Aircraft Technical Records From Burden to Benefit Technical Records From Burden to Benefit ......
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Transcript of Aircraft Technical Records From Burden to Benefit Technical Records From Burden to Benefit ......
Aircraft Technical Records
From Burden to Benefit
IATA – Atlanta Nov 2015
Rob SaundersHead of Engineering Business Improvement
& LEAN
Paper in Commercial Aviation
A highly optimised, hugely inefficient industry of
people, pens and paper held together by
silos of automation
A Challenging Problem
Barriers to Introducing Paperless Maintenance
Buy in from Regulatory Agencies
Many regulations are law - Many countries
Lessors and Finance companies driving the need for Paper
Driven by the regulators……. Driven by the Airlines
Availability of structured data from OEMs and repairers
Few Data Standards
Maturity of systems and technology to support changes to the processes
Ability to meet of Mechanics and Engineers mindset
Cost of introducing technology and process changes across industry
Lack of understanding or vision for ‘back office, not so trendy’ functions
Tendency for airlines to accept incremental improvement of Siloed
processes that should be redundant
Lease Return Vicious Circle• CX Component Acceptance Data Standard – 7335 out of 14152
acceptance requirements are Lease return driven
Lessorrequested
more from ex-operator
Ex-operatorpenalized by not fulfilling
requirements
Ex-operators
asked for more next time lease
A/C in
Lease Contract
(Authority req’t + Airline specific req’t)
Next Operator asked for
more
Operators asked for moreLessors ask for more
Alignment required to come up with ONE standard
Paperless Objectives – IATA paperless EWG
• Eliminate process inefficiencies
• Improve cost avoidance (Lease Returns. Inventory, paper Management)
• Reduce in service disruption
Enable Airlines to reduce Cost / ATK
and increase revenue
• Influence the Industry to introduce standards (birth record requirements, lease returns requirements)
• Drive priorities for OEMs to deliver paperless
• Drive to set up centralised repair/part history data for all Operators/MROs
• Create awareness in the industry
Introduce Industry
Standards
• Exploit new generation aircraft capabilities
• Leverage on Technology and tightly manage systems and organisational integration – ie avoid the siloed covert developments
• Account for technological growth opportunities – ie data volumes, band width, improved world wide access, mobile devices etc.
Ensure Sustainability & Usability
Mission: To influence Airlines, MROs and Suppliers and Regulators (the Industry) to introduce
business changes that enables the removal of paper records in aircraft maintenance.
Technical Records - scope
M&E Records:
• ‘Time Since’ data
•The Flying configuration
• LSAP / FLS
•The accomplishment history of all
‘airline aware’ maintenance.
Controls:
•Allowable config.
•Task frequency
• Flight Schedule
Paper / Electronic Records:
• Work Cards
• Component Certs.
• Workshop reports
• Repairs
All the Paper
Maintenance
Information System
Document
Information System
Cathay Pacific Airways Limited
Documents’ Copy Retrieval ProcessRetrieval Cycle
Request from
parties
Email to
HKG TRD
Manage requests
by HKG TRD
Email to
XMN TRD
Retrieve boxes
Retrieve documents
from boxes
Scan documents &
Put documents
back to boxes
Email back to
HKG TRD
XMN
HKG
Before
- Resources:
* 3 persons involved.
(1 in HKG, 2 in XMN)
- Availability:
* Working hours only.
- Process:
* Multi-user access is
not possible;
* Inefficient in fleetwise
documents retrieval;
* Waste created in
duplicated / repeated
requests;
* Documents retrieval
can only be based on
W/C ref. number.
Cathay Pacific Airways Limited
Documents’ Copy Retrieval ProcessRetrieval Cycle
Request from
parties
Email to
HKG TRD
Manage requests
by HKG TRD
Retrieve boxes
Retrieve documents
from boxes
Scan documents &
Put documents
back to boxes
Email back to
HKG TRD
XMN
HKG
Email to
XMN TRD
Retrieve documents from FLYdocs
(Self-service)
After
- Resources:
* Self-service via Web.
- Availability:
* 24 hours x 7 days.
- Process:
* Multi-user access
is available;
* Can do fleetwise
documents retrieval in
one-go;
* Eliminate requests
management;
* Documents retrieval
can be based on
any printed texts in
documents (inc. W/C
ref. number)
Cathay Pacific Airways Limited
0
5
10
15
20
25
WithoutFLYdocsRetrieval
FLYdocsRetrieval
Man-hours
Total Man-hours
Man-hours of Document Retrieval (Comparing)Case Study: Document Retrieval Requests in AUG 2015
23
6
Documents:
60 documents requests (different A/C) from sections;
Last A check of whole A330 fleets from TS.
After
- Resources:
* Self-service via Web.
- Availability:
* 24 hours x 7 days.
- Process:
* Multi-user access
is available;
* Can do fleetwise
documents retrieval in
one-go;
* Eliminate requests
management;
* Documents retrieval
can be based on
any printed texts in
documents (inc. W/C
ref. number)
Before
- Resources:
* 3 persons involved.
(1 in HKG, 2 in XMN)
- Availability:
* Working hours only.
- Process:
* Multi-user access is
not possible;
* Inefficient in fleetwise
documents retrieval;
* Waste created in
duplicated / repeated
requests;
* Documents retrieval
can only be based on
W/C ref. number.
Cathay Pacific Airways Limited
0
5
10
15
20
25
30
35
40
45
50
WithoutFLYdocsRetrieval
FLYdocsRetrieval
0
5
10
15
20
25
30
Maintenance Log(Last 3 months)
AD Workcards(9 items)
SB & AMSWorkcards(45 items)
FleetwiseWorkcards(186 items)
A & 2A ChecksDFP
(Latest)
Hardcopy Retrieval
FLYdocs Retrieval
Man hour
Individual Task’s Man-hours Consumption
Man-hours
Total Man-hours
Man-hours of Document Retrieval (Comparing)Case Study: Aircraft B-HUL - E&A Incident on 29th July, 2015
47
8
= Document retrieval according to individual W/O
= Except last 100 pages which remain on aircraft due to operation
Cathay Pacific Airways Limited
0
50
100
150
200
250
WithoutFLYdocsRetrieval
FLYdocsRetrieval
Aircraft Lease Return & Sale Projects Case Study: Cathay Pacific B747-400F (B-HUK) Sale Project in JUL 2015
B-HUK
• FLYdocs is used in whole project;
• Total 4,100 items required in records building
(including AD / SB / Repair / LLP etc.)
• Average 60 pages in a single item (record).
Man-days
Total Man-days
(Documents retrieval only)
213
106
Cathay Pacific Airways Limited
Aircraft Lease Return & Sale Projects On-time aircraft lease return & sale projects achieved
2013 2014 2015
B-HWJ
B-HWK
B-HWF
B-HWI
B-HWH
B-HUH B-HUK
B-HXK
B-HXI
• Achieved 100% on-time aircraft lease return & sale projects since Year 2013.
• B-HWJ is the first aircraft achieved on-time lease return in CX/KA history.
Airbus A330-300 Airbus A330-300 Airbus A340-300
Boeing B747-400FBoeing B747-400F
full lease return & sale projects
shown only .
Business Benefits – Records Management System
• No physical storage required for maintenance records
• Savings in Aircraft Lease Fees on redelivery processes
• Fast access to information
• Efficiency improvements in Tech Records section
• Improve security with the electronic information
• Rapid access for investigations
• Improve the Maintenance Program based on Data Analysis
Current Technical & Cabin Log Process
PRINTING PAGES DISTRIBUTE
OPERATE
TECH/CABIN LOG
ENTRIES
UM DATA ENTRY TRANSPORT AIR MAIL
DATA SCAN
STORAGE
e-RECORDS
1.3M pages / year 1 FTE
1M entries / year
HKG: 17 FTE
3000 sq. ft
~ 50M records
4 Dashboards
UM Data Correction
1.5 FTE
2.5 FTE
COLLECT
1.3M Log Pages
•Data Correction
•Storage
•30 Employees involved
8 FTE
E-log Process – Phase 1: Paperless
PRINTING PAGES DISTRIBUTE
OPERATE
TECH/CABIN LOG
ENTRIES
UM DATA ENTRY TRANSPORT AIR MAIL
DATA SCAN
STORAGE
e-RECORDS
1.3M pages / year 1 FTE
1M entries / year
HKG: 17 FTE
3000 sq. ft
~ 50M records
4 Dashboards
UM Data Correction
1.5 FTE
2.5 FTE
COLLECT
8 FTE
1.3M Log Pages
•Data Correction
•Storage
•30 Employees involved
• Real Time Data Entry
• Accurate / Granular Info
• Enhanced Defect Management
• Improved Contract and Warranty
Management
Cathay Pacific Airways Limited
So....... Job Done
All Happy
Its now fun to be in Tech Records
Well ........ Not Quite!
Planned Maintenance
Tech / Cabin Log
Records
History
Paper to Data Strategy – 3 project streams
The MRO(s)
Hangar Plan
Maintenance Requirements
(inc. AMS)
High Level hangar plan is generated
by applying Task Requirements to Fleet
and Facility constraints. This is based on
projected fleet utilisation (BOP)
Check Execution
Manage production plan
•Track critical path
•Track task ‘clock stops’
•Track shortages
•Track budget NRCs
•Electronic sign off of tasks
Actual man hour bookings
Material Usage
Task Accomplishment
Earned Value Management
•Reliability
•Check Escalations
•Float Calculations
•Technical Records
•Part Change
•Compliance
Hangar Execution
Maintenance Planning and Execution – 20/20 Vision
But There is No Standard
E2P - P2E
Electronic …..to…. Paper…. To…. Electronic
Maintenance Requirements
Technical Records
Tech Docs Management
System
Records Management
System
Check
Execution
Hangar
Execution
E-signature avoids paper and the
need to produce and scan a
document.
E through E
Line Services Mobility
• Mobility Apps for Line Services Frontline
• Available on iOS and Android
• Target company devices + staff BYOD devices
• Improve productivity and services
• Facilitate access to information• Flight Schedules, Meet & Greet Update
• Job Allocation, Workload plan
• Aircraft Defect Alert, Spare status
• Deferral Reference
• Facilitate reporting of tasks• Work Status Update
• Ultimately, all information required are on mobile device, no travelling
required between aircraft and base
22
Scope & Objectives
Improve Productivity
Faster aircraft turn around
Better service
23
Light Maint Mobility
Process Change a key project ingredient Light
Maint
Mobility
Identified paper based processes which can be eliminated
Must acommodate all customer processes / documents
24
• Streamlining Pre-input Planning
• Reduce paperwork & visual vetting
• Additional Dash Boards improves task scheduling and
manpower utilization
• Potential for future Business Intelligence
• Allow constant review of standard hours of particular tasks
• Allow future Business Intelligence for long term planning
• Safety & Quality improvement
• Allow engineers and mechanics to focus on the actual tasks
with information at proximity
• Avoid unnecessary bottleneck
• Visibility of Progress
• Visibility of Parts and Tooling required
Light Maint Mobility
…… and other intangible benefitsLight
Maint
Mobility
25
• Each Input on average of printing 700~ 1000 page. i.e.
hundreds of thousands pieces of paper and the
subsequent storage could be avoided
Light Maint Mobility
Environmental Benefit in addition…… Light
Maint
Mobility
The OEMs must recognise the issueAn airframe manufacturer’s records at a/c delivery:
• Not all Component locations are not provided.
• ARL / AIR does not include all config. control components
especially Reliability components.
• Required component information such as mfg date for a
calendar date control component is not provided.
• Data quality issue such as duplicate serial number, SN
mismatch with physical component.