Maintenance Prognostics Digital solutions to optimize ... · PDF fileAbnormal Trend 10 -11...

Copyright © 2015 Boeing. All rights reserved.

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The statements contained herein are based on good faith assumptions are to be used for general information purposes only. These statements do not constitute an offer, promise, warranty or guarantee of performance.

BOEING 1

Maintenance Prognostics – Digital solutions to optimize maintenance operationsJuan D. Lopez | Program Manager, Fleet and Maintenance SolutionsSeptember 2015

Copyright © 2015 Boeing. All rights reserved. BOEING 2

General trends in aviation

Today’s business realities

Historic profitability

Lifecycle approach

Opportunities

Reduce schedule interruptions

Increase maintenance efficiencies

Digital asset management

Summary


General trends

Operating costs high and volatile

Technology becoming a key enablerProfitability slowly improving

Traffic growth but prices declining


Historic profitability

Historic financial environment

Source: McKinsey & Company for IATA

0

1

2

3

4

5

6

7

8

9

10

1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013

Aviation Industry ROIC vs WACC (%)

WACC ROIC

• Weighted Average Cost of Capital

• Return on Invested Capital


General trendsCommercial Aviation Industry Costs

Stations(~15%)

Crew(~15%)

Fuel(~40%)

M&E(~10%)

Aircraft(~10%)

G&A(~10%)

$715B

(2014 Expenses)

Increasing operating complexity

Relentless cost pressures

Legacy information systems

Enabling information-rich airplanes

Disruptive and enabling technologies

Need for real-time information

Airlines Seeking New Levels of Operational Efficiency


Dispatch Arrival

Airplane Introduction

Airplane Transition

En Route

Maintenance

Tech logs

Health management

Airplane and engine

technical docs

Asset management

Records management

Maintenance Optimization


Opportunities throughout the lifecycle

Reduce schedule interruptions Increase maintenance efficiencies Digital asset management


Opportunities throughout the lifecycle



Some level setting

Technical performance measures

Schedule Reliability is expressed as a percentage of scheduled revenue flights that are not delayed or

interrupted

*Includes scheduled and unscheduled downtimes

𝐴𝑖𝑟𝑝𝑙𝑎𝑛𝑒 𝑂𝑝𝑒𝑟𝑎𝑡𝑖𝑜𝑛𝑎𝑙 𝐴𝑣𝑎𝑖𝑙𝑎𝑏𝑖𝑙𝑖𝑡𝑦 = 1 − 𝐷𝑜𝑤𝑛𝑡𝑖𝑚𝑒𝑠 ∗

𝑇𝑜𝑡𝑎𝑙 𝑇𝑖𝑚𝑒 𝐴𝑣𝑎𝑖𝑙𝑎𝑏𝑙𝑒


Maintenance strategies

Cost is an important part of the schedule reliability equation

Schedule Reliability

Cost

HIGH

HIGH

LOW

Cost

ReactivePreventive PredictiveReactive Preventive

Predictive

HIGH

LOW

Maintenance cost vs # failures Maintenance cost vs Schedule Reliability

Repair cost

Prevention

cost

Total cost

# of Failures HIGH


Opportunity: Airplane Health ManagementProactive use of airplane data

With AHM Real time

visibilityWith AHM, faults are known in

flight and maintenance action

planned before arrival.

AHM helps airlines to maintain their fleets in the air, on schedule and reduce schedule delays

Faults are not identified until the aircraft is on the ground. Unscheduled maintenance can cause

costly delays and cancellations

Without real time visibility


Health management goes beyond real-time visibility

Prognostic alerts for airplane systems

Abnormal

Trend

10 -11 days

Alert

GeneratedFailure

Predicting faults and minimizing operational disruption


Airplane SystemsMultiple systems generate performance data (pressure,

temperature, etc).

Data Availability Systems transmit data to a local data bus.

Data Collection & On

Board Processing

Central data (CMC, DFDAU) funnels and collects real

time performance data.

Data TransmissionData is transmitted to ground stations via ACARS or

Satellite.

Prognostic AlgorithmsGround station receives and processes data. Thresholds

are evaluated and Prognostic alerts are developed.

Prognostics health management value driversHardware constraints

CMC: Central Maintenance ComputerDFDAU: Digital Flight Data Acquisition Unit

Data availability and transmission are key to unleash prognostics value

Data


Example – Pneumatics System

ATA 36 Techlog reports

~80%

reduction in

rate of delay

Before

Airplane Health

Management

Post Airplane

Health

Management

implementation


Maintenance optimization

Opportunity throughout the lifecycle



How are we doing maintenance today?


Mechanic is by the airplane …

Mechanic is by the

airplane…

…Goes to maintenance

building…

…Logs onto multiple

systems…

…Prints job cards…


And then goes through non-value added steps…

…Double checks for the

latest revision of

manuals…

…Goes back to

airplane…

…Fixes the airplane…

…Properly documents

the fix in a

paper record…


Couldn’t we do this better?


M&E mobile applications

Can mobile devices help?

Mechanic is by the

airplane…

Gets the information he

needs…Fixes the airplane…

…Up to date and

compliant in all devices…


Opportunity: Toolbox Mobile suite

Toolbox Mobile Parts

Providing part inventory queries remotely via mobile devices

Maintenance Turn Time

A productivity solution to empower mechanics by the airplane,

organize and streamline maintenance information, and improve

visibility and collaboration

Toolbox Mobile Library

Extending and optimizing Maintenance Performance Toolbox

Library for mobile use


Records management

…Instead of paper

records…

…Go digital

And paperless…

What about tackling a large paper challenge?


Increases efficiency of maintenance records management • Saves time and labor costs during daily operations

• Significant savings during aircraft transition events

• Avoidance of costly fines and penalties due to incomplete records and paperwork errors

Direct maintenance and engineering labor costs savings• Faster and more efficient processing of maintenance records

• Access to all technical documents at the point of need

Opportunity: Toolbox Records module

Eases the pain during airplane transitions• Complete set of back to birth delivery documents

• Consolidated file for AD notes, repairs and overhaul

• Data regarding component repair and overhaul

A digital aircraft records system that benefits operators, lessors and MROs


Maintenance optimizationValue proposition

Opportunity throughout the lifecycle

Reduce schedule interruptionsIncrease maintenance

efficienciesDigital asset management


Loadable Software Airplane Parts (LSAP)

~ 30 LSAPs

> 300 LSAPs

~ 100 LSAPs

LSAPs are airplane operational

software

• Designed for electronic loading without altering the

hardware

• Managed as a “part”

• Installation is independent of the hardware part number

• Controlled as part of the airplane and configuration


Characteristics of today’s software management environment

More sophisticated avionics, requiring

more operational software (LSAPs)

Airplane operational software

distributed only via secure internet

A comprehensive ground system has to

be established to receive the LSAPs

A comprehensive suite of

configuration, management, and

utility software has to be installed

into a ground system

A maintenance laptop with the designated

security software can be used to load the

LSAPs onto the airplane


Imagine distributing software with traditional methods


Opportunity: LSAP Services

The ground systems and infrastructure required for setting up e-

enabling software suite and airline implementation

The e-enabling ground infrastructureSoftware

Distribution

Manager

The suite of software required for secure receiving,

managing, and loading of LSAPs from the OEM to the

airplane

The e-enabling software suite Software

Distribution

Tools

Managing of receiving, inspection, certificates, staging and

other aspects of LSAP Library and management processes

Management of LSAPsLibrary

Manager


Dispatch Arrival

Airplane Introduction

Airplane Transition

En Route

Maintenance

ELBPilot/Cabin Reports

Maintenance

ReleaseHosted SolutionsLoadable Software

Data Hosting Services

AHMFault Forwarding

Predictive Alerting

& Prioritization

ToolboxTech documents

Task Cards

Authoring

Structural Records

Digital Records

Mobile Mechanic Tools

Digital Records


SummaryTechnology solution decisions come down to a financial business case

Incremental Cost

Of

Solutions

Incremental

Benefit Of

Solutions

Cost/Benefit Analysis

Each operator defines the right balance in the cost/benefit scale

FUTURE

Data Transmission Costs.

Incremental Labor to monitor

health monitoring systems

PRESENT

Hardware retrofits to enable

data availability (sensors, etc).

Hardware mobile device costs

Infrastructure costs

FUTURE

Reduced Unscheduled

interruptions

Maintenance Efficiencies

Digital Asset management

Cost Benefit


Thank You

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