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作者: kinran 时间: 2011-6-4 23:28:40
作者: bocome 时间: 2011-7-31 04:32:58
Prevent CJ9/CJ10 Harness Chaffing on ATA's CFM56-7B27B1 Engines
