Alaska Airlines CFM56-7B HMU Caused HMU Disruption Improvement

航空发表于 2011-4-24 12:11:35

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航空发表于 2011-4-24 12:11:48

1 GE Transportation Project Description: Reduce Alaska Airlines Operational disruptions due to unscheduled HMU removals Voice of Customer: The reliability of the HMU is having a negative effect on our departure reliability Project Leader: Stuart Kramlich - GEAE Field Service Team Members: Paul Deutchle – GEAE CSM Keith Megargle – Alaska Power Plant Engineering Dave Fox – Honeywell Field Service Engineer BB Mentor: Jeff Milam – GEAE ACFC BB Defect: - Any HMU related operational disruption caused by a known failure mode that is addressed by an available product improvement Customer Metric: - ATO and D&C - Maintenance burden Alaska Airlines CFM56-7B HMU Caused HMU Disruption Improvement BPTS#: 2004-06-010448 DMAIC Step 0 2 GE Transportation DMAIC Steps 1 & 2 CFM PROPRIETARY INFORMATION Through March 2004 CFM56-7 Total Dispatch Reliability 99.700 99.750 99.800 99.850 99.900 99.950 100.000 199712 199804 199808 199812 199904 199908 199912 200004 200008 200012 200104 200108 200112 200204 200208 200212 200304 200308 200312 % Successful Departures CFM Goal Total Dispatch Reliability CFM PROPRIETARY INFORMATION Through March 2004 CFM56-7 Total Dispatch Reliability 99.700 99.750 99.800 99.850 99.900 99.950 100.000 199712 199804 199808 199812 199904 199908 199912 200004 200008 200012 200104 200108 200112 200204 200208 200212 200304 200308 200312 % Successful Departures CFM Goal Total Dispatch Reliability CFM PROPRIETARY INFORMATION D&C Top Causes (Basic engine last 12 months) Through March 2004 Cause Quantity Corrective Action HMU (158): MTBUR -- 15,200 hours - TBV 81 EHSV product improvements incorporated Feb 2003 - FMV 46 Corrective action for 12 out of 13 failure modes defined Rotor winding improvements Introduced Mar 2003 - HPSOV 14 Field program progressing nicely EEC 66 PSS modification SB 73-065. Improved ATP in place. Program improvements being monitored – MTBUR 18,000 hrs – Individual Pressure transducers failing Starter 55 P09 rework SB 80-006 issued (new turbine seal assembly) P10 - turbine stack improvements - SB 80-007 issued Fuel Filter Delta-P switch 36 Potted switch improvement S/B 73-042 1 flight allowance added to DDPG MMEL MTBUR at 70,000 hours Ignition System 28 Ignition lead/exciter ... no anomalies Power switching relay available for Aircraft incorporation. Soft time recommendation not universally incorporated. Utilize improved EEC S/W troubleshooting capability - Fleet Highlights published Feb 2002 –WTT Investigation Feb 2004 6 5 3 9 7 CFM PROPRIETARY INFORMATION D&C Top Causes (Basic engine last 12 months) Through March 2004 Cause Quantity Corrective Action HMU (158): MTBUR -- 15,200 hours - TBV 81 EHSV product improvements incorporated Feb 2003 - FMV 46 Corrective action for 12 out of 13 failure modes defined Rotor winding improvements Introduced Mar 2003 - HPSOV 14 Field program progressing nicely EEC 66 PSS modification SB 73-065. Improved ATP in place. Program improvements being monitored – MTBUR 18,000 hrs – Individual Pressure transducers failing Starter 55 P09 rework SB 80-006 issued (new turbine seal assembly) P10 - turbine stack improvements - SB 80-007 issued Fuel Filter Delta-P switch 36 Potted switch improvement S/B 73-042 1 flight allowance added to DDPG MMEL MTBUR at 70,000 hours Ignition System 28 Ignition lead/exciter ... no anomalies Power switching relay available for Aircraft incorporation. Soft time recommendation not universally incorporated. Utilize improved EEC S/W troubleshooting capability - Fleet Highlights published Feb 2002 –WTT Investigation Feb 2004 6 5 3 9 7 HMU related D&Cs top driver for CFM56-7B fleet DMAIC Steps 1 & 2 3 GE Transportation Fleet Statistics - Operational Impact HMU Reliability is Critical ttooCCFFMM5566--77BBDD&&CCRRaattee SOURCE: Honeywell HMU return data Delays and Cancellations HMU Caused Feb 1998 through Mar 2004 173 100 97 71 66 41 39 31 30 25 20 20 12 4 4 2 2 0 20 40 60 80 100 120 140 160 180 200 HPSOV TBV DMD and POS Disagree (SAC) FMV POS Out of Range FMV POS Disagree Unknown VBV Current Out of Range TBV DMD and POS Disagree (DAC) Vibration Leak No Start/Hung Start Flameout Uncommanded Throttle LPTACC DMD and POS Disagree Engine Control Light Precautionary Service Bulletin No Fault Mech Ovespd Protec Out of Range * * * * * * * * * * Denotes modification in place DMAIC Steps 3 4 GE Transportation ASA - HMU Removals per Month 0 1 2 3 4 5 6 Jan 03 Feb 03 Mar 03 Apr 03 May 03 Jun 03 Jul 03 Aug 03 Sep 03 Oct 03 Nov 03 Dec 03 Jan 04 Feb 04 Mar 04 Chi-Square Test Hypotheses: Ho: All groups the same Ha: At least one different Group Count N Expected Chi-sq A 3 20000 0.973 4.223 B 33 720000 35.027 0.117 Totals--------> 36 740000 4.340 <-------Chi-Sq df---> 1 3.841 <---------Critical Chi-Sq 0.037 <--------- p-value A = ASA monthly experience B = CFM56-7B fleet experience ASA Experience Similar to fleet HMU removal experience DMAIC Step 3 5 GE Transportation 0 2,000 4,000 6,000 8,000 10,000 12,000 14,000 16,000 18,000 Apr-00 Jun-00 Aug-00 Oct-00 Dec-00 Feb-01 Apr-01 Jun-01 Aug-01 Oct-01 Dec-01 Feb-02 Apr-02 Jun-02 Aug-02 Oct-02 Dec-02 Feb-03 Apr-03 Jun-03 Aug-03 Oct-03 Dec-03 Feb-04 P08 "New HPSOV" (Feb-02) P09 "FMV/TBV/BSV" (Jun-03) P07 "Rumble" (May-99) CFM56-7B Fleet Statistics - Reliability Performance Reliability PPeerrffoorrmmaanncceeCCoonnttiinnuueess ttoo IImmpprroovvee MTBUR: 15,266 hrs. MTBUR = (12 Month Flight Hours) / (12 Month Removals) “On-wing” HPSOV Switch Replacements (Mar-00) ASA MTBUR 9200 DMAIC Step 4&5 6 GE Transportation CFM56-7 HMU - Time to First Removal PPoossiittiivvee TTrreenndd Average Hours at First HMU Removal 0 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000 10,000 1998 1999 2000 2001 2002 2003 2004 ASA’s average time for removal is 6200 hours DMAIC Step 4&5 7 GE Transportation Alaska HMU Removals Jan 03 – Mar 04 Alaska Airlines HMU removal Causes 0 2 4 6 8 10 12 FMV NCFR Fuel Leak TBV chafed wire OSG # Removals Current Configuration P09 Config Current MTBUR 9245.667 P09 Potential MTBUR 18491.33 DMAIC Step 6 8 GE Transportation High Pressure Shutoff Valve (HPSOV) Switch  Wire Chafing Resulting in Wrap Faults  Burner Staging Valve (BSV) & Main Staging Valve (MSV) Faults  Fuel Leakage Increased Removals Partially Due to AFSO Switch Replacement Fuel Metering Valve (FMV) Feedback Faults  Fuel Metering Valve Resolver Demand / Feedback Faults  Transient Bleed Valve (TBV) EHSV  CFM56-7 HMU Removal Drivers DMAIC Step 6 9 GE Transportation 0 10 20 30 40 50 60 70 80 Jan-00 Mar-00 May-00 Jul-00 Sep-00 Nov-00 Jan-01 Mar-01 May-01 Jul-01 Sep-01 Nov-01 Jan-02 Mar-02 May-02 Jul-02 Sep-02 Nov-02 Jan-03 Mar-03 May-03 Jul-03 Sep-03 Nov-03 Jan-04 Mar-04 0 100,000 200,000 300,000 400,000 500,000 600,000 700,000 800,000 Unknown / Misc. Chafing / Wrap Fault BSV Leakage HPSOV Switch DMD/FDBK (TBV) FMV F/B Monthly Usage (Right Axis) CFM56-7 HMU - Removal Drivers Removals Decreasing Despite IInnccrreeaasseeddUUttiilliizzaattiioonn Monthly Removals (12 Month Rolling Average) Monthly Removals (12 Month Rolling Average) Monthly Removals Monthly Usage (hours) DMAIC Step 7 & 8 10 GE Transportation 3012 177 300 P07/P08 New P09 Upgraded to P09 70,000 336,000 27,844,000 Total Fleet 3,489 HMU抯 28,250,000 Hours ( 86%) ( 9%) ( 5%) Fleet Statistics - Fielded Configurations CFM56-7 HMU Fleet By Part Number CFM56-7 HMU Fleet By Part Number CFM56-7 HMU Fleet hours By Part Number CFM56-7 HMU Fleet hours By Part Number AAllaasskkaa’’ssPP0099PPeenneettrraattiioonn aatt4422%% DMAIC Step 8 11 GE Transportation CFM56-7 MTBUR 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 15000 16000 17000 18000 19000 20000 7/24/1998 2/9/1999 8/28/1999 3/15/2000 10/1/2000 4/19/2001 11/5/2001 5/24/2002 12/10/2002 6/28/2003 1/14/2004 8/1/2004 2/17/2005 9/5/2005 3/24/2006 10/10/2006 4/28/2007 Month/Year MTBUR ( Hours) Projected: No Changes Duane Growth Model 12 Month Actual Projected: 'P09 Changes Projected: 'P0' and P11 Crowe AAMSA Model - MTBUR to Date and Projected Projected HMU Reliability Growth (Honeywell data) P07 & P08 - ‘recent’ incorporations = wire grid & SPST switch P09 = FMV resolver module, TBV EHSV, BSV solenoid modifications P10 = proposed BSV solenoid elimination P11 = proposed fluorocarbon fuel-to-air seals Month/Year DMAIC Step 9 12 GE Transportation Go Forward plan (Steps 10 thru 12) • ECO written to proactively introduce p09 HMU’s -- Complete •Continue to drive p09 penetration » currently 2/month may increase based on recent commercial discussions with Honeywell -- In Work • Working with Alaska’s reliability group to monitor reliability improvements -- In Work •Leverage PFM approach to other reliability drivers - i.e., Starter oil leakage

kinran 发表于 2011-6-4 22:52:51

:victory: :victory:

bocome 发表于 2011-7-31 05:18:28

Alaska Airlines CFM56-7B HMU Caused HMU Disruption Improvement

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Alaska Airlines CFM56-7B HMU Caused HMU Disruption Improvement