US Norway Technology Conference 2017
FACING THE DOWNTURN:
LESSONS LEARNED FROM THE AVIATION INDUSTRY
March 1, 2017
Daniel Moczydlower
Embraer at a Glance
Business Units
Revenue Breakdown DEFENSE &
SECURITY
OTHER
0.4%
EXECUTIVE
AVIATION
24.2%
COMMERCIAL
AVIATION
61.2%
14.2%
Integrated Portfolio
17+ THOUSAND
MORE THAN 17,500 EMPLOYEES FROM
OVER 20 COUNTRIES
5,9 US$ BILLION
REVENUE
IN 2015
Where we operate
USA Nashville
Fort Lauderdale
Melbourne Mesa
Windsor Locks
Jacksonville
Irwindale
PORTUGAL Évora
Alverca - OGMA
UNITED
KINGDOM Farnborough
FRANCE Le Bourget
UAE Dubai
CHINA Beijing
IRELAND Dublin
NETHERLANDS Amsterdam
BRAZIL São José dos Campos Gavião Peixoto
Botucatu
Taubaté
Brasília
Belo Horizonte São Paulo
Rio de Janeiro
Sorocaba
Campinas
SINGAPORE Singapore
Flight Plan
Flight Plan
• Aeronautics & O&G Industry Similarities
• Engineering Knowledge and
Aeronautics Best Practices
• Results
• Oil & Gas Industry Applications
• Conclusion
Aeronautics & O&G Industry
Similarities
2000 2003 2005 2007 2009 2010 2011 2012 2013 2014 2015 2016 C
OM
ME
RC
IAL
EX
EC
UT
IVE
D
EFE
NS
E
EMBRAER 175
EMBRAER 190
EMBRAER 170
EMBRAER 195
E 175 Plus
E175-E2
E190-E2
E 195-E2
LEGACY 600 PHENOM 100
LINEAGE 1000 PHENOM 300
LEGACY 500
LEGACY 450
AEW&C
A-29 SUPER TUCANO COLOMBIA
ALX
A-29 SUPER TUCANO CHILE
AEW INDIA A1M
LAS
KC-390
2000 2003 2005 2007 2009 2010 2011 2012 2013 2014 2015 2016 C
OM
ME
RC
IAL
EX
EC
UT
IVE
D
EFE
NS
E
EMBRAER 175
EMBRAER 190
EMBRAER 170
EMBRAER 195
E 175 Plus
E175-E2
E190-E2
E 195-E2
LEGACY 600 PHENOM 100
LINEAGE 1000 PHENOM 300
LEGACY 500
LEGACY 450
AEW&C
A-29 SUPER TUCANO COLOMBIA
ALX
A-29 SUPER TUCANO CHILE
AEW INDIA A1M
LAS
• The story shows the need to
execute concurrent programs
• Highly Regulated
• Very Sensitive for Safety &
Environmental Issues
• Intense on Assets , Capital,
Technology
• Complex and Global Supply
Chain
• Highly Integrated Systems
• High Reliability Requirements
• Challenging to Innovate
• Hard to inspect
• Difficult to provide
maintenance while in operation
Geopolíticablog
• Emergency systems may never
be used/activated but shall be
maintained always ready
Reliability
Ability to be able to perform a function at a given time, taking into account the reliability, maintainability, and maintenance support, assuming that the required
external resources are provided.
Ability to perform a requested function under specific conditions for a given time.
Availability
Ability to be retained or replaced in conditions to perform its required functions under specified conditions of use, when maintenance is performed under given conditions
and using procedures and means prescribed.
Maintainability
Availability
Reliability Maintainability Maintenance/ Supportability
The assets availability
directly impacts competitiveness!
Aeronautics Best Practices
Asset Maintenance Strategy Maintenance Plan – Inspections – Condition Monitoring
Safety
Assessment
Operational / Economic
Assessment
FMEA / FMECA / FTA
RCM RBI CBM
Engineering & Design Field Operation
Prognostics and Health
Monitoring
Inspections
TP
M
Fie
ld S
ervi
ces
Pla
nnin
g –
Sch
edul
ing –
Exe
cutio
n
Re-
eval
uatio
n &
Upd
ate
Implementation Initial Definition & Revision Recommendation
MSG-3 Methodology
Life Cycle Cost Analysis
Reliability Analysis Root Cause Analysis
Maintenance Preventive
Predictive
Corrective
Continuous Improvement
Lean Maintenance OEE Management Process Improvements Kaizen
Asset Maintenance
Continuous Improvement & Optimization
Designing for Reliability
Market Aircraft
Aircraft Level needs and targets
System
System/Subsystem needs and targets
Equipment / Item
Component/LRU characteristics and
targets
Design
Verifiable Attributes
Requirements Management – Product Maturity
SR > 99,4%
SR > 99,4%
R(t) > 99,65%
R(t) > 99,986%
Risk Partnership – managing the supply chain
Technological Development
TRL1 TRL2 TRL3 TRL4 TRL5 TRL6 TRL7 TRL8 TRL9
Basic technology
research
Research to prove
feasibility
Technology development
Technology demonstration
System-Subsystem development
Systems test and operations
20 years average
Technological Development
Research & Technology
TECHNOLOGY DEVELOPMENT
FUNDAMENTAL KNOWLEDGE
TECHNOLOGY DEVELOPMENT
VALIDATION
PRODUCT DEVELOPMENT
CERTIFICATION
PRODUCTION
OPERATION
Universities
Research & Development
PRODUCT DEVELOPMENT
Research Centers
Industrial Research
1 6 2 3 4 5 7 8 9
Fundamental Research
Applied Research
Technology Demonstration
Cost
Motivation to invest
DEATH VALLEY
DEMONSTRATORS
Commercial Application Product / Service
From Aircraft Data to Value-added into Main Features
Integrated System Health Management
Major Customer Benefits
• Maintenance Cost Reduction
• Operational Efficiency
SHM - Structural Health monitoring
- 5 Technologies developed
- 1 Technology under development
- 2 Technologies in qualification process
- Application on Full-Scale Fatigue Test
Direct Detection
(Damage Detection Systems)
Assessment
(eSRM)
- eSRM - Phase 1 and 2 finished and
transferred to Commercial Aviation
- eSRM Composites under development
Management
(SHM Portal, AdHUMS)
- SHM Portal was a proof of concept developed
- AdHUMS is a upgrade under development and
in transfer process to Embraer Defense &
Security
SAE/ARP 6461
Customer Care Center
Integrated Customer Support
Prognostics is now part of
the integrated solutions
Global Collaboration
São Paulo
São Carlos
EcoDemonstrator / Boeing – Embraer
New technologies designed to reduce carbon emissions, fuel use and noise
ENVIRONMENTAL PERFORMANCE
Biofuels
Slat Noise Cove Fillers SYSTEMS
Optical Air Data System
FLIGHT TEST
Boundary Layer Measurements
ADVANCED MATERIALS
Ice Release Coating
Embraer´s commitment towards a
sustainable future !
Results
E-Jets longer intervals reduces quantity of Basic Checks
Note: Preliminary Information. Subject to change during product development.
Current 6,000 FH
7,500 FH
1 2 3 4 5 6 7 8 9 10 0
600nm; 2,650 FH/ year; 10 years.
Savings
1 Basic check per aircraft in 10 years
• 5 days avg downtime
• no Calendar Limit (CPCP schedule to coincide)
More Efficient Aircraft
Maintenance Cost Reduction
E175-E2 (80 seats) vs. E175 (76 seats)
E190-E2 (97 seats) vs. E190 (97 seats)
E195-E2 (120 seats) vs. E195 (106 seats)
-25%
-20%
-15%
0%
-5%
-10%
-15%
-20%
-25%
E190 CF34-10E6 baseline as per 2011 conditions E190 CF34-10E6 enhanced as per 2016 conditions *2,600FH/Yr & 1.5FH/FC; 10 years DMC
• E175 CF34-8E5 baseline as per 2011 conditions
• E175 CF34-8E5 enhanced as per 2016 conditions
• *2,600FH/Yr & 1.5FH/FC; 10 years DMC
Executive Aviation
Product Support Satisfaction – AIN
2011 2012 2013 2014
1º GulfstreamGII-G550 GulfstreamGII-G550 GulfstreamGII-G550 EMBRAER
2º Cessna EMBRAER EMBRAER GulfstreamGII-G550
3º Gulfstream Astra-G200 BoeingBBJ BombardierLearjet BombardierGlobal
4º BoeingBBJ BombardierChallenger Cessna BombardierChallenger
5º BombardierChallenger Cessna Gulfstream Astra-G200 Dassault
6º Dassault Dassault BombardierGlobal Gulfstream Astra-G200
7º BombardierGlobal Gulfstream Astra-G200 BombardierChallenger BombardierLearjet
8º BombardierLearjet BombardierGlobal Dassault Cessna
9º HawkerPremier, 400, 400XP BombardierLearjet HawkerPremier-400XP BoeingBBJ
10º HawkerHawker HawkerPremier-400XP HawkerHawker HawkerHawker
11º EMBRAER HawkerHawker NA
HawkerPremier-400XP
10º
2º 2º
1º
Oil & Gas Industry Applications
BOP Project
• Petrobras and Embraer partnered for
2 years (2014-2016) to assess the
reliability of critical systems of the oil
and gas industry
https://escolaelectra.wordpress.com/2011/12/28/353/
Gas Treatment & Power Plant
• Reliability engineering
• Critical equipment availability
improvement
• Maintenance schedule optimizer
http://www.petrobras.com.br/pt/nossas-atividades/principais-operacoes/refinarias/refinaria-henrique-lage-revap.htm
Work Orders Management system
• Excellence in productivity and
operational efficiency, through proper
smart and efficient planning and
effective service scheduling
Final Remarks
Designing for safety
and reliability
Processes integration
Create room for
innovation by suppliers
Cooperation
Collaboration
Cross industry
borders
Win the
innovation valley
Changes
Research and Technology Development
“The future is not a gift. It is an achievement!”
Robert F. Kennedy
Research and Technology Development
Daniel Moczydlower, M.Sc., PMP VP Technology Development
+55 (12) 3927-1227