CFM Proprietary Information 2 CFM56 Project Department Team T. Shuttleworth, Administrative Associate R. McAfee M. Schwartz J.A. Agnew W.H. Benham P. J. Busken B.P. Davey P. G. Gruber R. Goodall P.C. Kolbe E.B. Martin T. McClary A. P. Mihalchik J. Milam R. L. Nebuda B. Quinn R. Smith M. Wandersee CFM56 Project General Manager W. S. Clapper CFM56 Project General Manager W. S. Clapper CFM56-5 Program General Manager K.J. Foley CFM56-5 Program General Manager K.J. Foley CFM56-2/-3/-7 Program General Manager R. W. Adams CFM56-2/-3/-7 Program General Manager R. W. Adams CFMI e-Business and Product Support Integration Director S. Pawlikowski CFMI e-Business and Product Support Integration Director S. Pawlikowski CFM56 Product Support Engineering Manager D. N. Poli CFM56 Product Support Engineering Manager D. N. Poli CFM56 Manufacturing Programs Manager R.W. Adams CFM56 Manufacturing Programs Manager R.W. Adams CFM56 Upgrades Program Leader L.J. Baran CFM56 Upgrades Program Leader L.J. Baran CFM56 Project Master Black Belt S. O＊Day CFM56 Project Master Black Belt S. O＊Day CFM Proprietary Information 3 CFM56 in ＆02: The World＊s Best-Selling Engines Greatest aviation partnership in the world 每 5,000 CFM-powered aircraft 每 200,000 passengers every day 每 ~600 orders in ＆02 / 55% orders share First flight on A318 First flight of -5C/P on A340 testbed CFM56-3 Time on Wing upgrade 每 Entered service Oct. ＆02 at Southwest Excellent progress on Project TECH56 CFM Proprietary Information 4 CFM56 in ＆03: New Platforms, New Upgrades Certify / launch upgrades - CFM56-5B acoustic upgrade - CFM56-5C/P for A340 Define technology insertion for -5B & -7 Deliver reliable new products 每 CFM56-5B on A318 ＃ Frontier, July ＆03 每 CFM56-5C/P on A340-300 ＃ Swiss, Oct. ＆03 Execute 737-900X strategy with Boeing Manage fleet issues ＃HPT blade durability , -5C reverser CFM Proprietary Information 5 CFM56-7 1997 CFM56-5B/P 1996 Generation 4 • Wide chord fan blades • Powder metallurgy • Low emissions • 3-D aero 2000 Thrust (1000 pounds) 1970 •High bypass •Hydromechanical controls Generation 1 • Static composites • Containment tech • Noise reduction Generation 2 CFM56-2 CFM56-3 1984 25 30 35 CFM56-5C 1993 CFM56-5A 1988 •FADEC •Active clearance •Advanced turbine materials and coatings Generation 3 CFM56-5C/P 2002 CFM56 Engine Family: How the Best Keeps Getting Better B737-300 B737-400 B737-500 A319 A320 A340 A318 A319 A320 A321 B737-600 B737-700 B737-800 B737-900 DC-8 Military Incorporating Advanced, Proven Technology CFM Proprietary Information 6 Animation CFM56-3 Core Upgrade Program CFM56: Product Upgrades 3D aero in compressor and new HPT hardware Benefits: 每 Longer on-wing life 每 Lower operating cost 每 Lower maintenance costs 每 Enhanced durability 13 engines delivered to Southwest Airlines in 2002 每 7 engines are in-service flying on 6 aircraft Southwest Airlines is already experiencing the benefits CFM Proprietary Information 7 CFM56: Product Upgrades Objective - Meet Stage 4 (Stage 3 每 10.0 EPNdB) @ 95% confidence for 93-ton A321 每 Stage 4 approved by ICAO general assembly 每 In effect January 1, 2006 for new and derivative aircraft 每 Existing models grand-fathered Certification of acoustics and hardware 2nd quarter 2003 每 Thrust Reverser Mechanical certification complete 每 currently in production for A321 Acoustic certification 2nd quarter 2003 每 Chevron Nozzle Mechanical and acoustic certification 2nd quarter 2003 每 Inlet 每 certification 4th quarter 2004 if necessary Decision to include inlet will be made after acoustic data has been completed for Thrust Reverser and Chevron Nozzle Certification testing showed 1.6dB improvement CFM56-5B Acoustic Program CFM Proprietary Information 8 Major engine certification program in conjunction with aircraft improvements Benefits: 每 Completely interchangeable with current -5C 每 1% SFC improvement 每 13∼C lower EGT 10% lower maintenance costs 每 Maintains current CFM56-5C noise (26 EPNdB margin) 每 Uses the existing nacelle Market for 500 engines/upgrade kits Engine certification October 2003 EIS November 2003 CFM56: Product Upgrades CFM56-5C/P for Airbus A340-200/300 CFM Proprietary Information 9 Snecma • Swept fan • Light-weight structures • Low pressure turbine • High speed bearing GE • High pressure compressor • TAPS combustor • High pressure turbine • Brush sealing Jointly •Turbine interaction • Acoustics • Engine controls • Testing TECH56 Technology Programs CFM Proprietary Information 10 • Swept Fan Blade - Hollow design - Second generation for additional acoustic improvement • TAPS Maturation - Optimize NOx vs. CO; demonstrate durability • Six-Stage Compressor - Mature next-generation 3-D aerodynamics; optimize loading • Acoustics - Demonstrate additional acoustic improvement - Chevrons, acoustic liners, 2nd generation swept fan blade • High Efficiency LPC and LPT Technology Technology Maturation Plan 2001-2003 Engine test planned CFM Proprietary Information 11 CFM Project TECH56: The Next Phase Technology maturation Program has met all objectives to date 每 Technology development has been overwhelming success 每 Time to take TECH56 to next level Focus for 2001 - 2003: 每 Drive lower total cost of ownership 每 Reduce maintenance costs 每 Develop even simpler, more robust designs 每 Optimize engine cycle 每 Develop new controls technology 每 Improve systems integration Whatever the Market Needs, TECH56 Has the Answer CFM Proprietary Information 12 Driving Reliability and Satisfaction The whole CFM team is involved Communication and sharing information 每 Field Reporting 每 Scorecards and Digital Cockpit 每 WTT/Focus Teams Driving Improvements using Six Sigma 每 Cluster teams to analyze 每 Cluster teams to implement Driving Customer Satisfaction with CFM team involvement, communication and Six Sigma CFM Proprietary Information 13 Raj Varadarajan Jerry Otto Marketing Kent Weden Product Support Vince VanDenBriel Quality Bill Clapper General Manager Wayne Adams CFM56-3/-7 Programs Manufacturing & Quality Ken Foley CFM56-5 Program Shawn O＊Day Master Black Belt Scott Pawlikowski CFM e.Business and Product Support Integration Debbie Poli CFM56 Product Support Engineering Rebecca Goodall Compliance Len Baran CFM56 Upgrades Services Integration Bruce Mills Engineering John Mericle Business Operations The CFM56 Team CFM Proprietary Information 14 Issue Identification - - Fleet Experience Hours: 18,566,940 Cycles 2,928,473 Engines 975 Customers 31 Customer Sensitivities • Kuwait - HPT blades • Air Canada - No.4 Bearing / SV Planning • Cathay - Shop visits / LOTC • LanChile -- Engine durability / Starter • AFR -- Nacelle • CSW -- Hung starts • IBE / GFA / CCA / TAP/ -- Engine SV planning Issues Status Corrective Action • HPT blades SB 72-462 and 72-469 released • No. 4 bearing New material available June 10. • Performance Overhaul task force driving improvements • VSV LVDT Faults Engine test / component test in process to identify root cause of events • LOTC rate Investigating all known causes New N2 sensor 72-422 New T25 sensor 73-013 • Starter ring gear Date code inspection (SB 80-0011) • Soft starter pawls AOW has been sent to operators. SB 80-0012 approved Total Shop Visit Rate Goal 0.100 Current rate 0.068 Total ATO Rate Goal 0.001 Current rate 0.008 Total IFSD Rate Goal 0.003 Current rate 0.0070 Total Dispatch Reliability Goal 99.85 Current rate 99.67 June Airbus Data CFM56-5C Propulsion System Scorecard Total IFTB/Diversions Goal 0.008 Current rate 0.0126 Fleet Leading Indicators • IBE Fins Erosion • High Oil consumption • Starter FOD -- Airbus issue Y Y R Y G G Total UER Goal 0.040 Current rate 0.040 G It all begins with field reporting＃ • Scorecard data comes from field event reporting • Leading indicators are identified through event reports and field feedback • Prioritization and field fixes are based on data analysis CFM Proprietary Information 15 CFM＃ Top Repeatable Processes CFM56-5C Top UER cause 每 HPT Blades CFM International Proprietary information Top Unscheduled Engine Removal Causes (Last 12 months) Cause Quantity Corrective Action HPT Blades 41 SB 72-0469- Improved HPT blade durability High EGT / Performance 18 Performance restorat-io-Fnocus su-bteams driving recommendations and improvements Number 4 bearing 14 New Outer Race Material CESM 009- bearing shop practices High Oil Consumption 14 SB 72-0464- Introduction of new LPT seals Additional causes under investigation HPC Blades 12 FOD caused events Oil Leaks 6 Several engines under investigation Combustion Chamber 2 SB 72-0412-New outer cowl AGB Mounting pad 3 Loose hydraulic pump pad studs replaced N2 Vibrations 2 Improved shop practices. Several engines under investigation Data through September 30, 2002 UER＊s 每 Repeatable Process 每 Data depends on field reporting CFM Proprietary Information 16 Q1 Analysis Total Restored Shop Visits in Q1 0 1 2 3 4 5 6 7 8 9 10 11 Perf. Det. HPT Blade #4 Bearing O Rings High Oil Consumption Dome Number of Events 2001 HPT Blade • Q1 is d• epartment-wide initiative • Performed on all CFM models • Understand shop visit causes in Q1 - HPT blades driving removals for short-haul 每5C customers • Drive field actions through customer teams 0 5000 10000 15000 20000 25000 1996 1997 1998 1999 2000 Engine Flight Hours Minimum Q1 Mean Q3 Maximum CFM56-5C Shop Visit Q1 Analysis 每 Restored Shop Visit Stability Factor: .56 Implementing Corrective Actions to Reduce Variation CFM Proprietary Information 17 Goals: • Closer integration with Field Service • Drive Field improvements and airline implementation Product Cluster Strategy - - Top CFM56-5C Projects - Status Field Programs: - The Pipeline Cluster Projects: - The Execution Description Americas Asia SA Region HPT Blade BSI Video Implementation on trac k Waterwash Barriers identified / plan in place Reduction of delays c/b fuel leaks Barriers identified / recovery plan required N2 Sensor upgrade More data required Primary TR lock lubing #4 Bearing implementation Status BPTS #: Title Leader Metrics Impacted W&C Budget Impact? Status 2001-10-024569CFM56-5C Blade HPT Root TE CrMac. kWinagnBdeSrIsVeiedeoATO, IFSD, High cost failure Yes Implementation 2001-11-026141CFM56-5C Waterwash B. Vermillion TOW No Implementation 2001-12-02816R0eduction of delays caused by fuelSle.aPkaswlikowski D&C No Implementation 2002-05-012207N2 Sensor Upgrade S. Pawlikowski IFSD / LOTC Events No Implementation 2002-11-023139CFM56-5C TSM Improvements E. Martin LOTC / IFSD / UER No Analyze / Improve 2002-11-022400CFM56-5C / P Development A. Kemp TOW / UER Yes Improve 2001-08-01948C6 FM56-5C Inlet lip cracking durabiJli.tyCimallparnodveermentD&C / Maintenance cost No Improve/Control 2002-11-023261CFM56-5C Nacelle Cluster K. Foley Nacelle Maintenance cost Yes Analyze / Improve Fleet Experience Hours: 18,566,940 Cycles 2,928,473 Engines 975 Customers 31 Customer Sensitivities • Kuwait - HPT blades • Air Canada - No.4 Bearing / SV Planning • Cathay - Shop visits / LOTC • LanChile -- Engine durability / Starter • AFR -- Nacelle • CSW -- Hung starts • IBE / GFA / CCA / TAP/ -- Engine SV planning Issues Status Corrective Action • HPT blades SB 72-462 and 72-469 released • No. 4 bearing New material available June 10. • Performance Overhaul task force driving improvements • VSV LVDT Faults Engine test / component test in process to identify root cause of events • LOTC rate Investigating all known causes New N2 sensor 72-422 New T25 sensor 73-013 • Starter ring gear Date code inspection (SB 80-0011) • Soft starter pawls AOW has been sent to operators. SB 80-0012 approved Total Shop Visit Rate Goal 0.100 Current rate 0.068 Total ATO Rate Goal 0.001 Current rate 0.008 Total IFSD Rate Goal 0.003 Current rate 0.0070 Total Dispatch Reliability Goal 99.85 Current rate 99.67 June Airbus Data CFM56-5C Propulsion System Scorecard Total IFTB/Diversions Goal 0.008 Current rate 0.0126 Fleet Leading Indicators • IBE Fins Erosion • High Oil consumption • Starter FOD -- Airbus issue Y Y R Y G G Total UER Goal 0.040 Current rate 0.040 G Implementation tracked and reported at Quality Meeting CFM Proprietary Information 18 6 Warrantees & Concessions Q1 Analysis Project Clusters HPT Blade ANOVA Weibull WTT & Focus Teams UERs Design of Experiments Box Plots Cause & Effect Pareto Trend Analysis Mini Tab Implementation 每 HPT Blade Example CFM Proprietary Information 19 B. Clapper - Cluster Leader CFM56 HPT Blade Programs Project #: 2002-02-002501 M. Wandersee - Leader CFM56-5A ANA P08 HPTB Dovetail Cracking 2001-05-012202 CFM56-5C - 2D Root/Trailing edge crack 2001-05-012203 Implemented CFM56-5B/P HPT Blade Shank Separation 2001-05-012205 CFM56-5BP/-7 HPTB Trailing Edge Separation 2002-02-003122 CFM56-5BP/-7 HPTB Trailing Edge Separation 2002-02-003122 Design Improvements Repair Development Programs T. Norris - Leader CFM56-5A S1 HPTB Improved Durability Blade 2001-10-023245 Implemented CFM56-7, -5B/P S1 HPTB MXX Design Durability Improvement 2001-10-023260 Implemented Various - Leaders Shank Strip of CFM56-7B,- 5B/P HPT Blades 每 Eight projects 2002-01-001353 2002-08-016872 2002-08-016874 2002-08-016875 2002-08-016870 2002-082-016867 2002-08-016864 2002-04-010030 Implemented Matt Saylor -Leader Modified PtAl Process for CFM56-7 HPT Blade 2002-01-000908 Various - Leaders Shank cracking of CFM56- 7B,-5B/P HPT Blades - Four projects 2002-08-016862 2002-03-007565 2002-08-016884 2002-08-016886 Implemented Field Programs Various - Leaders Shank cracking of CFM56- 7B,-5B/P HPTB -Two projects 2002-08-016878 2002-09-019040 Implemented Tingfan Pang -Leader HPTB For CFM56-5CP (thru TG6) 2002-04-008488 Implemented DFSS CFM56-5C/P Optimum Accelerated Durability Test Definition 2002-11-022400 -5C/P HPT Blade 每 TG7 thru Certification 2002-11-023679 Scott Carson - Leader Tapered Tip HPTB 2002-02-003305 Ys: Two-run HPT Blade No HPTB-caused IFSDs CFM56 HPT Blade Cluster CFM Proprietary Information 20 $0 $5,000,000 $10,000,000 $15,000,000 $20,000,000 $25,000,000 $30,000,000 CFM56-3 CFM56-5A CFM56-5B CFM56-5C CFM56-7B 0 10 20 30 40 50 60 70 80 CFM56 Concessions - Analysis CFM56-5C is biggest contributor to CFM concession volume & cost One-way Analysis of Variance Analysis of Variance Source DF SS MS F P Factor 4 2.889E+12 7.224E+11 4.36 0.002 Error 261 4.322E+13 1.656E+11 Total 265 4.611E+13 Individual 95% CIs For Mean Based on Pooled StDev Level N Mean StDev ----------+---------+---------+- ----- CFM56-3 67 166097 290803 (-----*------) CFM56-5A 21 176623 199922 (-----------*----------) CFM56-5B 34 161682 281807 (--------*--------) CFM56-5C 71 372221 673451 (------*-----) CFM56-7B 73 105548 185192 (-----*-----) ----------+---------+---------+- ----- Pooled StDev = 406924 150000 300000 450000 CFM56-3 20% CFM56-5A 7% CFM56-5B 10% CFM56-5C 49% CFM56-7B 14% CFM Proprietary Information 21 CFM56-5C Concessions by Hardware - Analysis $0 $1,000,000 $2,000,000 $3,000,000 $4,000,000 $5,000,000 $6,000,000 $7,000,000 $8,000,000 $9,000,000 #4 Brg #3 Brg HPT Blade HPC Case IGB HMU Other Perf EGT Probe Fuel Pump Air/Oil Sep LPT Shroud C-Clip Unknown Upgrade HPC Vane 0 5 10 15 20 25 HPT Blade is Top Cause for CFM56-5C Concessions CFM Proprietary Information 22 HPT Blade Cluster＃ Driving Improvements • Field Control Program Customer training video Reduce borescope interval Cancel repairs Rotables availability for quick turns Critical Xs: • New Blade Design DFR Scoring Accelerated endurance testing Leading indicators Optimized cooling 1000 10000 0.1 1 2 3 5 10 20 40 60 80 99 Percent UERreq. Cycle:3800 DPMO:6210 ScrapReq. B10:3800 B50:6000 11000 M73P02 LCFPred.. M73P02Rupture M60P01Rupture M60P01 LCF CFM56-5C4 Fleet Asia Fleet Gulf Fleet Cycles to failure / removal CFM Proprietary Information 23 Summary Communication from you All data analysis is based on field data Events Customer Sensitivities Field Fix Effectiveness Involvement from entire team is required Cluster Teams FSE Reporting PSE Identifying issues/leading indicators Teams using Six Sigma tools for analysis PSE communicates control program implementation FSE driving implementation Communication to you Digitization to share information WTT/Focus Team information CFM Weekly News Livelink Presentation Files Digital Cockpit and Scorecards Maintain communications ＃ Feedback is critical to Reliability and Customer Satisfaction釬氪: kinran 奀潔: 2011-6-4 23:12:03
