheduling program

• Forecasting of Future Maintenance DatesForecasting of Future Maintenance Dates

• Adjustment of Future Maintenance Dates Adjustment of Future Maintenance Dates

•Change Log

• Change documents created for all changes to Change documents created for all changes to

maintenance plans/items/schedulesmaintenance plans/items/schedules

•Performance based check approach for A/C Maintenance

• Dynamic SchedulingDynamic Scheduling

•Checks occur according to Counter Sequence or Calendar Plan

221Cycles

A1 Check

124 h

40 Day

A2 Check221 Cycles

124 h

40 Day

221Cycles

A3 Check

124 h

40 Day

Maintenance Plans Maintenance Plans Maintenance Plans Maintenance Plans

A3221 CyclesA240 DaysA1

Time

Performance

Due Dates are adjusted Due Dates are adjusted

124 h

Maintenance SchedulingMaintenance Scheduling

Maintenance PlanCounters

Scheduling

Check Intervals

A2221 Cyc A1

124 H

221 Cyc

124 H

•Maintenance Plans are scheduled daily Maintenance Plans are scheduled daily to update planned dates based on A/C to update planned dates based on A/C performanceperformance

•System forecasts future planned System forecasts future planned notifications based on Annual estimate notifications based on Annual estimate for flying hoursfor flying hours

Notification Notification

01/05/200801/05/2008 02/14/200802/14/2008Check A1 Check A2

Planned Routine WorkPlanned Routine Work

40 Days 40 Days

Traffic Light warning SystemTraffic Light warning Systemin place for early warning as in place for early warning as Due Dates get closer. If overdue:Due Dates get closer. If overdue:RedRed – A/C immediately OOS – A/C immediately OOS

Traffic Light warning SystemTraffic Light warning Systemin place for early warning as in place for early warning as Due Dates get closer. If overdue:Due Dates get closer. If overdue:RedRed – A/C immediately OOS – A/C immediately OOS

Work Packaging (Base Maintenance)Work Packaging (Base Maintenance)

•MEB is SAP’s function for Packaging & Sequencing of Maintenance Requirements:

•One tool for displaying all outstanding maintenance One tool for displaying all outstanding maintenance requirements for:requirements for:

• Aircraft• Fleet

•Planning of work packages early in advance to:Planning of work packages early in advance to:• Efficiently combine outstanding maintenance requirements• Ensure regulatory compliance

•Central monitoring of critical maintenance requirementsCentral monitoring of critical maintenance requirements

•Elimination of redundant tasks within work packageElimination of redundant tasks within work package

•Automatic sequencing of tasks according to project planAutomatic sequencing of tasks according to project plan

SAP Maintenance Event Builder (MEB)SAP Maintenance Event Builder (MEB)

Work PackagingWork Packaging

• RevisionRevision• Revision represents work

package to be performed during one maintenance event – Maintenance Check

Manuallycreated

from MEB

Revision

• Revision number• Planning plant• Description• Functional Location• Dates / Times• Responsible work center / Plant •PS Network

• Revision number• Planning plant• Description• Functional Location• Dates / Times• Responsible work center / Plant •PS Network

•Status Management•Change documents

Maintenance Event BuilderMaintenance Event Builder

Maintenance Event Builder

Notifications

Revision

Project Network

ScheduledMaintenance

Directives

Deferred Work

Task Lists / Task Cards

Output:Output:

Automatic generation of Work OrdersAutomatic generation of Work OrdersAllows unpackaging for further deferralAllows unpackaging for further deferral

Automatic generation of Work OrdersAutomatic generation of Work OrdersAllows unpackaging for further deferralAllows unpackaging for further deferral

Work OrderCreation

THANK YOUTHANK YOU

Flight Hours RecordedFlight Hours RecordedFlight Hours RecordedFlight Hours Recorded

April, 2008

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