Eliminate CFM56-7B27B1 HMU HPSOV Switch Failures at American Trans Air

瑤諾楷桶衾 2011-4-14 10:41:21

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瑤諾楷桶衾 2011-4-14 10:42:01

1 Six Sigma -- Define/Measure/Analyze/Improve/Control Phases GE Aircraft Engines GE Proprietary Information GE Aircraft Engines g GE Aircraft Engines Six Sigma Project Eliminate CFM56-7B27B1 HMU HPSOV Switch Failures at American Trans Air BPTS # 2002-11-022509 Amandio Morais ATA Field Service Program Manager November 2002 2 Six Sigma -- Define/Measure/Analyze/Improve/Control Phases GE Aircraft Engines GE Proprietary Information GE Aircraft Engines g GE Aircraft Engines Project Summary - Page 1 Area/Location: Indianapolis, IN Cluster ID: Title: Eliminate HMU HPSOV Switch failures at ATA BPTS ID: 2002-11-022509 Who is the customer? American Trans Air Why is this important? 1) #1 Cause of Engine-Related Delays 2) Effecting ATA’s Reliability Rate What do I want to improve? 1) Incorporate Latest HPSOV Switch Into HMU 2) Engine Reliability at ATA How will I measure the problem? 1) Monitor engine-related delays related to HMU HPSOV switch failures 2) Check status in event summary Can I trust the process output (Y) data? Yes Timing: Start: 9/7/01 Complete: 11/19/02 Implement: 11/19/02 Leader Org.: GCFS Sponsors: Sponsors: Rod Jarvis Process Owner: American Trans Air Resources: Project Leader: Amandio Morais MBB/Mentor: Scott Kopczynski Required for Project Approval Required for Project Closure Optional Step 0 1 2 3 Defi ne Meas ur e Project Summary Step 0 1 2 3 Defi ne 2 Meas ur e 2 3 Six Sigma -- Define/Measure/Analyze/Improve/Control Phases GE Aircraft Engines GE Proprietary Information GE Aircraft Engines g GE Aircraft Engines Project Summary - page 2 Project Summary - Page 2 How good am I today? Z = 0.565949 How good do I need to be? Z = 6 Variation Source Summary Vital X Impact on Average/Variation of your Y Improvement Plan HMU HPSOV Switch Failures 100% Incorporate S/B on-wing Control Plan Summary Vital X Control Plan to insure Improvement is Sustained S/B Incorporation Monitor engine-related delays Have I reached my Goal? Yes (no engine-related HMU HPSOV delays since April 13, 2002) Required for Project Approval Required for Project Closure Optional Step 4 5 6 789 10 11 12 Anal yz e I mpr ove Cont r ol Step 4 5 6 789 10 11 12 An al yz e 2 I mpr ove 2 Cont r ol 4 Six Sigma -- Define/Measure/Analyze/Improve/Control Phases GE Aircraft Engines GE Proprietary Information GE Aircraft Engines g GE Aircraft Engines Project Summary - page 3 Action Plan - Complete if project has open actions Open Action Items Person Responsible Est / Actual Completion Date Functional Implementation Status (Excel spreadsheet - double click to open) Group1 Group2 Group3 Group4 Group5 Engagement Status Committed Plan to Commit Plan to Commit Committed Committed Committed Plan to Commit Does Not Support Leveragable Project Where can this project be immediately leveraged? How? Comments / Lessons Learned Cost/Benefit Profile (Excel spreadsheet - double click to open) QX QX QX QX Total Expenditures 61,986 $61,986.00 Savings Indirect $0.00 Avoidance 106,260 $106,260.00 Total $168,246.00 Required for Project Approval Required for Project Closure Optional 5 Six Sigma -- Define/Measure/Analyze/Improve/Control Phases GE Aircraft Engines GE Proprietary Information GE Aircraft Engines g GE Aircraft Engines Define - Project Summary Problem Statement: ‧ ATA has experienced several HMU HPSOV switch failures in the fleet. ‧ #1 cause for engine-related delays Defect(s) Definition: ‧ HMU HPSOV switch failure Critical Metric Affected: 1) Customer Satisfaction Issue 2) At The Customer, For The Customer Project 3) Effects Reliability metrics Team: Amandio Morais - Field Service PM Jim Smith – ATA Powerplant Manager Jeremy Ubelhor - ATA Powerplant Engineer Zach Bolt - CSM CFM56-7 Product Team FSE’s Leadership: BB: Scott Kopczynski Sponsor(s): Rod Jarvis Goal/Objective: ‧ Eliminate all future HMU HPSOV switch failures Issues / Concerns: ‧ Time involvement to incorporate S/B into ATA’s fleet 6 Six Sigma -- Define/Measure/Analyze/Improve/Control Phases GE Aircraft Engines GE Proprietary Information GE Aircraft Engines g GE Aircraft Engines Measure – Event Report Spreadsheet 71 888417 1/31/02 1904 918 N302 1 IND SAGE Data Scatter No No T49.5 Probe Removed P/N TC296-02 72 888441 2/26/02 1830 907 N303 2 PIE HMU HPSOV Yes - 38 Minutes No None Not Applicable 73 888568 3/2/02 1300 599 N307 2 LAS HMU HPSOV Yes - 19 Minutes No None Not Applicable 74 888742 3/3/02 610 293 N314 2 MDW HMU HPSOV Yes - 41 Minutes No None Not Applicable 75 888470 1/31/02 1459 726 N304 2 MDW Broken DMS Detector No No DMS Detector Removed S/N 6109-3 Installed S/N 6237-H 76 888843 3/7/02 3 1 N317 1 IND DMS No No None Not Applicable 77 888741 3/7/02 641 311 N314 1 DFW Oil Filter Bypass Light Yes - 61 Minutes No Oil Filter DP Switch Not Available 78 888843 3/14/02 67 37 N317 1 DFW Control Light No Yes EEC Removed S/N LMDN7120; Installed S/N LMDN6616 ‧ All Field Events Are Tracked Via FSE’s Spreadsheet ‧ Data is collected daily from ATA’s America system (hard copy) HMU HPSOV Failures 7 Six Sigma -- Define/Measure/Analyze/Improve/Control Phases GE Aircraft Engines GE Proprietary Information GE Aircraft Engines g GE Aircraft Engines Measure – Pareto Chart HMU H PSO V Co n t ro l Lig h t O il Filte r B y pa s s L ig h t Engin e No S ta rt Fa ile d To In c re a s e En gine Pow e r A c o us tic a l Pa n e l Dama ge DMS Fa n B lad e Re p a ir FO D Fu e l Filte r B y pas s Ligh t Fu el L eak age No Eng ine V ib ra tio n In dic a t ion O th e rs 14 13 7 4 2 1 1 1 1 1 1 1 2 29 27 14 8 4 2 2 2 2 2 2 2 4 29 55 69 78 82 84 86 88 90 92 94 96 100 0 1 0 2 0 3 0 4 0 5 0 0 2 0 4 0 6 0 8 0 1 0 0 De fe c t C o unt P e rce nt C um % Percent Count ATA E n g in e-Related Delay s S um m ary (s in ce Day 1 of O p eration ) ‧ First airplane into revenue service in June 24, 2001 ‧ Total of 49 engine-related delays (FOD, airframe systems not included) ‧ Total cost of HMU HPSOV delays $61,986 (24%); Total cost of ATA 73 delays $254,475 8 Six Sigma -- Define/Measure/Analyze/Improve/Control Phases GE Aircraft Engines GE Proprietary Information GE Aircraft Engines g GE Aircraft Engines Measure – Delay Cost Data ‧ Cost of delays data was retrieved from ATA’s Reliability Dept. 9 Six Sigma -- Define/Measure/Analyze/Improve/Control Phases GE Aircraft Engines GE Proprietary Information GE Aircraft Engines g GE Aircraft Engines Analyze – Z Score Before Fix Description: Classify units as defective or non defective, traditionally uses the Binomial distribution formula listed below. Glossary: Mean Average Sigma Standard Deviation p(d) Probability of Defects Enter Numbers Below Formulas: Enter Numbers Above p(d) = 1-FTY "=>" 0.285714 Z = 0.565949 FTY= 0.714286 14 49 p(d)= 0.285714 No. of Bad Units Total No. of Units p(d)= "=>" 10 Six Sigma -- Define/Measure/Analyze/Improve/Control Phases GE Aircraft Engines GE Proprietary Information GE Aircraft Engines g GE Aircraft Engines C FM I P rop rie ta ry In fo rm a tion A TA C FM 5 6 -7 T e c h Re v iew M a rc h 2 0 0 2 H M U /H P SO V Sw itc h B a c kg ro u n d ‧ H P SO V sw itc h le a d in g c a u s e o f H M U rem o v a ls a n d D & C ’s - O n -win g s witc h re p la c em e n t in p la c e fo r c o n ta inm e n t - C om m itte d to o p e ra to rs to in tro fix b y 4Q ’0 1 ‧ J o in t C FM I/B o e in g /H o n e yw e ll te am h a v e s tu d ie d d e s ig n a lte rn a tiv e s to in c re a s e re lia b ility to a c c e p tab le le v e l - S P S T sw itc h with A /C m o d ific a tio n s e le c te d ‧ S P S T sw itc h e lim in a te s p re d om in a n t fa ilu re m o d e v ia ru n re e d d e le tio n - “L a tc h o n s h u td own ” c o n s titu te s 9 0% o f rem o v a ls - O th e r switc h c h a ra c te ris tic s m a in ta in e d a s ris k a b a teme n t ‧ N ew HM U P /N (P 0 8 ) c re a te s o n e -w a y e n g in e /a irc ra ft in te rc h a n g e a b ility - S P S T sw itc h re q u ire s re v is e d P 5 -2 c a rd ; re v is e d c a rd c om p a tib le with c u rre n t o r p ro p o s e d switc h Q u a lific atio n T e s tin g S tatu s ‧ C om p re h e n s iv e te s t p ro g ram c om p le te d th a t a d d re s s e d p o te n t ia l f ie ld fa ilu re m o d e s ‧ E n d u ra n c e te s tin g fo r b o th ru n a n d s h u td ow n m o d e s ‧ B o u n c e te s tin g c om p le te d a t 1 .2 5 X e n g in e “ g ” le v e ls w ith B o e in g P 5 -2 c a rd - N o “flic k e rin g ” lig h t o b s e rv e d . ‧ P ro to ty p e sw itc h in s ta lle d o n d e v e lo pm e n t e n g in e fo r e n d u ra n c e c y c lin g - 4 0 0 0 c yc le e n d u ra n c e te s t with p e rio d ic switc h m o n ito rin g s u c c e s s fu lly c om p le te d NC NO Arm N C N O A rm P ro p o s e d Sw itc h C o n fig u ra tio n C u rre n t D o u b le T h row P ro p o s e d S in g le T h row R u n co n ta c t e lim in a te d In tro d u c tio n L o gis tic s ‧ C FM I/B o e in g /H o n e yw e ll la u n c h te am fo rm e d . C h a r te r: In s u re a ll d o c um e n ta tio n , h a rdwa re , s e rv ic e b u lle tin s a re a v a ila b le fo r sm o o th in tro d u c tio n o f th e re v is e d H P SO V in d ic a tio n s ys tem in to p ro d u c tio n a n d in -s e rv ic e a irc ra ft ‧ In tro d u c tio n p o in ts c h o s e n - P 5 -2 C irc u it c a rd : - A /C lin e N o 1 0 4 7 (c omp le te ) - S P S T S w itc h (P 0 8 H MU ): - A /C lin e N o 1 0 7 7 -- F e b . ‘0 2 A irc ra ft d e liv e ry C o n tro ls a n d A c c e s s o rie s Analyze – HMU HPSOV Overview 11 Six Sigma -- Define/Measure/Analyze/Improve/Control Phases GE Aircraft Engines GE Proprietary Information GE Aircraft Engines g GE Aircraft Engines Analyze – HMU HPSOV Overview CFM56-7 All Operators Conference - April 17 - 19, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 6 Current SPDT Switch N S NC NO Arm Shutdown Position HPSOV Switch 12 Six Sigma -- Define/Measure/Analyze/Improve/Control Phases GE Aircraft Engines GE Proprietary Information GE Aircraft Engines g GE Aircraft Engines CFM56-7 All Operators Conference - April 17 - 19, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 9 SPST Switch Concept NC NO Arm N S Shutdown Position HPSOV Switch Analyze – HMU HPSOV Overview 13 Six Sigma -- Define/Measure/Analyze/Improve/Control Phases GE Aircraft Engines GE Proprietary Information GE Aircraft Engines g GE Aircraft Engines Improvement – Incorporate New S/B �h HPSOV switch changed to single-pole, single throw (SPST) switch to eliminate “latch on shutdown” failure mode by removing “run” reed – Switch faults have historically driven D&C’s and HMU removals – New switch introduced to production in February, 2002; HMU P/N rolled to “P08” – No switch faults on HMU’s shipped from factory as P08’s �h P08 HMU creates one-way engine/aircraft interchangeability limitations – SPST switch requires revised P5-2 cockpit card; revised card compatible with current or proposed switch �h P5-2 cards and SPST switches field retrofit program on-going – SB 73-0067R1….Program communicated via All Ops, Fleet Highlites messages – Cards and switches can be ordered via “No charge purchase order” – On-wing switch change will also be provided “free of charge” by Honeywell field service �h HPSOV switch improvement program in place New single pole switch in P08 HMU Capable of on-wing replacement - Field program Service Bulletins issued - Boeing SB 737-28-1179 - CFM SB 73-067 - Overall going well, some recent issues 14 Six Sigma -- Define/Measure/Analyze/Improve/Control Phases GE Aircraft Engines GE Proprietary Information GE Aircraft Engines g GE Aircraft Engines Symptom: Improper indication of cockpit P5-2 light Fault Code: None Average Monthly Removals for this Issue: 3.2 Root cause: �h Rev K SPDT switch not performing �h Fixes to improve the SPDT design did not improve primary switch failure mode. – Switch sticking on shutdown Long Term Resolution: �h Replace/modify P5 panel in the cockpit �h Replace SPDT switch with SPST switch on-wing ATA first to complete the retrofit - Thank you Control – Honeywell Feedback 15 Six Sigma -- Define/Measure/Analyze/Improve/Control Phases GE Aircraft Engines GE Proprietary Information GE Aircraft Engines g GE Aircraft Engines �h HMU HPSOV Failures Were The #1 Cause For Engine Related Delays at American Trans Air �h Boeing S/B 737-28-1179 & CFM S/B 73-067 Were Applied To All Engines In The Fleet �h Once The S/B’s Were Incorporated Into The Fleet, All HMU HPSOV Failures Were Eliminated �h ATA’s cost summary: $61,986 in delays �h ATA’s cost avoidance: $61,986 / 7 months = $8,855/month x 12 months = $106,260 (could be more if actual airplane delivery is taken into consideration) �h First delay occurred on 9/17/01, and the last delay occurred on 4/13/02 �h Majority of modifications occurred in April/May/June timeframe Control – Summary

kinran 楷桶衾 2011-6-4 23:28:35

:victory: :victory:

bocome 楷桶衾 2011-7-31 04:33:37

Eliminate CFM56-7B27B1 HMU HPSOV Switch Failures at American Trans Air

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Eliminate CFM56-7B27B1 HMU HPSOV Switch Failures at American Trans Air