Resetting the-LRU-Replacement-Norm
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Transcript of Resetting the-LRU-Replacement-Norm
© 2016 Copernicus Technology Ltd. All Rights Reserved. www.copernicustechnology.com
Resetting the LRU Replacement Norm
© 2016 Copernicus Technology Ltd. All Rights Reserved. www.copernicustechnology.com
© 2016 Copernicus Technology Ltd. All Rights Reserved. www.copernicustechnology.com
The LRU Replacement Norm
When tasked with repairing an Avionics fault the default assumption routinely made by repair technicians is that changing a Line Replaceable Unit (LRU) will fix the problem
© 2016 Copernicus Technology Ltd. All Rights Reserved. www.copernicustechnology.com
Reported Fault
LRU is the Cause
LRU is not the Cause
LRU to be Replaced & Sent for Repair
LRU ‘Repair’
Fault Not Found
A Fault Found & Fixed
No Fault Found
© 2016 Copernicus Technology Ltd. All Rights Reserved. www.copernicustechnology.com
Reported Fault
LRU is the Cause
LRU is not the Cause
LRU to be Replaced & Sent for Repair
LRU ‘Repair’
Fault Not Found
A Fault Found & Fixed
No Fault Found
We need to Reset the LRU Replacement Normto stop incorrect LRU
replacements
© 2016 Copernicus Technology Ltd. All Rights Reserved. www.copernicustechnology.com
LRUs that keep going round this loop are
‘rogues’ or ‘bad actors’
Reported Fault
LRU is the Cause
LRU to be Replaced & Sent for Repair
LRU ‘Repair’
Fault Not Found
A Fault Found & Fixed
© 2016 Copernicus Technology Ltd. All Rights Reserved. www.copernicustechnology.com
Why is this The Norm?§ ‘The book’ (FIM / TSM / AMM) says change
an LRU
§ ‘There’s one in stock & it’s a quick fix’
§ ‘When you replace the LRU it passes BITE so that’s it fixed’…and flying somewhere else
§ It’s what we’ve always done’
§ There’s limited maintenance history available for that LRU so it gets replaced anyway
§ Despatch rate is so important to reputation that all the LRUs mentioned in the TSM get replaced
§ ‘What are you supposed to do when the symptom has disappeared?
§ The diagnostic process doesn’t reproduce conditions as per when the symptom occurred
§ ‘We changed LRU X and the fault came back so this time we’re going to change LRU Y’
§ ‘We changed LRU X and the fault came back so this time we’re going to change LRU X’
§ ‘Suspect DOA’ or ‘Suspect U/S on fit’
§ ‘Other shift’…
§ ‘This wasn’t covered in training’
§ Lack of data on NFF / FNF / First-Time Fix rates etc
§ It takes 15 times longer to investigate the EWIS to see if it’s the cause
© 2016 Copernicus Technology Ltd. All Rights Reserved. www.copernicustechnology.com
Why is this The Norm?
Fault Diagnosis
Policy
Culture
Technology
Training
© 2016 Copernicus Technology Ltd. All Rights Reserved. www.copernicustechnology.com
A new LRU Replacement Norm is needed
© 2016 Copernicus Technology Ltd. All Rights Reserved. www.copernicustechnology.com
LRU Replacement Norm
When tasked with repairing an Avionics fault the default assumption routinely made by repair technicians is that changing a Line Replaceable Unit (LRU) will fix the problem
© 2016 Copernicus Technology Ltd. All Rights Reserved. www.copernicustechnology.com
LRU Replacement Norm
Replacing an LRU should be the last resortfor an Avionics repair unless faced with clear evidence to the contrary
© 2016 Copernicus Technology Ltd. All Rights Reserved. www.copernicustechnology.com
Cont
ainm
ent
Mea
sure
men
t
Impr
ovem
entStrategy Approach
© 2016 Copernicus Technology Ltd. All Rights Reserved. www.copernicustechnology.com
Cont
ainm
ent
Mea
sure
men
t
Impr
ovem
ent
NFF Maturity Model shortfalls
Manage rogue assets
Intermittent Fault Detection (IFD)/Integrity testing of EWIS and rogue LRUs
Modify LRU repair procedures v IFD results
Symptom Diagnostics: correlate symptom/fault/fix data to upgrade diagnostic procedures/training
Correlate Symptom Diagnostics data with LRU repair organisations
Embed new ways of working in Contracts
NFF Maturity Model
Identify ‘rogue’ ac/LRUs/SRUs
Correlate repeat arisings v LRU changes
Analyse Ship or Shelf data for quick wins in diagnostic procedures/training
NFF Reduction policy
Ship or Shelf
Notify repair organisations of repeat arisings v LRU changes
Strategy Approach
Copernicus Technology “No Fault Found” Maturity Model © 2015. Copernicus Technology Ltd. All Rights Reserved.
No Fault Found Maturity Model Unmanaged Developing Advanced Dynamic
Strategy
Policy No published policy Policy is published but not used or reviewed
Published policy is successfully used Published policy is successfully used and frequently reviewed/updated
Champion There is no NFF reduction ‘champion’ in the organisation
It is an implied role against a specific post
It is a secondary duty against a specified post but is not deemed a priority
NFF champion is empowered and proactive in implementation, KPIs & best practice
Contracts Contracts with repair bodies don’t include NFF reduction
NFF reduction is included but with no targets
NFF reduction is included with targets/KPIs
Contracts include gainshare opportunity from NFF reduction
Data Exploitation
Impact on Cost
Not recorded across the repair chain
Recorded in some parts of the repair chain but not used
Recorded in some parts of the repair chain and used occasionally/in isolation
Recorded and used proactively throughout the repair chain for evidence-based decision-making
Impact on Downtime
Not recorded across the repair chain Recorded in some parts of the repair
chain but not used Recorded in some parts of the repair chain and used occasionally/in isolation
Recorded and used proactively throughout the repair chain for evidence-based decision-making
Symptom & Repair
Not used to support fault diagnosis Used occasionally to inform fault diagnosis
Policy mandates use of Symptom & Repair data to inform fault diagnosis
Symptom & Repair data is codified, correlated & quantified automatically for fault diagnosis use
Fault Diagnosis
Training Does not cover NFF or ‘unable to reproduce symptom’ (UTRS) or intermittent fault scenarios
Anecdotally covers NFF/UTRS/ intermittent faults
Specifically includes NFF/UTRS/ intermittent fault strategies
Dedicated NFF/UTRS/intermittent fault training provided and regularly refined by Symptom & Repair data findings
Manuals Do not cover NFF/UTRS/ intermittent fault scenarios
NFF/UTRS/intermittent faults addressed by LRU replacement only
Provide greater latitude for root-cause analysis when diagnosing NFF/UTRS/intermittent fault problems
NFF/UTRS/intermittent fault content is regularly refined by Symptom & Repair data findings
LRUs All LRUs replaced during trouble-shooting are shipped for repair
LRUs replaced during trouble-shooting are occasionally held back pending repair-success confirmation
Policy enables quarantine of LRUs replaced during trouble-shooting pending repair-success confirmation
LRU-quarantine results vs repair-success data is used to optimise fault diagnosis training and manuals
Test Equipment
Rarely used due to lack of familiarity
Used occasionally in trouble-shooting but only as a last resort
Effectively deployed in trouble-shooting to detect ‘hard’ faults
Effectively deployed to successfully detect ‘hard’ and intermittent faults
Score per box: 1 2 3 4
Copernicus Technology “No Fault Found” Maturity Model © 2015. Copernicus Technology Ltd. All Rights Reserved.
Unmanaged Developing Advanced Dynamic
Strategy
Policy No published policy Policy is published but not used or reviewed Published policy is successfully used Published policy is successfully used
and frequently reviewed/updated
Champion There is no NFF reduction ‘champion’ in the organisation
It is an implied role against a specific post
It is a secondary duty against a specified post but is not deemed a priority
NFF champion is empowered and proactive in implementation, KPIs & best practice
Contracts Contracts with repair bodies don’t include NFF reduction
NFF reduction is included but with no targets
NFF reduction is included with targets/KPIs
Contracts include gainshare opportunity from NFF reduction
Data Exploitation
Impact on Cost
Not recorded across the repair chain
Recorded in some parts of the repair chain but not used
Recorded in some parts of the repair chain and used occasionally/in isolation
Recorded and used proactively throughout the repair chain for evidence-based decision-making
Impact on Downtime
Not recorded across the repair chain Recorded in some parts of the repair
chain but not used Recorded in some parts of the repair chain and used occasionally/in isolation
Recorded and used proactively throughout the repair chain for evidence-based decision-making
Symptom & Repair
Not used to support fault diagnosis Used occasionally to inform fault diagnosis
Policy mandates use of Symptom & Repair data to inform fault diagnosis
Symptom & Repair data is codified, correlated & quantified automatically for fault diagnosis use
Fault Diagnosis
Training Does not cover NFF or ‘unable to reproduce symptom’ (UTRS) or intermittent fault scenarios
Anecdotally covers NFF/UTRS/ intermittent fault
Specifically includes NFF/UTRS/ intermittent fault strategies
Dedicated NFF/UTRS/intermittent fault training provided and regularly refined by Symptom & Repair data findings
Manuals Do not cover NFF/UTRS/ intermittent fault scenarios
NFF/UTRS/intermittent faults addressed by LRU replacement only
Provide greater latitude for root-cause analysis when diagnosing NFF/UTRS/intermittent fault problems
NFF/UTRS/intermittent fault content is regularly refined by Symptom & Repair data findings
LRUs All LRUs replaced during trouble-shooting are shipped for repair
LRUs replaced during trouble-shooting are unofficially held back pending repair-success confirmation
Policy enables quarantine of LRUs replaced during trouble-shooting pending repair-success confirmation
LRU-quarantine results vs repair-success data is used to optimise fault diagnosis training and manuals
Test Equipment
Rarely used due to lack of familiarity
Used occasionally in trouble-shooting but only as a last resort
Effectively deployed in trouble-shooting to detect ‘hard’ faults
Effectively deployed to successfully detect ‘hard’ and intermittent faults
Score per box: 1 2 3 4
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In the above example the score is 28 / 100
Apply these scores, by column, to each completed box
10 12 6 0
No Fault Found Maturity Model
Scoring Method
© 2016 Copernicus Technology Ltd. All Rights Reserved. www.copernicustechnology.com
Conclusions (1)The LRU Replacement Norm
Is a major driver of repeats arisings, NFFs & degraded readiness/availability/ dispatch performance
Is caused by policy, culture, training & technology factors
The NFF Maturity Model is the basis of resetting the Norm through:
• Containment
• Measurement
• Improvement
© 2016 Copernicus Technology Ltd. All Rights Reserved. www.copernicustechnology.com
Conclusions (2)Essential areas to target:
• Data correlation at and between airframe and LRU maintenance levels
• Use of Symptom Diagnostics & Ship or Shelf data to optimise Fault Diagnosis procedures & training
• Managing ‘rogues’
• IFD testing of rogue systems’ EWIS and rogue LRUs
© 2016 Copernicus Technology Ltd. All Rights Reserved. www.copernicustechnology.com
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@CopernicusTech
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