Data and Test Solutions to Defeat NFF - Through Life ... and Test Solutions to Defeat NFF Giles Huby...

NFF Symposium – 18th March 2013 – EPSRC TES Centre © 2013. All Rights Reserved. © 2010

Data and Test Solutions

to Defeat NFF

Giles Huby

Managing Director

[email protected]

NFF Symposium – 18th March 2013 – EPSRC TES Centre © 2013. All Rights Reserved.

Presentation Scope

About Copernicus Technology Ltd

NFF Context:

• Factors, Impact & Culture

NFF Solutions:

• Data Exploitation & Intermittent Fault Detection

• Case Study Examples

Conclusions

Q&A


Giles Huby BEng(Hons) CEng FRAeS

MD of Copernicus Technology Ltd (2008 to date)

• UK - Chairman of NFF Working Group (ADS MRO&L Network)

• USA - Member of NFF Steering Committee (American Institute of

Aeronautics & Astronautics – Product Support Technical Committee)

RAF Engineer Officer (1992-2008)

• Front-Line and Support/Procurement tours spanning Harrier,

Tornado, ASRAAM, ALARM


About Copernicus Technology Ltd (CTL)

CTL deliver effective and proven Through-Life Services to defeat NFF and

downtime, and reduce Cost/Flying Hour:

• Testing & Investigations – Intermittent Fault Detection/Integrity test

• Data Exploitation

• Training in NFF & Advanced Diagnostics

Offices in the UK, Netherlands and Australia

Clients include MOD, Fokker Services, Selex ES

Strategic partners include USC, Cassidian Test & Services, Derco Aerospace, VR

Aviation Safety

ISO9001-accredited


Our Industry & Academic Relationships


No Fault Found Solutions


© 2011. Copernicus Technology Ltd. All Rights Reserved.

NFF Context


NFF Factors: System Integrity

Usage

Role

Correct operation

Maintenance Capability

Maintenance Schedule

Health Management &

Prognostics

Environment

Operating Environment

Duty Cycle

Maintenance Disturbance

Design

Functional Design

Materials

Build Quality

Product Assurance

The System Integrity ‘Zone’


System Integrity degrades in

vulnerable points of a system:

interconnects in wiring,

components and PCBs

This causes Intermittency

These problems also occur

during assembly of new-build

equipment or equipment

undergoing

maintenance/upgrade

NFF Factors: System Integrity


Repeat

Faults

Intermittency vs Maintenance

Intermittent

Faults

Test Equipment

optimised to hard

faults, not

intermittent

Maintenance Data

& Knowledge

optimised to hard

faults, not

intermittent

Ops/Business

pressure demands

‘quick fixes’

‘Box

Swapping’


2012 NFF Survey Results – Leading NFF Causes

0 50 100 150 200 250

BITE coverage

Test Equipment - ease of use

Test Equipment - capability

NFF Maintenance policy

Software

Maintenance disturbance

Component integrity - LRU / SRU

Business pressure

Technician experience with Test Equipment

Maintenance Human Factors

Component integrity - Connectors

Component Integrity - Wiring

Flight Crew Human Factors

Technician training in NFF diagnostics

Operational pressure

Troubleshooting guidance in manuals

Technician experience with NFF

Environmental (heat, vibration etc)

Technician experience with Fault Diagnosis

Technician experience with Intermittent Faults

Intermittent Faults


NFF: on-aircraft

A fault occurs in

the electronics

or wiring The pilot

observes a

symptom Technicians can’t

reproduce the

symptom or find

the fault

Repair?

Speculative LRU

change? NFF?

Successful Repairs

Functional Test Only, but fault returns

Speculative Replacement, but fault returns

Industry average for

on-aircraft Repair

Success Rate is

less than 60%


NFF: off-aircraft

Speculative LRU

change

Successful Repairs

Functional Test Only, but fault returns

Speculative Replacement, but fault returns

ATE Testing at

the MRO/OEM

A Repair, or

The Repair?

Charge for the

repair whether it

was the original

cause or not On-Aircraft


NFF: the Bill

Commercial Aircraft

• IATA 1997 estimate: $100k per aircraft per year ($185k in 2013)

• Using the $100k estimate still equates to a global bill of $1.5Bn per

year, growing to $2.8Bn per year by 2025

US DOD

• Over $2Bn per Year

UK MOD

• ?


Don’t know the cost

Culture Barriers to Solving NFF

It’s not killing anyone

It’s not sexy

It’s not my problem

Don’t know how many

30%

67%


Don’t know the cost

Culture Barriers to Solving NFF

It’s not killing anyone

It’s not sexy

It’s not my problem

Don’t know how many

Data: you can

find these

out…

…to overcome

these

30%

67%


NFF Solutions


NFF Solutions

1. Data Exploitation

Get data to underpin:

• Prioritisation of your NFF plan of attack

• Diagnostics – to improve repair success rate

• Training– to improve repair success rate

2. Intermittent Fault Detection

• Targeted use to find root causes


Data Exploitation: the Challenge

Maintenance Data

Design

Data

Operator

Data

Vendor

Repair

Data

Different uses

Different users

Different formats

Free-text

Config control issues

‘Local’ spreadsheets

Not integrated “Islands of Data”


Free-Text Symptom Capture

Example 1

• Tyre Flat

• Flat Tyre

• Puncture

• Nail in tyre

• Air hissing out of tyre

Example 2

• Car dead

• Will not start

• No lights

• Flat battery


Free-Text Symptom Capture

Fast Jet Example 1

• ECS cap illuminated in ERA

• Horn sounds with ground

power applied

• ecs caption with era selected

(ok with asm on)

• ECS horn sounds intermittently

with power on

• Int’ ECS capt in ERA on ground

recycled ok

Fast Jet Example 2

• Rdr cwp main fail and NoGo

and D12

• Gmr full house

• GMR capt with main fail and

No-Go

Each example is one

fault, shown with all

the different, free-text

symptom descriptions


NOVA

Correlates outputs from ‘Islands of

Data’

Trend over Timelines

Tailored outputs

Standardised symptom capture:

SYMPTOM DIAGNOSTICS


NOVA

NOVA Generates:

• Repair success rates

• Rogue tail nos, LRUs

• Repeat arising alerts

• Fleet management

data

• Investigation

analysis support


2. Intermittent Fault Detection

Data exploitation identifies:

• High hitting ‘repeat arisings’ and NFF

• Rogue aircraft

• Rogue LRUs/components

..and, therefore, where to target use of Intermittent Fault

Detection (IFD) testing


Intermittent Fault Detection:

Detection vs Measurement

Random Intermittent

Test Window

Synchronization

Measure

Scanning

U U T


4 Test Points 8 Test Points 1000 Test Points

Tester A

Intermittent Fault Detection:

Testing vs Scanning

Ncompass™

• All test points tested

continuously &

simultaneously

• 1 to 16,384 test points

• No scanning

• No sampling


Tests LRU interconnects, EWIS items (circuit

breakers, relays), PCB and wiring

Use from OEM to User Maintenance Levels

Rapid test set-up with user software interface

Tests “all of the lines all of the time”

Performance:

• 256 test points per unit

• Detects intermittency < 50 ns

• Detection Probability >106 more than

conventional equipment

Ncompass™ Test Capabilities


• Intermittency Test

• Continuity Test

• Log Scope

• Shorts Test

• Dry Circuit Test

• Analyze Test

• Automap

CE

EMC-compliant

Proven in on and off-aircraft testing

Ncompass™ Test Capabilities


Case Studies


NOVA Case Studies

NOVA is in current use for technical data exploitation

on 2 MOD platforms, focusing on specific systems’

maintenance & support.

Outputs to date:

• NFF extent quantified

• Fully quantified impact of systems and their

components on Availability, Downtime, Mission

Success and Repair Effectiveness

• Rogue LRUs and SRUs identified

• Root cause components identified at earliest stages

• “Ship-or-shelf” candidate LRUs identified

• Emerging fault arising trends identified

• MTBF & MTBR calculated


F-16 MLPRF

Pin not soldered

Cracked solder joint

Broken wire


F-16 MLPRF: Results

Many Rogue LRUs

• 137 LRUs ‘Un-repairable’

• 171 LRUs tested to Nov 2012

• Ncompass™ recovered 67%

Benefits to date > $50M

Mean Time Between Repair

(MTBR) up from 290 to 882 flying

hours

Through-life savings est >$200M


290

882

0

200

400

600

800

1000

Before IFDS With IFDS

MTBR (Hrs)

MLPRF MTBR


F-16 MLPRF: Results

Many Rogue LRUs

• 137 LRUs ‘Un-repairable’

• 171 LRUs tested to Nov 2012

• Ncompass™ recovered 67%

Benefits to date > $50M

Mean Time Between Repair

(MTBR) up from 290 to 882 flying

hours

Through-life savings est >$200M


13 Nov 2012 – IFD technology wins the DoD

“Great Ideas” award again.

Mr. John B. Johns (right), Deputy Assistant Secretary of

Defense for Maintenance, Office of the Secretary of

Defense, presents the Winning Maintenance “Great Ideas”

Award – the DOD’s highest award for maintenance

innovation - to Mr. Ken Anderson, VP Sales & Business

Development (Universal Synaptics Corp) at the 2012 DoD

Maintenance Symposium, Grand Rapids, Michigan


Tornado Cross-Drive Clutch

5-year Intermittent Fault

>500 maintenance hours incurred

>30 components changed on spec

CTL fault history review ruled out LRUs

3 days Ncompass™ testing ruled out EWIS

Led directly to root-cause identification:

Ncompass™ testing of CB immediately

confirmed intermittency


ISTAR Mission System Gimbal Motor

Antenna Gimbal identified by NOVA

analysis as root cause of Antenna

problem

>20 days downtime + multiple

‘parking turbulence’

Tested on removal and

intermittencies found

In repair at OEM

No repeat of fault on ac


Conclusions - 1

System Integrity Factors (Design/Use/Environment) are directly causal

to No Fault Found (NFF)

System Integrity degradation causes intermittency

Intermittency is the leading cause of NFF events

The global cost impact of NFF is measured in $Billions

Data Exploitation vital to NFF improvement momentum by:

• Mitigating cultural norms and barriers

• Identifying priority/high hitting aspects to focus on


Conclusions - 2

Recommended NFF Solution Strategy:

• Use Data Exploitation and Symptom Diagnostics to:

– Identify where to prioritise effort

– Inform Fault Diagnosis decision-making and training

– Stop speculative changes of prioritised LRUs

• Targeted use of Intermittent Fault Detection testing to rapidly find

fault root causes in wiring, EWIS components and LRUs


^ KEEP CALM

AND

DETECT

INTERMITTENCY


Contact us

Find us on the web www.CopernicusTechnology.com

LinkedIn group: No Fault Found Solutions

Head Office +44 1343 842406

Lincoln Office +44 1522 668901

[email protected]

Maastricht Office +31 636 114320

Australia Office +61 412 831410

Data and Test Solutions to Defeat NFF - Through Life ... and Test Solutions to Defeat NFF Giles Huby...

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Transcript of Data and Test Solutions to Defeat NFF - Through Life ... and Test Solutions to Defeat NFF Giles Huby...