Prevent CJ9/CJ10 Harness Chaffing on ATA's CFM56-7B27B1 Engines

航空发表于 2011-4-14 10:42:43

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航空发表于 2011-4-14 10:42:53

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 Prevent CJ9/CJ10 Harness Chaffing on ATA's CFM56-7B27B1 Engines BPTS # 2002-12-024777 Amandio Morais ATA Field Service Program Manager December 2002 2 Six Sigma -- Define/Measure/Analyze/Improve/Control Phases GE Aircraft Engines GE Proprietary Information GE Aircraft Engines g GE Aircraft Engines Measure – CJ9 Harness Removal • CJ9 Harness was removed on 8/27/02 due to chaffing wear • Maint required 10 hours for removal & replacement • Luckily, aircraft was a spare aircraft and no delays/cax were incurred 3 Six Sigma -- Define/Measure/Analyze/Improve/Control Phases GE Aircraft Engines GE Proprietary Information GE Aircraft Engines g GE Aircraft Engines Analyze – Discussed Other Airline Action Plan Possible Solution #1 • GB Project # 2002-03-006382 was leveraged from other Airline to see if ATA was interested in incorporating – response was “fix was too complicated” • Worked with ATA CSM for alternatives since ATA was concerned with issue and impact to their fleet The Clamp Application at a specific location for the CJ9 P/N 325-027-701-0 harness is creating a problem for the customer that leads to premature replacement of this harness. CJ9 harness cost $13,532.00. IPC Location 73-00-00-25, Item 520. The fix for this location will have a material cost of $171.00 +/- and a labor cost of two ( 2 ) man hours •Can be accomplished at A/C letter check inspection’s. •Can be accomplished on an overnight where mechanic is available. •Can be accomplished when engine is at a shop visit. Project # 2002-03-006382 W.P. Johnson 4 Six Sigma -- Define/Measure/Analyze/Improve/Control Phases GE Aircraft Engines GE Proprietary Information GE Aircraft Engines g GE Aircraft Engines Analyze – Discussed AA Action Plan Present hardware at the location of concern: Bracket assembly: P/N 1870M69G01, Cost $163.00 Clamp assembly P/N 649-411-955-0, Cost $84.25 Hardware to be used at location of concern for Fix: Bracket assembly: P/n 1870M69G01( Modified ), Cost $0.0 Clamp assembly : P/N 649-411-953-0, Cost $82.75 x 2 = $165.50 Bolt, P/N AS3237-08, Cost $3.20 +/- Nut , P/N AS3485-10, Cost $3.00 +/- Due to this chaffing problem over the past year AA has had to change out 15 CJ9 leads for the CMM repair. Repair cost to AA of $3700.00 each = total repair cost of $55,000.00 + the loss of 30+ man hour to change harness’s. Also to support this problem AA has had to procure extra CJ9 harness’s to cover the fleet until repaired harness returns. AA procured 3 addition CJ9 harness’s at a cost of $13,532 each = total cost $40,596.00 to support their fleet. Problem has created for AA, a material / repair cost to AA = $ 95,596.00 + loss man hours. 5 Six Sigma -- Define/Measure/Analyze/Improve/Control Phases GE Aircraft Engines GE Proprietary Information GE Aircraft Engines g GE Aircraft Engines CFM56-7 CJ9 Harness Clamp of Concern Analyze – Discussed AA Action Plan 6 Six Sigma -- Define/Measure/Analyze/Improve/Control Phases GE Aircraft Engines GE Proprietary Information GE Aircraft Engines g GE Aircraft Engines Problem with present Clamping Hardware Chaffed Harness Material Missing Cushion Material Analyze – Discussed AA Action Plan 7 Six Sigma -- Define/Measure/Analyze/Improve/Control Phases GE Aircraft Engines GE Proprietary Information GE Aircraft Engines g GE Aircraft Engines Suggested Clamping Configuration Fix 11 12 13 14 Tape being added as extra protection for longer life of harness. Analyze – Discussed AA Action Plan 8 Six Sigma -- Define/Measure/Analyze/Improve/Control Phases GE Aircraft Engines GE Proprietary Information GE Aircraft Engines g GE Aircraft Engines As you will note by picture process: The procedure is very simple • Drill tooling controls mounting hole application • Tooling does not harm other hardware • Tooling not hard to make • Will not have a high cost to apply • Can be applied at both shop & on-wing • Harness configuration position and pattern flow is not changed • No areas of concern with other hardware interference • Two clamp application will do a better job of protection for the CJ9 harness and help prevent repair and procurement cost to customer • At shop visit or at new make a nut plate could be incorporated a new bracket assembly hole location to eliminate the use of a nut. Analyze – Discussed AA Action Plan • Summary: despite other Airline-sharing experience, ATA still decided not to incorporate fix since they wanted to evaluate the other clamp locations as well 9 Six Sigma -- Define/Measure/Analyze/Improve/Control Phases GE Aircraft Engines GE Proprietary Information GE Aircraft Engines g GE Aircraft Engines Analyze – Discussed Incorporation of S/B 72-0285 Possible Solution #2 • Replacement of current clamps by new clamps with inner diameter material thickness increased • Cat. 7 S/B – ATA requested CFM participation since clamps were too expensive Part Number Eng Part Name $ Price Qty Days 649-411-981-0 (13) Clamp 82.5 (1) 30 649-411-982-0 (10) Clamp 82.75 (1) 30 649-411-983-0 (20) Clamp 84.25 (1) 30 • S/B introduces 3 new part numbers for different locations • Requires replacement in 43 locations • Cost per engine $3,585 for clamps only (no labor) • Effectivity: N301 – N321 + 2 spare engines ($157,740) 10 Six Sigma -- Define/Measure/Analyze/Improve/Control Phases GE Aircraft Engines GE Proprietary Information GE Aircraft Engines g GE Aircraft Engines Analyze/Improvement – Proactively Wrap 3M Tape Possible Solution #3 • Letter was signed on 11/6/02 by ATA • Gives 4 labor hours to proactively wrap fiberglass tape on clamp Areas • Remaining action item is to notify ATA where to install tape since all clamp areas can’t be done in 4 hours (Telecon will be schedule with Lloyd Rawson soon 11 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 "=>" 0.022727 Z = 2.000425 FTY= 0.977273 1 44 p(d)= 0.022727 No. of Bad Units Total No. of Units p(d)= "=>" 12 Six Sigma -- Define/Measure/Analyze/Improve/Control Phases GE Aircraft Engines GE Proprietary Information GE Aircraft Engines g GE Aircraft Engines  Get ATA to proactively wrap fiberglass tape around selected CJ9/CJ10 harness clamp locations  GE receives benefit due to lower warranty payments  GE FMO receives benefit due to less harness damages (lower repair costs) when engine is received in the overhaul shop  ATA will see fewer CJ9/CJ10 harness removals on-wing (lower maint labor costs)  Will avoid costly engine delays/cax due to harnesses removals on the line  Allows ATA to proactively manage the situation on wing  Repair would allow continued operation until the next shop visit Control – Summary

kinran 发表于 2011-6-4 23:28:40

:victory: :victory:

bocome 发表于 2011-7-31 04:32:58

Prevent CJ9/CJ10 Harness Chaffing on ATA's CFM56-7B27B1 Engines

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Prevent CJ9/CJ10 Harness Chaffing on ATA's CFM56-7B27B1 Engines