NEW NEW MAINTENANCE MAINTENANCE PHILOSOPHYPHILOSOPHY

On-condition Maintenance vsOn-condition Maintenance vsReliability-Centered MaintenanceReliability-Centered Maintenance

OCMOCM Repair Only What Is BrokenRepair Only What Is Broken

Maintenance Is UnplannedMaintenance Is Unplanned

Maintenance Driven by Maintenance Driven by Equipment Conditioner or Equipment Conditioner or Lowest Rs/Shop VisitLowest Rs/Shop Visit

(What's Easiest Today)(What's Easiest Today)

RCMRCM Repair Not Only What Is Repair Not Only What Is

Broken but What is Likely to Broken but What is Likely to Fail Before a Defined TimeFail Before a Defined Time

Focus is Planned Focus is Planned MaintenanceMaintenance

Facilitates Resource Facilitates Resource Requirements PredicationsRequirements Predications

Maintenance Based on Maintenance Based on LCC & ValueLCC & Value(What's Best for the Long (What's Best for the Long

Term)Term)

Information ManagementModel-Based Reasoning,Trending, Pattern Recognition (Enhanced Diagnostics, Fault Isolation)

Operational Loads/Usage MonitoringStructures, Landing / Arresting GearGun, EPS Starter/GeneratorCSMU (Write Cycles)

Capacity Trending28 & 270 volt BatteriesCryo Cooling CapacityESA (loss of Elements)OBIGGS / OBOGS HIPPAG Recharge Rate

Enhanced Sensor TechnologiesEngine - FOD Detection, Oil Debris, Oil Condition, Blade Tip Monitoring, Vibration MonitoringSDLF - FOD Detection, Oil Debris, Oil Condition, Shaft Alignment / Torque, Clutch Wear / VibrationBrake TemperatureLanding Gear (Strut Servicing, ‘Smart Tire’)

Auto Calibration / Gain TrendingRadarDisplaysFuel ProbesStick & Throttle

Performance Monitoring / TrendingPTMS (IPP, Filters, Reservoirs, Coalescer, etc.)Hydraulic System (Pumps, Filter, Reservoirs, Accumulators)Fuel System (Pumps, Valves, Heat Exchanger)Weapon Bay Door Drive (Pump Speed & Swashplate Angle)Rotary Actuators, EHAsWeapon RacksOBIGGS Filter

Cross-Comparison (Redundancy Management)Flight Controls (VMC, Inceptors, EHAs, Sensors)EPS (Degraded modes, Emergency Power)Fuel Probes

Automated TestingWBDD Actuator BacklashExternal Fuel TanksRIOs, VSP SoftwareNose Wheel Steering Friction CollarCSMU (Periodic Read/Write Testing)Aircraft Wiring

Off-Board TechnologiesDiagnostic ToolsIntelligent HelpPrognosis Models

PHM Is an Integral Part of Every Facet and Subsystem of the Weapon System

Joint Strike FighterJoint Strike FighterPrognostics and Health Management

The Engineering ParadoxThe Engineering Paradox

Universities teach engineers to buildUniversities teach engineers to buildthings that never fail--but they fail!things that never fail--but they fail! Universities teach engineers aboutUniversities teach engineers aboutentropy--but most engineers can’tentropy--but most engineers can’tcalculate maintenance demands tocalculate maintenance demands toprevent or overcome deteriorationprevent or overcome deterioration Propaganda traps us into “dynamicPropaganda traps us into “dynamicinaction”—we look busy but no attempt to do inaction”—we look busy but no attempt to do Life Cycle Costs (LCC).Life Cycle Costs (LCC).

The Elephant is like …

Breaking The ParadoxBreaking The Paradox

Reliability is the probability that aReliability is the probability that adevice, system, or process will performdevice, system, or process will performits prescribed duty without failure for aits prescribed duty without failure for agiven time when operated correctly in agiven time when operated correctly in aspecified environmentspecified environment Reliability problems are entropy drivenReliability problems are entropy drivenfailures which cost money and requirefailures which cost money and requiretrade-off considerations based on LCCtrade-off considerations based on LCC

Maintenance Program?

The days of doing maintenance just for the sake of maintenance or because it makes us ‘feel good’ are past.

Studies have revealed that technicians performing maintenance based on ‘tribal knowledge’ rather than the OEM’s approved maintenance program have generated errors.

In other cases, technicians performing approved maintenance that was not necessary have also generated maintenance errors.

Each time we provide technicians access to an aircraft, we also provide the potential for that technician to inadvertently induce an error.

Maintenance Program Today

The modern aircraft, although extremely The modern aircraft, although extremely complex when compared to its older complex when compared to its older predecessors, requires less and less predecessors, requires less and less maintenance. maintenance.

Nowadays, maintenance costs represent Nowadays, maintenance costs represent only a fraction of total operating costs. only a fraction of total operating costs.

AIRCRAFT OPERABILITYAIRCRAFT OPERABILITY

LOWER MAINTENANCE RELATED COSTSLOWER MAINTENANCE RELATED COSTS

BETTER OPERATIONAL RELIABILITYBETTER OPERATIONAL RELIABILITY

BETTER AIRCRAFT AVAILABILITYBETTER AIRCRAFT AVAILABILITY

A higher level of aircraft operability will A higher level of aircraft operability will require an integrated require an integrated HEALTH HEALTH MANAGEMENTMANAGEMENT approach, which is at the approach, which is at the heart of the TATEM concept.heart of the TATEM concept.

"Technologies And Techniques for nEw Maintenance concepts"

""TTechnologies echnologies AAnd nd TTechniques echniques for nfor nEEw w MMaintenance conceptsaintenance concepts""

A four-year, €40 million ($50 million) project co-A four-year, €40 million ($50 million) project co-funded by the European Commission under its funded by the European Commission under its Framework 6 research programme that aims to Framework 6 research programme that aims to cut future generation aircraft maintenance costs cut future generation aircraft maintenance costs by 50% within 20 years.by 50% within 20 years.

TATEM research and technology project has TATEM research and technology project has now identified 19 top-level requirements and is now identified 19 top-level requirements and is working to apply these principles.working to apply these principles.

AVIONICS AVIONICS

Today - Built-In Test equipment - Today - Built-In Test equipment - conventional avionics architectures conventional avionics architectures

Complex boards - more and more Complex boards - more and more integrated components - complex integrated components - complex troubleshooting - long maintenance cycles troubleshooting - long maintenance cycles

AVIONICSAVIONICS

Future - Highly Interactive and Distributed Future - Highly Interactive and Distributed Avionics Architectures.Avionics Architectures.

"Selective Passivisation" - To enable an "Selective Passivisation" - To enable an avionics computer to continue some part of its avionics computer to continue some part of its functionality even when a hardware or software functionality even when a hardware or software failure occurs failure occurs

"Disposable Electronics" - Meeting functional "Disposable Electronics" - Meeting functional performances whilst dramatically decreasing performances whilst dramatically decreasing maintenance costs. maintenance costs.

Maintenance-free avionics that require no Maintenance-free avionics that require no scheduled maintenance work. scheduled maintenance work.

ENGINESENGINES

European Project - OBIDICOTE - (European Project - OBIDICOTE - (On On Board Identification, Diagnosis and Board Identification, Diagnosis and Control of gas Turbine EnginesControl of gas Turbine Engines )- )- Health Monitoring of the core engine Health Monitoring of the core engine components (turbines etc.). components (turbines etc.).

Also to improve engine health monitoring Also to improve engine health monitoring by fusing engine performance data with by fusing engine performance data with vibration analysis. vibration analysis.

STRUCTURES STRUCTURES

Structural Sensing Systems - Monitoring of Structural Sensing Systems - Monitoring of the airframe structural elements and the airframe structural elements and landing gear. landing gear.

Integrated Systems for the detection of Integrated Systems for the detection of flaws can not only increase safety but also flaws can not only increase safety but also facilitate inspection of parts of the facilitate inspection of parts of the structure that are not accessible during structure that are not accessible during normal aircraft operation or simple checks. normal aircraft operation or simple checks.

STRUCTURESSTRUCTURES

Health Monitoring systems can be used to Health Monitoring systems can be used to shift the repair actions to dates where they shift the repair actions to dates where they can be included into scheduled, bigger can be included into scheduled, bigger maintenance actions in a more clever way. maintenance actions in a more clever way.

UTILITIESUTILITIES

Incorporate local control electronics into the Incorporate local control electronics into the systems - System monitoring without the need systems - System monitoring without the need for additional sensors.for additional sensors.

Electro-hydraulic Actuators (EHA) and Electro-hydraulic Actuators (EHA) and Electromechanical Actuators (EMA).Electromechanical Actuators (EMA).

Micro-controllers - in place of the conventional Micro-controllers - in place of the conventional contactor and relays in Electrical power contactor and relays in Electrical power distribution systems - monitoring the health and distribution systems - monitoring the health and performance of the electrical loads as well as the performance of the electrical loads as well as the electrical power generation and distribution electrical power generation and distribution system. system.

DATA MANAGEMENTDATA MANAGEMENT

Post-flight analysis now - using ground-based Post-flight analysis now - using ground-based analysis systems.analysis systems.

Future - An integrated data management system Future - An integrated data management system which will enable data to be communicated in a which will enable data to be communicated in a common format.common format.

Onboard communication media, air to ground Onboard communication media, air to ground communications media, air and ground computing communications media, air and ground computing resources and data storage and access devices. resources and data storage and access devices.

Signal processing techniques (e.g. fuzzy logic, neural Signal processing techniques (e.g. fuzzy logic, neural networks, model-based reasoning), which can be networks, model-based reasoning), which can be used to convert data into information about the health used to convert data into information about the health of the systems. of the systems.

GROUND CREW SUPPORTGROUND CREW SUPPORT

Line mechanics spend 30% of their time Line mechanics spend 30% of their time trying to access information to diagnose trying to access information to diagnose and rectify failures.and rectify failures.

Human error in the maintenance task has Human error in the maintenance task has been estimated as contributing to 15% of been estimated as contributing to 15% of aircraft accidents. aircraft accidents.

Current maintenance activities can be Current maintenance activities can be inefficient in the use of the maintainers’ inefficient in the use of the maintainers’ skills. skills.

GROUND CREW SUPPORTGROUND CREW SUPPORT

System-oriented approach to a Process-System-oriented approach to a Process-oriented approach. oriented approach.

The right Technical Data and tools The right Technical Data and tools necessary to complete those tasks.necessary to complete those tasks.

Today’s structure and content of the Today’s structure and content of the aircraft Technical Data cannot be aircraft Technical Data cannot be considered optimized with regard to these considered optimized with regard to these processes. processes.

GROUND CREW SUPPORTGROUND CREW SUPPORT

Enable the rapid update of the technical Enable the rapid update of the technical information onboard the aircraft to information onboard the aircraft to support the operability driven aircraft support the operability driven aircraft approach. approach.

Human interface technologies to provide Human interface technologies to provide the ground crew with information, data the ground crew with information, data and advice at the point of work. and advice at the point of work.

AIRCRAFT / FLEET HEALTH AIRCRAFT / FLEET HEALTH MANAGEMENTMANAGEMENT

Novel on-board sensor technology to gather data Novel on-board sensor technology to gather data from the aircraft (avionics, utilities, actuation, from the aircraft (avionics, utilities, actuation, engines and structures), to feed prognostic or engines and structures), to feed prognostic or diagnostic systems. diagnostic systems.

The integration of prognostic data into the The integration of prognostic data into the maintenance planning process so that pro-active maintenance planning process so that pro-active maintenance activities can be performed. maintenance activities can be performed.

Improvements to scheduling and the preparation of Improvements to scheduling and the preparation of maintenance actions (e.g. inspections) through an maintenance actions (e.g. inspections) through an implementation of a full digital process from implementation of a full digital process from scheduling (based on health data) to maintenance scheduling (based on health data) to maintenance task sign-off through digital generation of job cards.task sign-off through digital generation of job cards.

GROUND CREW SUPPORTGROUND CREW SUPPORT For line maintenance - emerging technologies For line maintenance - emerging technologies

- comprehensive picture of the aircraft - comprehensive picture of the aircraft condition and its foreseeable serviceability.condition and its foreseeable serviceability.

Human Factors issues - maintainability life Human Factors issues - maintainability life cycle.cycle.

Focus on embedded training technologies - Focus on embedded training technologies - train the ground crew within the operational train the ground crew within the operational environment - use the advanced HMI features environment - use the advanced HMI features - evaluate the proficiency of trainees. - evaluate the proficiency of trainees.

Diagnostic methods to identify and locate Diagnostic methods to identify and locate failures and malfunctions and so reduce the failures and malfunctions and so reduce the incidence of ‘no fault found’ alarms. incidence of ‘no fault found’ alarms.

FUTURE WEAPONS

TO ENHANCE RANGE OF EXISTING UNGUIDED BOMBS INTO STANDOFF GUIDED BOMBS

SWITCH OVER FROM LASER / TV GUIDED BOMBS TO DIGITAL SCENE MATCHING GUIDED BOMBS WITH DIFF RANGE ENHANCEMENT

SMALL DIA PGMS WITH DUAL SEEKER TECHNOLOGY

LOW COST SMALL DIA GUIDED WEAPONS AIR TO GROUND WEAPONS WITH DATA

LINKING WITH THIRD PARTY TRAJECTORY SHAPING

FUTURE WEAPONS AIR TO AIR - ACTIVE SEEKER MISSILES

WITH RANGE OVER 100 M NEW GENERATION A4M AIR TO GROUND MISSILES - STANDOFF

RANGE BEYOND 250 KM CONTOUR MATCHING CRUISE MISSILES LOITERING FEATURE– DATA LINKING

HELICOPTER ARMAMENT ARMED UAV ANTI RADIATION MISSILES SENSOR FUZED WEAPONS

INTERNATIONAL QUALITY INTERNATIONAL QUALITY MANAGEMENT STANDARD - MANAGEMENT STANDARD -

AEROSPACE INDUSTRYAEROSPACE INDUSTRY

EN 9100 - Europe EN 9100 - Europe AS 9100 - United States AS 9100 - United States SJAC 9100 - Far EastSJAC 9100 - Far East

AS EN SJAC 9100 is based on the philosophy of AS EN SJAC 9100 is based on the philosophy of the integration of key aerospace industry the integration of key aerospace industry concepts with the generic quality management concepts with the generic quality management principles contributed by ISO 9001. principles contributed by ISO 9001.

Lean is…

“Eliminate all costs which do not add value to a product or process”

“Becoming ‘lean’ is a process of eliminating waste with the goal of creating value”

Maxim 1Maxim 1

OLDOLD

Maintenance is about preserving Maintenance is about preserving physical assetsphysical assets

NEWNEW

Maintenance is about preserving the Maintenance is about preserving the functions of assetsfunctions of assets

Maxim 2Maxim 2

OLDOLD

Routine maintenance is about Routine maintenance is about preventing failurespreventing failures

NEWNEW

Routine maintenance is about avoiding, Routine maintenance is about avoiding, reducing or eliminating the reducing or eliminating the consequences of failuresconsequences of failures

Maxim 3Maxim 3

OLDOLD

Most equipment becomes more likely Most equipment becomes more likely to fail as it gets to fail as it gets olderolder

NEWNEW

Most failures are not more Most failures are not more likely to occur likely to occur as equipment gets olderas equipment gets older

Maxim 4Maxim 4

OLDOLD

There are three basic types of There are three basic types of maintenance:maintenance:

predictivepredictive preventivepreventive correctivecorrective

Maxim 4Maxim 4

NEWNEW

There are four basic types of There are four basic types of maintenance:maintenance:

predictivepredictive preventivepreventive correctivecorrective detectivedetective

Maxim 5Maxim 5

OLDOLD

Comprehensive data about failure rates must Comprehensive data about failure rates must be available before it is possible to develop a be available before it is possible to develop a really successful maintenance programreally successful maintenance program

NEWNEW

Decisions about the management of Decisions about the management of equipment failures will nearly always have to equipment failures will nearly always have to be made with inadequate hard data about be made with inadequate hard data about failure ratesfailure rates

Maxim 6Maxim 6 OLDOLD If both are technically appropriate, fixed If both are technically appropriate, fixed

interval overhauls/replacements are usually interval overhauls/replacements are usually both cheaper and more effective than both cheaper and more effective than condition-based maintenance.condition-based maintenance.

NEWNEW If both are technically appropriate, condition-If both are technically appropriate, condition-

based maintenance is nearly always both based maintenance is nearly always both cheaper and more effective than fixed cheaper and more effective than fixed interval overhauls/replacements throughout interval overhauls/replacements throughout the life of the asset.the life of the asset.

Maxim 7Maxim 7

OLDOLD The quickest and surest way to improve the The quickest and surest way to improve the

performance of an existing "unreliable" asset performance of an existing "unreliable" asset is to upgrade the designis to upgrade the design

NEWNEW It is nearly always more cost-effective to try It is nearly always more cost-effective to try

to improve the performance of an unreliable to improve the performance of an unreliable asset by improving the way it is operated and asset by improving the way it is operated and maintained, and only to review the design if maintained, and only to review the design if this cannot deliver the required performancethis cannot deliver the required performance

Maxim 8Maxim 8 OLDOLD It is possible to find a quick, one-shot It is possible to find a quick, one-shot

solution to all our maintenance effectiveness solution to all our maintenance effectiveness problemsproblems

NEWNEW Maintenance problems are best solved in two Maintenance problems are best solved in two

stages: stages: (1) change the way people think (1) change the way people think (2) get them to apply their changed thought (2) get them to apply their changed thought

processes to technical / process problems - processes to technical / process problems - one step at a timeone step at a time