Reducing the cost of ownership of the CFM56 engines family · GE 90-94B Booster changes Jul 2011,...
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Serguei Vizenkov Technical Sales in Russia, General Manager AFI KLM E&M Reducing the cost of ownership of the CFM56 engines family MRO Russia 2015 – Moscow
Transcript of Reducing the cost of ownership of the CFM56 engines family · GE 90-94B Booster changes Jul 2011,...
Serguei VizenkovTechnical Sales in Russia, General ManagerAFI KLM E&M
Reducing the cost ofownership of theCFM56 engines family
MRO Russia 2015 – Moscow
Table of contents
AFI KLM E&M Overview Our Engine Services AFI KLM E&M a major CFM56 engine MRO Reducing the cost of ownership of CFM56 enginesEngine Condition MonitoringOn-wing and On-site servicesPart repairsEngine shop process improvements
Conclusion
Table of contents
AFI KLM E&M Overview Our Engine Services AFI KLM E&M a major CFM56 engine MRO Reducing the cost of ownership of CFM56 engines:Engine Condition MonitoringOn-wing and On-site servicesPart repairsEngine shop process improvements
Conclusion
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The Air France – KLM group
2 airlines
1 group
GroupAir- France KLM
3 businesses
Passenger
Cargo
Maintenance
5
AFI KLM E&M, a multi-product MROwith nose-to-tail adaptive solutions
AFI KLM E&MMRO
Solutions
Engine
Aerostructure
Airframe
AdditionalServices
Total Care
CabinModifications
Components
GLOBAL No.2INITSMARKET
14,000EMPLOYEES
3,134TOTAL REVENUES 1,300+
AIRCRAFT INCOMPONENTSUPPORT
ENGINESHOPVISITSPER YEAR
>40035%
CUSTOMERTURNOVER
2014 & 2015MRO OF THE YEAR
Airline EconomicsBest Component MROAircraft Technology E&M
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AFI KLM E&M MRO Network
Table of contents
AFI KLM E&M Overview Our Engine Services AFI KLM E&M a major CFM56 engine MRO Reducing the cost of ownership of CFM56 engines:Engine Condition MonitoringOn-wing and On-site servicesPart repairsEngine shop process improvements
Conclusion
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Introduction& Growth
Maturity Decline &End of Life
GE90-94
CF6-80E
PW4000
CFM56-5C
CFM56-5A
CF6-50
CF6-80C2
Leap-X
PW1000G
Trent XWB
Trent1000
GEnx
CFM56-5B
CFM56-7B
GE90-110/115
GP7200
Keep a strong & competitive engine MRO activity
Current capability
Potential development
JT8D
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A Customer Driven Organization
Revenue : 1.116 billion euros
100+ customers worldwide
2300 trained employees
5 maintenance sites in France, Netherlands and USA
220 customer overhauls out of 400 overhauls per year
CUSTOMER
Sales Manager
EngineeringSupport
Customer SupportManager
A dedicated Support Team proactiveand flexible at Customer service
AFI KLM E&M
Engine MRO Turnover (m€)
480595
533521
2012 2013
External Customer Group
+24%
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EngineMRO
Center
Amsterdam
Engine Shop in Amsterdam
APU Repair &Overhaul Shop
Engine parts repair Repair development
On-Site Support 24/7 Engine Pool Hospital Shop Engine Test Cell
Fleet & Shop Engineering Full Overhaul Shop
Low Pressure and Coremodules
Piece part level
Accessories shop
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EngineMRO
Center
Paris
Engine Shop in Paris
Fan ThrustReversers Shop
Engine parts repair Combustor TCF
Repair development
On-Site Support 24/7 Engine Pool Hospital Shop Engine Test Cell
Fleet & Shop Engineering Full Overhaul Shop
Low Pressure and Coremodules
Piece part level
Accessories shop
Table of contents
AFI KLM E&M Overview Our Engine Services AFI KLM E&M a major CFM56 engine MRO Reducing the cost of ownership of CFM56 engines:Engine Condition MonitoringOn-wing and On-site servicesPart repairsEngine shop process improvements
Conclusion
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MRO
Extensive Shop Experience, worldwideleader in CFM56-5 & -7 engine maintenance,repair & overhaul
Over 900 CFM56 engines supported
Optimized on-wing & off-wig policy for all kindof operations
~200 Shop Visits per year
Hospital Chain, On-Wing services withdedicated tooling
Smart solutions to maximize TOW up toperformance restoration
Very good spare availability to supportcustomers
CFM56 experience, expertise & know-how
Airline
Combinedexperience
Air France launch customer 1988, A320 with CFM56-5A 1993, A340 with CFM56-5C 1994, A320 equipped with CFM56-5B
KLM operates CFM56-7B enginessince 1999
The group operates 230+ CFM56-5B (secondworld largest fleet) and 100+ CFM56-7Bincluding latest standards
Unrivaled experience & a broad engineeringexpertise from legacy airlines as well as fromlow cost carriers
A key role toward the OEM, in optimizingprocedures and repairs to reduce total cost ofownership
Table of contents
AFI KLM E&M Overview Our Engine Services AFI KLM E&M a major CFM56 engine MRO Reducing the cost of ownership of CFM56 engines:Engine Condition MonitoringOn-wing and On-site servicesPart repairsEngine shop process improvements
Conclusion
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Engine Condition MonitoringSmart monitoring prevents UER and limits spare utilization
Operational experience from the airlines used within MRO support
From Diagnostics to Prognostics
Diagnostics : basic alerting system on specific parameters
Prognostics : large data availability combined withadvanced algorithms leads to early warning / avoid unexpectedfailure / reduce damage to critical equipment
AFI KLM E&M able todetect defects at earlierstage, predict futuredeterioration and avoidmajor damages
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Engine Condition MonitoringSmart monitoring prevents UER and limits spare utilization
AFI Specific designed tools
CFM56: IGV ring failure / HPT shroud burns / HPC condition /HPTCC & PS3 leakage / VBV flex shaft failure
GE90 tip curl issue : AF designed specific tool which generatesautomatic alert to MCC before the end of incriminated flight
Engine Trend Monitoringis more and more crucial
Table of contents
AFI KLM E&M Overview Our Engine Services AFI KLM E&M a major CFM56 engine MRO Reducing the cost of ownership of CFM56 engines:Engine Condition MonitoringOn-wing and On-site servicesPart repairsEngine shop process improvements
Conclusion
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Engine Repairs On-Wing Services
Reach expected TimeOn Wing Engine monitoring Technical
recommendations Water wash AMM limits
optimization
Minimize flight operationdisruptions On-Wing
repairs/inspections Outstation engine or
booster change Quick Turns Assistance in Transit Spare engine Logistics
Most of new generation engines require on-wing and/oroff-wing repairs before going to shop for performance restoration Cost savings are gained by combination of Line and Shopmaintenance operations
Overhaul & Repair Engine shop overhaul Hospital chains with
dedicated workscopes Customized workscopes In-house capability Co-development of
repairs with OEM& independents
Used parts sourcing
That’s why AFI KLM E&M developed Adaptive On-Wing Services
total coverage
Adaptive On-Wing Services
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On-Site & On-Wing Engine SupportUnrivaled know-how, some examples
Oct09 to Jun10, Montreal - Air CanadaGE90, 6 LPT6 Quick Changes carriedout during maintenance checks
Dec 2005, Hanoi - Vietnam AirlinesGE 90-94B Booster changes
Jul 2011, Rome - AlitaliaGE 90-94B Booster change
Nov 2011, Sardaigna – AKFEDCFM56-5B Fan disk replacement
Apr 2011, Miami – LANGE90 Engine preservation
Sep 2010, Mauritius – Air MauritiusCFM56-5B HPC bushing & VBV chainreplacement during maintenance check
Feb 2012, Abu Dhabi – Air MauritiusCFM56-5B HPC bushing & VBV chainreplacement during maintenance check
Jul 2010, Miami – LANCFM56-5C Engine preservation
Feb 2010 Amman – Gulf AirCFM56-5A HPC blades replacement
Aug 2009, Bahrain – Gulf AirCFM56-5C HPC blades replacement
Feb 2012, Novosibirsk – Vladivostok AirCFM56-5B HPC bushing & VBV chain
Jun 2012, Novosibirsk – Vladivostok AirCFM56-5B HPT blade replacement
Feb 2012, Novosibirsk – Vladivostok AirCFM56-5B HPC bushing & VBV chain
Jun 2012, Novosibirsk – Vladivostok AirCFM56-5B HPT blade replacement
Apr 2012, Trois Rivieres – SunwingCFM56-7B J-hook repair
Mar 2014 Nairobi – Kenya AirwaysCFM56-7B AGB replacement
Aug 2009, Istambul – PegasusCFM56-7B HPT blades replacement
Aug 2014, Moscow – TransaeroCFM56-7B J-hook repair (jointproject with Transaero)
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On-Site ServicesExample of CFM56-5B HPT blade replacement
Vladivostok Air experienced HPT blades out of limit followingboroscopic inspection
AFI developed dedicated tooling including lifting device to be able toperform On-Site Support anywhere in the world and proposed an On-Site solution to avoid the engine shop
HPT blade replacement performed in Novosibirsk for Vladivostok Air
Able to perform on-wing & on-site services anywhere In full autonomy At locations lacking hoisting facilities With highly experienced mechanics
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On-Site ServicesExample of CFM56-7B, J-Hook Repair
On-Site repair performed in Vnukovo in cooperation with Transaero AFI KLM E&M developed CFM56-7B On-wing support to fix specific
technical issues for AFKL Fleet, and is proposing it to MRO Customers Earlier performed in Trois Rivières (Canada) during aircraft maintenance
check
Share scale effect, specific On-Site processes & solutions Smooth flight operations Avoid engine shop visit, transportation and spare lease
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On-Site ServicesSome other solutions in place for CFM56-7B issues
And others: Fan OGV refurbishment Fan case elongated boltholes VBV Guide pad wear HPC IGV Ring wear HPT Blade replacement HPT & LPT Nozzle Guide Vane replacements Oil tube coking TRF Cracking…
Fan Disk replacement Accessory gearbox replacement
Table of contents
AFI KLM E&M Overview Our Engine Services AFI KLM E&M a major CFM56 engine MRO Reducing the cost of ownership of CFM56 engines:Engine Condition MonitoringOn-wing and On-site servicesPart repairsEngine shop process improvements
Conclusion
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Overhaul and Repair Services
Reach expected TimeOn Wing Engine monitoring Technical
recommendations Water wash AMM limits
optimization
Minimize flight operationdisruptions On-Wing
repairs/inspections Outstation engine or
booster change Quick Turns Assistance in Transit Spare engine Logistics
Most of new generation engines require on-wing and/or off-wingrepairs before going to shop for performance restoration Cost savings are gained by combination of Line and Shopmaintenance operations
Overhaul & Repair Engine shop overhaul Hospital chains with
dedicated workscopes Customized workscopes In-house capability Co-development of
repairs with OEM& independents
Used parts sourcing
That’s why AFI KLM E&M developed Adaptive Shop Services
total coverage
Engine Shop
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Part repairExample: Development of repair for multi-holes combustors
CFM56 OUTER LINER
CFM56 OUTER LINER
CFM56 INNER LINER
GE90 OUTER LINER LASER DRILLIING
First worldwide MRO to offer Combustor Multi-holes repairs
Full overhaul capability for 5B & 7B combustors Taking advantage of GE90 expertise and know-how Developed full capability for multi-hole combustors
(including Tech Insert standards)
Combustor Assembly modifications: Multi-Holes liners
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Part repairExample: Bevel Gear Shaft Fwd Thread
No existing repair for Fwd thread damage Repair developed using e-beam welding technology Real innovation is in the use of e-beam welding in a critical area AFI KLM E&M sole engine MRO with full range of repairs on this part
Repair than replace Lower repair cost: less than 50% of new part catalog price OEM-approved repair Meets customer and Lessor expectations
Table of contents
AFI KLM E&M Overview Our Engine Services AFI KLM E&M a major CFM56 engine MRO Reducing the cost of ownership of CFM56 engines:Engine Condition MonitoringOn-wing and On-site servicesPart repairsEngine shop process improvements
Conclusion
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Decide locallyThe best level to
make a decision isthe one closer
to the field
From Wing to reDeliveryA global approach to meet customer expectation
« ForWarD »
Improve the qualityperceived by the customer
Reduce the engine TAT
Reduce the number ofstandard exchanges
A global project, not restricted toproduction activities, but also involvingsupport staff
An extensive participation of the employeesin a bottom up approach, covering all areasof progress
Do the job rightthe first timeQuality is the first pillarof TAT. The efficientshift is the one whichperforms the jobwithout rework
Decide locallyThe best level to
make adecision is the
one closerto the field
Make it simpleLook for simple
solutions to guaranteean effective work and
eliminate waste
Remove thebarriersThe smoothest processis the one whichcontains thefewest interruptionsand changes ofresponsibilities
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AF’s Team : We improved our dedication to the CFM56-5B program Reinforced support teams CSM/CSE
Customer program management implementation TRM/CRM twice a year Management Meeting & Shared KPI’s Customer Procedure Manual customisaton
Communication & Shop visit management : Better anticipation Before SV : anticipation of constraints as Lessors requirements, LLP needs etc During SV : Real time updates, weekly status After SV : Wash-up meeting 10 days after re-delivery
Supply Chain (USM & Purchasing contract) Used serviceable material : more aggressive chasing on CFM56-5B 2nd market Structured contract with major sources
Engine Flow Process : increasing of repair window “Premium” shop flow process by reinforced resources utilization
Paris Shop Process improvements achievedAnticipation and Communication as a key for success
Enlarged repair window allowing upto 100% closed-loop repairs
Prelim.Works+Worksc
ope
Engine &modulesdisassy
Repair and partsreplacement
Eng/modules assy
test & delivery
Invoiceandfinal
balance
Improved Shop Process in line with market expectations+ wing to wing vision
Anticipation of specificcustomers / lessorsneeds
Reduced discrepanciesand quality issues
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Return Own Engine or Fleet principle Repair carefully rather than replace rapidly
Separate full performance shopvisit production lines with separate disassembly and assembly lines
Separate Quick Turn or Hospital Visit production lines
Process control using SAP ERP Flow lines within the stages concept
Amsterdam Shop Process improvements achievedSimples Solutions Eliminating Waste
dis-assembly
dis-assembly
internalrepair
internalrepair
externalrepair
externalrepair
assemblyassemblypreparation
workscope
preparationwork
scope
Stage 0 Stage 1 Stage 2 Stage 3
dis-assembly
dis-assembly
internalrepair
internalrepair
externalrepair
externalrepair
assemblyassemblypreparation
workscope
preparationwork
scope
Stage 0 Stage 1 Stage 2 Stage 3
U/S S/E
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Gaspath Analysis Tool and Core Trim balanceSmart tools for limiting of the workscopes/module exposure
No gaspath analysis toolsavailable by the OEM
KLM E&M developed this toolin cooperation with theTechnical University andNational Aerospace Laboratory
Analyze the performance ofthe gas turbine after overhaul orafter an inbound test run GSP Output file
Continuous improvement by sharing of process-, product-, lean- knowhow,between engine services, OEM’s and Universities such as: Core Trim balance with OEM
Gaspath Analysis with Universities
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Table of contents
AFI KLM E&M Overview Our Engine Services AFI KLM E&M a major CFM56 engine MRO Reducing the cost of ownership of CFM56 engines:Engine Condition MonitoringOn-wing and On-site servicesPart repairsEngine shop process improvements
Conclusion
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Conclusion
Cost savings are gained by combination of On-Wing/On-Site and Shop maintenance operations
Engine condition monitoring is key
On-wing & on-site services smooth flight operationsand avoid engine shop visit
Development of high tech part repair with theobjective of cutting cost
Continuous development of innovative solutions inevery areas
Reducing total cost of ownership of the CFM56
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Thank You
Visit us at www.afiklmem.com
