Automating Job Card Generation forMaintenance, Repair and Overhaul

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Automating Job Card Generation
forMaintenance, Repair
and Overhaul
INSERVICE JCG WHITE PAPER
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Solution Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
A High-Value Solution to a Critical Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
About InService JCG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
The InService JCG Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Digital signatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Deploying InService JCG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Extending InService JCG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Benefits of InService JCG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Customer Scenario . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
About Enigma . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Copyright © 2007. Enigma, Inc. All rights reserved.
Automating Job Card Generation for Maintenance, Repair and Overhaul Enigma, Inc.
Introduction
For airlines and MRO shops, the maintenance
organization is one of the largest workforces in the
company and among its biggest operating
expenses. To work efficiently, and to comply with
FAA/CAA regulations and safety standards, these
highly trained technicians and engineers must be
fully informed about the jobs they are to perform.
The creation and generation of complete, accurate,
and properly organized job or task cards are among
the most critical processes supporting maintenance
activities. Yet, in many organizations this remains a
largely manual function that can involve searching
for data in multiple systems, sorting the
information, and then entering it into the proper
job card format.
This time-consuming and error-prone process
contributes to maintenance errors and slows down
the maintenance and repair of aircraft and engines.
Not only are these efficiency constraints painfully
obvious on heavy maintenance checks that may
require job cards exceeding 1,000 pages, but also
they waste precious time on A&B checks,
unscheduled maintenance and non-routine jobs,
directly contributing to flight delays.
This time-consuming and error-prone process
contributes to maintenance errors and slows down
the maintenance and repair of aircraft and engines.
Not only are these efficiency constraints painfully
obvious on heavy maintenance checks that may
require work and job cards packages exceeding
1,000 pages, but also they waste precious time on
A&B checks, unscheduled maintenance and nonroutine
jobs, directly contributing to flight delays.
Solution Requirements
Most methods for generating job cards fail to offer
the efficiency, flexibility, and control that
maintenance organizations need:
Manual labor. In many organizations, job card
generation remains a largely manual, painfully
slow, and labor-intensive process that, for C and D
checks, can take weeks or months. Typically the
planning system holds reference data used to
generate job cards (the aircraft, model, ATA tasks,
skills, hours, etc.). A planning engineer must work
from these references, merging Airbus, Boeing,
Embraer, or other OEM data, adding service
bulletins, checking for updates, and so forth. Job
cards for heavy maintenance (C and D checks) must
often be revised before they are used, because the
job card generation process takes so long. This
usually involves manually comparing and
synchronizing recent updates to vendor data,
service bulletins, and so forth—another
error-prone and inefficient process.
Outsourcing. Some airlines outsource the
generation of job cards. This appears to simplify
the process but actually it only shifts some
responsibility, adds expense and presents control
and coordination challenges around maintenance
activities. In the end, each airline is still responsible
for the maintenance of its fleet and ensuring that
aircraft comply with maintenance regulations and
aviation directives.
Purchasing from vendor. Aircraft manufacturers,
such as Boeing and Airbus, offer generic job cards
for the equipment they build. Any airline-specific
processes, customer originated changes (COC),
best practices, etc. must be appended to the end of
a generic job card or work package, rather than
being inserted as a part of the relevant tasks or
subtasks, as there is no way to integrate or
reference other data with the pre-packaged,
vendor-supplied job cards. Furthermore, in a mixed
fleet environment an airline needs multiple systems
to properly maintain all of their aircraft.
Automating Job Card Generation for Maintenance, Repair and Overhaul Enigma, Inc.
| 1
The creation and generation
of complete, accurate, and
properly organized job or task
cards are among the most
critical processes supporting
maintenance activities.
>>
A High-Value Solution
To A Critical Problem
Maintenance organizations will benefit from a highly
automated system that can generate job cards (even
for heavy maintenance checks) in print and/or
online formats at the push of a button, in a matter
of minutes or hours rather than months. Ideally the
planning or maintenance and engineering software
would drive such a system; not only for optimal
efficiency and control, but also to avoid the cost and
aggravation associated with changing business
processes.
A fully automated job card generator must
automatically access all the latest service data to
ensure accuracy, eliminate manual intervention and
minimize maintenance rework. Further, it must
automatically include all the relevant source data
from manufacturers such as Boeing, Airbus, etc.
At the same time, a complete system for automated
job card generation would be flexible enough to
integrate in-house standards and processes at the
task and sub-task level, rather than appending
them to the end of the job card where they are
awkward to reference and easy to overlook.
About InService JCG
The Enigma® InService Job Card Generator
(InService JCG) enables airlines and MROs to
reduce maintenance errors and save thousands of
hours of labor-intensive activity by fully automating
job card generation. This ATA-compliant solution,
based on Java 2 Enterprise Edition (J2EE) open
standards, can generate any number and any type
of job card using a uniform process. It can generate
job cards using Boeing, Airbus or any other OEM
source data and insert customer-ordered changes
(COCs) and best practices at the task and subtask
level in the proper location on the job card—not just
tacked on at the end.
Among its key features, InService JCG:
• Improves the quality of job cards by assembling all
relevant technical service information and
merging it with planning data in the appropriate
order and context
• Ensures that only relevant information, based on
maintenance task and equipment serial number,
is included in the job card and delivered to the
technician
• Generates job cards (in PDF format) that can be
used electronically and/or printed on paper, along
with all required information and standardized,
company-specific formatting
• Supports all different kinds of data: OEM data
such as wiring diagrams and service bulletins;
COCs; and airline-specific documentation,
procedures and best practices
• Can integrate with, and be driven directly by, a
planning system without any manual intervention
or effort.
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Automating Job Card Generation for Maintenance, Repair and Overhaul Enigma, Inc.
How itWorks
InService JCG pulls together core planning
information such as resource, material and tooling
data from maintenance planning systems and
merges it with procedural, parts, and service
bulletin data from the central InService JCG
repository. The information is analyzed and filtered
to ensure it matches the specific serial number
(tail number) of the aircraft or engine being
serviced. The maintenance tasks are then printed
or sent electronically to the appropriate technician
in the form of one or more job cards. This process
is illustrated in Figure 1.
InService JCG generates a separate PDF document
for each job card within a work package. Each PDF
can contain multiple tasks and subtasks. These
documents can be printed and used for
maintenance and sign-off purposes in the
traditional manner. Organizations also have the
option (see below) to leverage digital signature
capabilities and automated, document-level
workflow while working with job cards using
laptops or handheld devices. These features
expedite sign-off and reduce errors and omissions.
The InService
JCG Architecture
InService JCG consists of two separate, but closely
linked, environments (see Figure 2):
• The data load environment, in which disparate
data from relevant applications is automatically
combined into a single content repository that is
up-to-date with all the latest service bulletins,
technical revisions, and company-specific
procedures and best practices. This data, once
imported, is indexed for faster access and online
viewing, and can be enriched with active links to
service bulletins, COCs and other aircraft or fleet
information.
• The job card generation environment, in which the
actual job cards are produced. Driven by job card
output from the planning system, InService JCG
identifies which data is relevant to what jobs,
tasks, and subtasks; filters extraneous data; and
generates one or more documents in PDF format.
When the planning system generates a work
package request (including the tail number, job
description, ATA references and any relevant
planning information), InService JCG automatically
pulls the relevant technical information (text,
graphics, diagrams, schematics, OEMdata, best
Automating Job Card Generation for Maintenance, Repair and Overhaul Enigma, Inc.
Figure 1: How InService JCG works
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practices, etc.) fromits unified repository. It then
renders the combined and organized information in
PDF format according to company layout/formatting
requirements, and sends it to a specified location, such
as a central server or archival system, as a complete
work package. Job cards can include task-specific
planning data contained in theM&E system, such as
fleet, skill, zone, access panel, hours, andmaterial.
Different types of jobs can automatically be given a
specific appearance or layout.
Digital signatures
Digital signature capability helps streamline
maintenance activity, eliminates paperwork, and
simplifies regulatory compliance. Maintenance
engineers and supervisors can apply their esignatures
from the line or the hangar using a
laptop, PDA or other handheld device, or e-mail
PDF documents for signoff.
This optional module, separately available from
Enigma, supports all basic sign-off procedures per
regulatory requirements. That is, a technician can
sign off on each subtask, and technicians and
supervisors can sign off on each completed task
and job card. Multiple technicians and/or
supervisors can sign off on a job, task, or subtask:
e-signature authorization is not limited to the
person who started a task unless the organization
desires this.
InService JCG generates interactive job cards that
support electronic completion of checkboxes,
comment fields, and signoffs; all adhering to
regulatory requirements in line with your business
processes. E-signatures and task data (how long
the job took, notes on problems, etc.) can easily be
exported for synchronization with the planning
system—eliminating the need to manually scan and
import paper documents. These capabilities help
prevent data loss associated with misplaced paper
documents and scanning errors, and protect job
cards and edited data from unauthorized access.
Advanced job cards with e-signature capability can
also include built-in workflow to ensure that
subtasks and tasks are all carried out, and
completed and signed off in the right order.
Organizations can easily add and configure these
simple but powerful workflows to suit their own
processes, or use a document management or
other system to manage job card workflow.
Automating Job Card Generation for Maintenance, Repair and Overhaul Enigma, Inc.
Figure 2: The InService JCG architecture
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Deploying InService JCG
Enigma InService JCG is specifically designed for
fast implementation and deployment—often in 10-
12 weeks. For example, it comes pre-packaged with
standard ATA job card style sheets that are easy to
customize to meet your specific requirements.
Alignment with your current business processes
facilitates quick and smooth user adoption.
Its modern, standards-based architecture makes
InService JCG straightforward to integrate with
M&E or MRO planning systems, as well as content
management, document management or other
systems, using an API such as XML, Web Services
or HTTP. No new software or changes to current
business processes are required to fully leverage
the power and flexibility of InService JCG.
Data interchange between systems takes place
in Enigma’s predefined XML format. Integration
can be:
• Unidirectional, where the planning system
“pushes” the data required to generate a job to
InService JCG using XML
• Bidirectional, which further enables InService JCG
to push data on completed jobs back to the
planning system.
Bidirectional integration helps to support ongoing
maintenance planning, streamlines audits and
compliance processes, and provides management
with the latest status information. It also supports
improved configuration management through
faster, more accurate tracking of data on
new/changed parts. This optional level of
automation can be implemented at any point.
Extending InService JCG
Based on well-proven Enigma 3C® technology,
InService JCG is an enterprise class, fully scalable
and upgradeable solution, making it straightforward
to add new fleets or additional types of manuals—
even adding documentation for a new aircraft model
or, to support organizational growth, an entire
airline.
A further compelling advantage of this open and
highly flexible architecture is that it is vendor- and
system-neutral. In the future you can upgrade or
replace your planning system, add new content
management capabilities, or otherwise enhance
your business processes in any way you choose,
while still retaining all the capabilities of InService
JCG.
Customers can also easily extend the core
capabilities of InService JCG in a variety of ways,
including:
• Adding Enigma Revision Manager to InService
JCG. Revision Manager allows you to compare two
versions of job card data to see what task-level
content has changed. This tells you immediately
whether a job card needs to be revised, and
initiates the process at the click of a button. You
can then feed this information back to your
planning system to flag all in-process job cards
that need to be regenerated. You can then update
your Enigma repository so that all future job cards
automatically incorporate the latest data.
• Upgrading to the Enigma InService MRO solution,
to optimize your entire maintenance information
delivery process, with online manuals, parts
catalogs and collaboration, as well as automatic
job card generation.
Automating Job Card Generation for Maintenance, Repair and Overhaul Enigma, Inc.
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Enigma partners with other leading vendors to
provide pre-defined, integrated solutions that
incorporate InService JCG and other Enigma
technology. These currently include:
• Oracle’s Complex MRO (CMRO) maintenance
management and delivery solution, to automate
the full maintenance planning function
• IBM’s Technical Document Management and
Delivery (TDMD) content management and
delivery solution, to automate your whole
technical publications function.
Benefits of InService JCG
InService JCG’s automated and advanced
capabilities offer a range of benefits by making job
card generation faster and more accurate, leading
to increased productivity across maintenance
planning and execution functions and simplifying
maintenance auditing and compliance.
Faster, smoother job card generation reduces
manual labor and maintenance delays (such as
“dead time” spent waiting for job cards)—all leading
to faster turnaround time and fewer delays at the
gate. Automation also saves significant time on
unscheduled maintenance and non-routine job
cards, where the savings often matter most.
Moreover, because job card generation is no longer
a highly labor-intensive, “variable” factor in
maintenance activities, you can streamline resource
allocation to realize further efficiencies. In
particular, planning engineers who would otherwise
be spending large amounts of time preparing and
validating work packages are free to focus on higher
value activities.
Greater job card accuracy confers an equally wide
range of advantages. Most importantly, it reduces
rework resulting from the inadvertent inclusion of
incorrect or out-of-date information. Enigma’s
highly efficient filtering mechanism ensures that all
relevant data is automatically included. This
improves first-time fix rates while decreasing
the number of errors caused by incorrect
documentation. Greater job card accuracy further
improves maintenance execution by ensuring that
maintenance instructions are consistent over time.
Customer Scenario
A large European airline leverages InService JCG
technology to help reduce aircraft maintenance
costs at more than 100 airports in 40 countries. The
new system generates custom job cards with up-tothe-
minute maintenance and repair information,
and is currently used by thousands of technicians,
maintenance planners and engineers worldwide.
Leveraging its core competence in aircraft MRO,
this airline not only maintains its own fleet but
those of nearly 50 other airlines. Efficient
maintenance is thus all the more critical to the
organization’s success. The customer uses the
InService JCG system to dynamically generate
custom job cards that not only indicate maintenance
tasks but also include all relevant maintenance data
for the specific aircraft being serviced.
InService JCG technology extracts maintenance and
execution information from the customer’s
maintenance planning and content management
systems and generates a comprehensive job card
that includes all the references, equipment, tools,
codes and other critical instructions necessary to
perform a specific maintenance procedure.
On completion of allocated tasks, engineers sign off
on physical job cards and check the completed
paperwork back into the planning system. The
company is now in the process of extending their
Enigma solution to include digital signatures.
The maintenance planning department credits the
new system with eliminating 80% of the manual
intervention activity associated with generating job
cards. Reducing manual activity has also reduced
human error and improved the quality of job cards.
Automating Job Card Generation for Maintenance, Repair and Overhaul Enigma, Inc.
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For aircraft maintenance technicians (AMTs),
Enigma has improved efficiency by eliminating the
need to look for missing data (e.g., the latest service
bulletins) needed to carry out the maintenance
assignment.
Overall, InService JCG technology has significantly
improved the airline’s service workflow, while
enhancing maintenance accuracy and increasing
AMTs’ efficiency.
Conclusion
Manual job card generation processes significantly
hamper maintenance efficiency and accuracy for A,
B, C, and D checks alike, directly resulting in lost
time, errors, and flight delays. While traditional
options offer partial solutions, airlines and MRO
shops will benefit greatly from a highly automated
solution that can generate job cards in print and/or
online formats on demand. The automated system
must be integrated with current planning, content
management and/or document management
systems and related business processes. Further, it
must offer the flexibility to incorporate in-house
standards and processes at the task and sub-task
level within job cards—even vendor-supplied job
cards.
Enigma InService JCG addresses the needs of
technicians, planners, and engineers with a
comprehensive, automated job card generation
solution that empowers a more efficient and
consistent service organization, leading to:
• Reduced operating costs
• Increased equipment uptime
• Enhanced customer support and satisfaction
• Improved on-the-job safety
• Improved support for regulatory compliance
By making these direct and significant contributions
to the bottom line, Enigma InService JCG drives
significant competitive advantage in the MRO
marketplace.
About Enigma
Enigma is the only software company with a full
suite of products aimed at improving the
installation, operation and maintenance of complex
equipment. Enigma takes data from enterprise
applications to create an interactive maintenance
solution that delivers the latest service, parts, and
diagnostic information, helping every technician
perform like an expert. By capturing best practices
and providing an optimized workflow, Enigma
simplifies maintenance. Enigma focuses on
aftermarket service and support, maximizing
customers’ profits through improved workforce
productivity, parts logistics, and equipment uptime.
For more information please visit
www.enigma.com.
Automating Job Card Generation for Maintenance, Repair and Overhaul Enigma, Inc.
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