P&WC Safety Management System For International Helicopter Safety Symposium

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P&WC Safety Management System
For International Helicopter Safety Symposium
30 September 2009 / Montreal
P&WC PROPRIETARY INFORMATION 2
OUTLINE
P&WC Overview
P&WC SMS Implementation
Approach and Philosophy
Governance / Management Structure
Key SMS Components & Elements
Implementation Status
Lessons-learned
P&WC PROPRIETARY INFORMATION 3
P&WC GLOBAL PRESENCE
45,000 engines, 9,300 operators and 195 countries
Production
Headquarters
P&WC Service Centers
Research and development
Longueuil
West Virginia
Rzeszow
Other Service Centers
P&WC PROPRIETARY INFORMATION 4
P&WC GLOBAL CUSTOMER BASE
Over 35 major aircraft OEM’s
Embraer
Air Tractor
Boeing
Cessna
Eclipse
Epic
Gulfstream
Hawker Beechcraft
Learjet
MD Helicopters
Piper
Quest Aircraft
Thrust Aicraft
Sikorsky
Bell Helicopter Textron
Bombardier Aerospace
Viking Air
Pacific Aero
Pilatus
Agusta
Dassault
EADS
Airbus
ATR
CASA
PZL-Okecie
Socata
Eurocopter
Piaggio
Sikorsky PLZ-Mielec
Harbin
Chenghe
NAL Xian
Ilyushin
Kazan
MIL
Tashkent
P&WC PROPRIETARY INFORMATION 5
P&WC IN SERVICE (As of Sept 09)
539,470,000 total flight hours
24,000,000 flight hours per year
68,716 engines delivered
45,010 flying engines
31,566 flying aircraft
9,660 operators
199 countries
163 engine models
P&WC PROPRIETARY INFORMATION 6
6 KEY BUSINESS SEGMENTS
Corporate
Military
Regional Civil helicopters
Aftermarket
General aviation
Cessna Citation XLS Dassault F7X
ATR 72 AgustaWestland AW139 Bell 427
King Air C90GT
Bombardier Q400
Embraer Super Tucano
Pilatus PC-12
CASA C295 Customer First Centre Repair & Overhaul
P&WC PROPRIETARY INFORMATION 7
P&WC HELICOPTER PRESENCE
Bell 412
PT6T-3B/D EIS 1981
AgustaWestland AW139
PT6C-67C EIS 2004
AgustaWestland Koala
PT6B-37A EIS 2001
Bell Agusta BA609
PT6C-67A EIS 2011
Eurocopter EC135 UH-1N EIS 1970
PW206B EIS 1996
MD900
PW206A EIS 1994
AgustaWestland Power
PW206C EIS 1997
Kazan Ansat
PW207K EIS 2003
Sikorsky S76D
PW210 EIS 2010
Bell 427
PW207D EIS 2000
Bell 429
PW207D1 EIS 2009
AgustaWestland Grand
PW207C EIS 2005
PT6C
1,600 – 2,100 shp
PT6T/B
1,800 – 2,250 shp
PW210
950 – 1,200 shp
PW200
600 – 750 shp
EC175
PT6C-67E EIS 2011
Sikorsky S76B
PT6B-36A EIS 1985
In
Development
> 11,000 engines, 42 million hours, 600 operators
P&WC PROPRIETARY INFORMATION 8
OUTLINE
P&WC Overview
P&WC SMS Implementation
Approach and Philosophy
Governance / Management Structure
Key SMS Components & Elements
Implementation Status
Lessons-learned
P&WC PROPRIETARY INFORMATION 9
P&WC SMS IMPLEMENTATION
Approach & Philosophy
P&WC:
embraces the concept of SMS and has been actively working on
implementation since 2004
is deploying a company-wide SMS that covers all functions and
Transport Canada approval/certificates
has incorporated proactive risk management processes consistent
with SMS and UTC policies
is leveraging many existing systems as foundation elements for the
SMS
P&WC PROPRIETARY INFORMATION 10
TCCA SMS Implementation Dates
Updated: June 10, 2009
Forecast - November 2011
November 2011
Forecast -
September 2011
Aircraft
Certification
Forecast - February 2010
February 2010
Forecast -
December 2009
Approved
Maintenance
Organization*
(AMO) (573)
Forecast – December 2010
October 2010
Forecast - June
2010
Approved
Manufacturers
(561)
P&WC is prepared for SMS initial
certification phase I by Transport Canada
of CAR 573 Approved Maintenance
Organizations (AMOs) in February 2010
P&WC PROPRIETARY INFORMATION 11
TCCA Certificates Issued TO P&WC
Design Approval Organization (DAO)
AWM 505
CAR 511
Private Operator Certificate (POC)
CAR 604 (CBAA)
Approved Manufacturing Organization
CAR 561
Approved Distribution Organization
AWM 563
Approved Training Organization
CAR 403
Approved Maintenance Organizations (2)
CAR 573
Certificate Holder
P&WC Corp.
Corporate Aircraft and Flight Test Bed
Corporate Aircraft
Engines
Engine / APU Type Certificates (Multiple)
Approved Maintenance Organization
CAR 573
P&WC PROPRIETARY INFORMATION 12
Transport Canada
SMS Requirements
6 Components
17 Elements
1. Safety Management Plan
1.1 Safety Policy
1.2 Non-punitive SMS disciplinary policy
1.3 Roles, Responsibilities & Employee Involvement
1.4 Communication
1.5 Safety Planning, Objectives & Goals
1.6 Performance Measurement
1.7 Management Review
2. Document Management
2.1 Identification & Maintenance of Applicable
Regulations
2.2 SMS Documentation
2.3 Records Management
6. Emergency Preparedness
5. Quality Assurance
4. Training
3. Safety Oversight
3.1 Reactive Processes
3.2 Proactive Processes
3.3 Investigation and Analysis
3.4 Risk Management
CAR 106 – Accountable Exec
CAR 107 – SMS Reqirements
P&WC PROPRIETARY INFORMATION 13
P&WC SMS Governance Approach
Manufacturing
Produce to
approved design
Maintenance
Maintain to
approved design
Approved Engine Design
Establishes safe limits
Core SMS elements
(Manual & Procedures)
ACE operating system
Safety objectives & measurement
Risk based safety decisions
Accountable Executive
SMS board
SMS steering group
P&WC PROPRIETARY INFORMATION 14
P&WC SMS Governance Structure
SMS Accountable Executive
SMS Board
SMS Steering Group
SMS Steering Group Chair
Chief Engineer
Customer Service
Chief Engineer
Product Integrity
Manager
Quality Systems
Chief Engineer
AW & Certification
Manager
C/S Ops QA & Eng
SMS Implementation Team
AMO
St. Hubert, Lethbridge
Flight Ops
Design
DAO
Engineering
Type Certificates
Post Certification
Production
Engine Centres, IMO
Manufacturing
Training Private Operator
St. Hubert, Mirabel
Implementation Team Leaders
SMS Board meets 4x yr
SMS SG meets every month
P&WC PROPRIETARY INFORMATION 15
P&WC SMS BOARD - Composition
Certificate TCCA Reqm’t PWC Position
SMS Role SMS Board Role PWC Position
SMS Board Core Executive
AMO / Training CAR 573 / AWM 403 VP Customer Service
AMO CAR 573 VP Operations Customer Service
CAR 561 VP Operations
AWM 563
Manufacturing Distribution
CAR 511, AWM 505 CAR 604, VP Engineering
CAR 573
DAO / Design
Flight Ops POC AMO
SMS Board Members – Responsible Executives
Exec Responsible Alternate SMS Board Chair VP Quality
SMS Impl’n
Senior VP
Service Centres & Operations
Accountable Executive Alternate SMS Board Chair
Delegate
Accountable Executive SMS Board Chair President
P&WC PROPRIETARY INFORMATION 16
P&WC SMS BOARD Composition cont’d….
Chief Engineer,
SMS Folder Management Customer Service
Status
SMS Folder Management
Chief Engineer
Product Integrity
SMS Role SMS Board Role PWC Position
Chief Engineer, AW & Certification
SMS Implementation SMS Board Administrator J. Diamant Boustead
Team Lead
Manager, Quality Systems & Processes
Linda Jankov
SMS Board Role PWC Position
SMS Board Members / Other
VP Human Resources
VP Finance
VP Counsel
VPs Marketing
SMS
Board Member
SMS Board Members / Other Executives
P&WC PROPRIETARY INFORMATION 17
SMS Policy signed by
Accountable Executive
provided to TCCA
01 January 2009
P&WC Safety Policy
(SMS Element 1.1)
P&WC PROPRIETARY INFORMATION 18
P&WC Non-Punitive Reporting Policy
UTC Code of Ethics
(SMS Element 1.2 )
P&WC PROPRIETARY INFORMATION 19
P&WC Non-Punitive
Employee Reporting Systems
DIALOG
UTC OMBUDSMAN
(SMS Element 1.2 )
P&WC PROPRIETARY INFORMATION 20
Transport Canada
SMS Requirements
6 Components
17 Elements
1. Safety Management Plan
1.1 Safety Policy
1.2 Non-punitive SMS disciplinary policy
1.3 Roles, Responsibilities & Employee Involvement
1.4 Communication
1.5 Safety Planning, Objectives & Goals
1.6 Performance Measurement
1.7 Management Review
2. Document Management
2.1 Identification & Maintenance of Applicable
Regulations
2.2 SMS Documentation
2.3 Records Management
6. Emergency Preparedness
5. Quality Assurance
4. Training
3. Safety Oversight
3.1 Reactive Processes
3.2 Proactive Processes
3.3 Investigation and Analysis
3.4 Risk Management
CAR 106 – Accountable Exec
CAR 107 – SMS Reqirements
P&WC PROPRIETARY INFORMATION 21
P&WC
Certificate Holder
Safety Management
CAR 107
Quality and Safety Management System Manual
Certified by Accountable Executive
DAPM
Certified by
VP Engineering
DESIGN
AWM 505
QPM
Certified by
VP Operations
MANUFACTURING
CAR 561
TPM
Certified by
VP Customer
Service
TRAINING
AWM 403
MPM
Certified by
VP Customer
Service Ops
MAINTENANCE
CAR 573
P&WC SMS Documentation Structure
UTC Policy 45
Quality
UTC Policy 53
Safety
(SMS Component 2)
P&WC PROPRIETARY INFORMATION 22
Transport Canada
SMS Requirements
6 Components
17 Elements
1. Safety Management Plan
1.1 Safety Policy
1.2 Non-punitive SMS disciplinary policy
1.3 Roles, Responsibilities & Employee Involvement
1.4 Communication
1.5 Safety Planning, Objectives & Goals
1.6 Performance Measurement
1.7 Management Review
2. Document Management
2.1 Identification & Maintenance of Applicable
Regulations
2.2 SMS Documentation
2.3 Records Management
6. Emergency Preparedness
5. Quality Assurance
4. Training
3. Safety Oversight
3.1 Reactive Processes
3.2 Proactive Processes
3.3 Investigation and Analysis
3.4 Risk Management
CAR 106 – Accountable Exec
CAR 107 – SMS Reqirements
P&WC PROPRIETARY INFORMATION 23
P&WC SMS Implementation
Safety Oversight Process
Required Elements are based
on existing P&WC systems &
processes
– Multiple data collection and
management systems
– ACE
– Investigations / Analysis
– Multiple Risk Analysis tools
– Management reviews
– Corrective Action
Continued integration required
to optimize to fully meet Phase
IV intent
Quality Escapes
Design Escapes
Engineering
Action
Engine
Investigation
Root Cause
Implement
Corrective Action
Reliability Meetings
Event Review
Best
Practices
Future
Designs
In- Service
Engine Event
Screening
(SMS Component 3)
P&WC PROPRIETARY INFORMATION 24
P&WC Data Collection System and Sharing
DEVELOPMENT/DESIGN
•Enovia (Discrepancy
system)
MANUFACTURING
•SAP (Quality
Notifications)
•Enovia (Audit, CAR)
AFTERMARKET / FIELD
•Enovia (Audit, CAR, field
reports)
•CMS (Event)
•TRAC (Events &
Reliability)
•SAP-EIs (Repair
Deviations)
•RFEs (Repair
Deviations)
•WSDR (Service
Difficulty Reports)
P&WC PROPRIETARY INFORMATION 25
Tracking Reliability Aircraft Census (TRAC)
P&WC’s Field Experience Data Warehouse
Configuration /
Campaign Management
Reliability
IFSD / BUR
Census
Reporting
Reliability theor y is the foundati on of rel iability engineering. For engineering purposes, reli abilityi s defined as:
the probabilit yt hat a device will perform it s intended function during a specified period of time under stated conditions.
Root Cause
P&WC PROPRIETARY INFORMATION 26
Tracking Reliability Aircraft Census (TRAC)
TRAC / SAS Reliability Analysts
Statistical System Engineering Report
Lab. Report
Service Center Report
Shop Report
Tear Down Report
UR Notification
Warranty claim
CMS Report
Contact Reports
OEM Reports
Operator Reports
Document
storage
Automated data feed
TRAC
database
Reporting
Shops, OEMs, FMP
manual data feed
Census, reliability, configuration
Data extraction for analysis & decision making
Reporting of issues, trends, reliability rates, etc.
to Aviation Authorities, OEMs, & Operators.
DATA ACTIVITY
72,800,000 Data points
690,600 Engine records
146,678 Aircraft records
185 Unique fields
P&WC PROPRIETARY INFORMATION 27
MANAGING FLEET SAFETY
Screening Criteria and Procedures Standardized
Multiple Filtering of In-Service and Overhaul findings
Statistically Based Assessments
Utilize Industry-Accepted Practices (FAA / TCCA approved)
Evaluate Unmitigated Risk and Corrective Action impacts
Mitigate Risk through Fleet Campaign Plans
Safety Review Prior to Release External to P&WC
Engine Safety Criteria Appropriate to Type of Flight Operations
Offshore / CAT A
General Aviation
Single Engine
Regional / Civil Transport
P&WC PROPRIETARY INFORMATION 28
Control System Benefits
Full-Authority Digital Electronic Control system (FADEC)
Reduced pilot workload
Enhanced dispatch reliability
Pilot training mode – OEI (twin engines application)
Automated starting with over temperature protection
Variable Nr governing
Automatic limiting
Power sharing
State-Of-Art Diagnostics / Prognostics
Engine run time
Fractional cycle counting
Creep count
Engine Fault Code, Exceedance and Event monitoring
Engine Performance
HUMS capability
Preventative Maintenance
Flexible State of Art Diagnostics & Prognostics for HUMS
Operator
OEM
PWC
FADEC HUMS
AC Systems
Dedicated Website
ECTM Files
Fault Codes
Transient Data
GBS Output
P&WC
OEM
Local Cell Phone Network
Smart Software
Internet
DTU
AC Systems
P&WC Product Initiatives
CONTROLS / DIAGNOSTICS & PROGNOSTICS
P&WC PROPRIETARY INFORMATION 29
Transport Canada
SMS Requirements
6 Components
17 Elements
1. Safety Management Plan
1.1 Safety Policy
1.2 Non-punitive SMS disciplinary policy
1.3 Roles, Responsibilities & Employee Involvement
1.4 Communication
1.5 Safety Planning, Objectives & Goals
1.6 Performance Measurement
1.7 Management Review
2. Document Management
2.1 Identification & Maintenance of Applicable
Regulations
2.2 SMS Documentation
2.3 Records Management
6. Emergency Preparedness
5. Quality Assurance
4. Training
3. Safety Oversight
3.1 Reactive Processes
3.2 Proactive Processes
3.3 Investigation and Analysis
3.4 Risk Management
CAR 106 – Accountable Exec
CAR 107 – SMS Reqirements
P&WC PROPRIETARY INFORMATION 30
P&WC SMS Implementation
Communication
General SMS awareness via PWC website and publications
Teams involved in two day SMS Gap analysis workshops
SMS Communication Plan under further development as part of SMS
Implementation plan
Training (SMS Component 4)
SMS Module now part of 3 day Airworthiness and Certification
Training
Human Factors Training part of CAR / STD 573 Requirement for AMO
SMS Training requirements by certificate to be further developed &
delivered per SMS Implementation plan
(SMS Element 1.4)
P&WC PROPRIETARY INFORMATION 31
Consolidate & Develop Procedures
2008 2009 2010 2011 2012
SMS Manual
AE Commit Statement
Safety Policy Revised
Implement Plan (All phases for all certificates)
Gap Analysis
SMS Board & Steering Group Oversight
Reg in force
Feb 2010
AMO
Phase I
Feb 2011
AMO
Phase II
Feb 2012
AMO
Phase III
Feb 2013
AMO
Phase IV
Dec 2010
Reg in force
Manufacturing
Phase I
Nov 2011
Reg in force
Certification
Phase I
Develop Plan
TCCA SMS Implementation dates
Regular meetings with TCCA
to update SMS progress
P&WC PROPRIETARY INFORMATION 32
Gap Analysis & Implementation Plan
All required SMS elements reviewed
Specific cross certificate teams to be formed to address
identified gaps
Management review and acceptance
P&WC PROPRIETARY INFORMATION 33
P&WC SMS Implementation
Lessons Learned and Benefits
Specific measurement of cost and benefits of SMS implementation not
currently available, although similar initiatives have showed tangible
benefits in quality and safety related metrics (CoPQ’s, Escapes)
Certificates issued under CAR 561 and CAR 573, and AS9100
certification, addresses component 5 “Quality Assurance”, and part of
component 4 “Training” requirements
Several existing systems (e.g., EH&S, Quality, ACE tools and processes)
require integration within the enterprise-wide SMS framework
Culture and communication are keys to success
Benchmarking with similar companies provides knowledge transfer
opportunity and best practice sharing
Active participation in rulemaking and industry working groups has
advanced understanding of SMS requirements
P&WC PROPRIETARY INFORMATION 34
SUMMARY
Extensive and diversified product line of small gas
turbine engines and customers
Continuous investment in technologies & products
Global manufacturing and aftermarket presence
Founded on the highest ethical standards
Committed to product and service safety through
implementation of a fully integrated SMS

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