CFM56-7 Scorecard Data through December 2003

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CFMI PROPRIETARY INFORMATION
Data through December 2003
ATO Rate
Goal 0.010
Current rate 0.012
Dispatch Reliability
Goal 99.95
Current 99.96
Fleet Statistics
• 12 month rolling
average
In-Service
Current month
Previous month
Fleet Experience
Issue Status
CFM56-7 Scorecard
Total IFSD Rate
Goal 0.006
Current 0.003
Total ATO Rate
Goal 0.020
Current 0.013
Total SV Rate
Goal 0.100
Current 0.017
Total UER rate
Goal 0.040
Current 0.019
Leading Indicators
Booster Abradable Damage
Vane Corrosion
AGB axial link spherical bearing wear
Main Heat Exchanger inserts
VSV Inner Bushing Wear
Y
Y
Y
G
Y
Y
•HPT Blade: SB 72-115R2, 72-326
•TGB Ball Bearing: SB 72-0445
•Fan Frame Shroud Cracks: SB 72-0440R3
•Fuel Tube Wear: SB 73-0104
•AGB Bearing failures: SB 72-0368
•Aft Sump Leakage:
•Aft Scavenge Nipple Crack: Y
Hours: 25,215,271
Cycles: 13,186,383
Engines: 3,021
Aircraft: 1,418
Customers: 155
CFMI PROPRIETARY INFORMATION
Data through December 2003
• AEROMEXICO-AEROVIAS DE MEXICO S.A. (6)
• AIR ALGERIE (12)
• AIR BERLIN (31)
• AIR CHINA INTL CORP. (14)
• AIR EUROPA (19)
• ALASKA AIRLINES (33)
• ALOHA (11)
• AMERICAN AIRLINES (77)
• ARAMCO SERVICES (5)
• ATA AIRLINES (32)
• AZZURA AIR (4)
• BRAATHENS (9)
• BWIA INTERNATIONAL AIRWAYS LIMITED (7)
• CHINA AIRLINES (11)
• CHINA EASTERN AIRLINES (10)
• CHINA SOUTHERN AIRLINES (13)
• CHINA SOUTHWEST AIRLINES (12)
• CHINA YUNNAN AIRLINES (4)
• CONTINENTAL AIRLINES (129)
• COPA-PANAMENA DE AVIACION S.A. (16)
• DELTA AIR LINES (70)
• EASY JET (26)
• EL AL ISRAEL AIRLINES LTD. (6)
• EURALAIR (6)
• EUROCYPRIA AIRLINES (4)
• EXCEL AIRWAYS (7)
• FUTURA INTERNATIONAL (7)
• GERMANIA FLUGGESELLSCHAFT MBH (10)
• GOL TRANSPORTES AEREOS (21)
• HAINAN AIRLINES (15)
• HAPAG LLOYD FLUG (31)
• JET AIRWAYS PRIVATE LTD (27)
• KENYA AIRWAYS (4)
• KLM ROYAL DUTCH AIRLINES (17)
• KOREAN AIRLINES (25)
• LAUDA AIR (8)
• MAERSK AIR A/S (8)
• MALEV (4)
• OMAN AIR (5)
• PEGASUS AIRLINES (12)
• QANTAS (21)
• ROYAL AIR MAROC (12)
• RYANAIR (44)
• SAHARA INDIA AIRLINES (7)
• SCANDINAVIAN AIRLINES SYSTEM (50)
• SHANGHAI AIRLINES (11)
• SHENZHEN AIRLINES (18)
• SOUTH AFRICAN AIRWAYS (21)
• SOUTHWEST AIRLINES (146)
• STERLING EUROPEAN AIRLINES (8)
• SUN COUNTRY (4)
• SUNEXPRESS (10)
• TAROM (4)
• TRANSAVIA AIRLINES (22)
• TRAVEL SERVICE (4)
• TUNIS AIR (7)
• TURKISH AIRLINES INC. (27)
• U. S. NAVY (6)
• VIRGIN BLUE (40)
• WESTJET AIRLINES LTD. (26)
• XIAMEN AIRLINES (10)
• XINJIANG AIRLINES (4)
• 737-BBJ (75)
• OTHERS (69)
CFMI PROPRIETARY INFORMATION
Data through December 2003
Age Distribution - Hours
CFMI PROPRIETARY INFORMATION
Data through December 2003
Age Distribution - Cycles
CFMI PROPRIETARY INFORMATION
Data through December 2003
Fleet Leaders CFM56-7B Ratings
SAC W/O Shop Visit SAC W Shop Visit DAC W/O Shop Visit DAC W Shop Visit
B18 Rating
Fleet Leader in Hours 13337 10358
Fleet Leader in Cycles 5433 4209
B20 Rating
Fleet Leader in Hours 14887 15160 9530 11010
Fleet Leader in Cycles 11405 11099 7360 12000
B22 Rating
Fleet Leader in Hours 24519 20878 1105 5682
Fleet Leader in Cycles 12375 13941 3994 5033
B24 Rating
Fleet Leader in Hours 20945 19290 5175
Fleet Leader in Cycles 12809 11304 2529
B26 Rating
Fleet Leader in Hours 22026 21240 5319 10852
Fleet Leader in Cycles 11226 9314 9097 11040
B27 Rating
Fleet Leader in Hours 18600 20902
Fleet Leader in Cycles 7931 7728
CFMI PROPRIETARY INFORMATION
Data through December 2003
IFSD Rate
CFM56-7 IFSD Rate
0.000
0.010
0.020
0.030
0.040
0.050
0.060
0.070
0.080
0.090
199712
199803
199806
199809
199812
199903
199906
199909
199912
200003
200006
200009
200012
200103
200106
200109
200112
200203
200205
200208
200211
200302
200305
200308
200311
IFSD per 1K hours
120 Minute ETOPS Criteria
Basic 12 Month Rolling Average
Total 12 Month Rolling Average
180 Minute ETOPS Criteria
CFMI PROPRIETARY INFORMATION
Data through December 2003
IFSD Causes - Total Last 12 Months
Cause Quantity Corrective Action
No 4 brg 1 New outer race material introduced - SB 72-0352 Issued Oct. 17, 2002
AGB Brgs: 4 On-going investigation on AGB bearings; suspect abusive grinding and lack of
- line 3 (2event) burnoff checks during manufacturing process. SN working with supplier to
- line 4 (2 event) define population. SB 72-0368 issued for specific population of ln 4 brg NDT for
Hardness check
Aft Sump Oil Leak 4 Aft Sump cover O-ring replaced, Cracked Scavenge line nipple
Starter Failure (P08) 3 Turbine thrust bearing - three cases since E IS, P10 starter addresses stack-up
1 – Needle Beraing Failure
No 3 brg 2 Engine Test for Offset-Bearing Test Compete – Results Being Analyzed
Engine controls 1 EGT excedance caused by table pointer RAM corruption (7.B.O not installed)
HPT Blade Shank Failure 2 M10P01 HPT blade in production, all removed blades to have shank coating
stripped
Engine – LPT module damage 1 HMU identified as root cause
Flame out – Descent Idle 1 HMU identified as root cause
Data for total rate:
Maintenance 5 Hand cranking pad not installed - Oil loss, Oil tank not serviced prior to ferry Flt
Spinning Fuel Filter S/B Issued June 2002, Installation of MCD
Bird Strike 1 Under investigation – outer panel of one fan blade liberated, fuel supply tube
separated
-1
-1
+2
+1
+1
+1
+1
+1
CFMI PROPRIETARY INFORMATION
Data through December 2003
Aborted Takeoff Rate
C FM56-7 ATO R ate
0.000
0.005
0.010
0.015
0.020
0.025
0.030
0.035
0.040
ATO per 1000 departures.
Bas ic 12 m o Rolling
Total 12 m o Rolling
CFMI PROPRIETARY INFORMATION
Data through December 2003
Aborted Takeoff Causes - Last 12 months
Cause Quantity Corrective Action
Data for basic rate:
HMU - TBV 2 Corrective action introduced – feedback spring
Engine Control 1 No fault code reported
light
Data for total rate:
FOD/Bird strike 7 N/A
Misc A/C Indications 8 (2) Thrust Reverser, (2) MLG Brake indication, Door Prox, MLG
indication, Pitot Probe Blocked
Operation 5 3 occurrences of Pitot probe heat not turned on. EEC S/W
version 7.B.P (1Q04) to address timer in logic. Water Wash Proc.
Fuel Contamination 1 Contamination of the OSG system in the HMU
+1
-2
+2
CFMI PROPRIETARY INFORMATION
Data through December 2003
Shop Visit Rate
CFM56-7 Total Shop Visit Rate
0
0.01
0.02
0.03
0.04
0.05
0.06
0.07
0.08
1997 12
1998 04
1998 08
1998 12
1999 04
1999 08
1999 12
2000 04
2000 08
2000 12
2001 04
2001 08
2001 12
2002 04
2002 08
2002 12
2003 04
2003 08
2003 12
Shop Visit per 1K hours
CFMI PROPRIETARY INFORMATION
Data through December 2003
Shop Visit Top Causes - Total engine Last 12 months
Cause Quantity Corrective Action
HPT Blade
T/E cracks 35 SB 72-115 R1 issued to retire P05 blades at first shop visit. SB 72-326
recommends a 1000 cycle BSI interval (approx. 5 per month)
Shank Separation 2 M10P01 HPT blade in production, all removed blades to have shank
coating stripped
Fan Shroud Cracks 22 Fleet inspection SB 72-0440R4, issue Feb 04 (24% fallout), TIG repair
developed for piece part. -103 panel being removed. CFM Doubler
repair expected mid 2004.
FOD/Other 7 N/A
Fan Disk replacement 1 CESM 005 and S/B 72-253 issued. Testing complete and in-service
wear limits approved (0.010 inch). Limits to be issued 1Q03
No. 4 Bearing 2 New outer race material introduced - SB 72-0352 Issued Oct. 17, 2002
Aft Sump 8 7 cracked scavenge lines
1 aft sump cover o-rings – o-ring RR procedure added to AMM
Design/O-ring material change under review
No. 3 Bearing 7 Engine Test Complete – Results Being Analyzed
AGB hand cranking pad 3 Population defined. Imbalance in grinding tool root cause. Bearing
replacement at shop visit - SB 73-A0368 issued.
TGB Ball Bearing 2 Spalling initiating at micro cracks in outer race – Population defined as
305 brgs with abusive grinding – Field program being developed
SB 72-0445
Fan Blade Platform 2 Fan blade platform pin torque check SBs issued: 72-374 and
Liberations 72-386. SB revision to increase all torques – Sept 04
Combustor 4 2 – Combustor Distress : 2 Outer Cowl Missing Material
2
7
11
1
1
5
3
CFMI PROPRIETARY INFORMATION
Data through December 2003
Total Unscheduled Engine Removals
0.000
0.010
0.020
0.030
0.040
0.050
0.060
0.070
0.080
199712
199804
199808
199812
199904
199908
199912
200004
200008
200012
200104
200108
200112
200204
200208
200212
200304
200308
200312
UERs per 1k hours
CFMI PROPRIETARY INFORMATION
Data through December 2003
CFM56-7 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
12 Month Rolling Average
CFMI PROPRIETARY INFORMATION
Data through December 2003
Delay and Cancellation Top Causes
(Basic engine last 12 months)
Cause Quantity Corrective Action
HMU: MTBUR -- 13,000 hours
- TBV 68 EHSV product improvements incorp’d Feb 03
- FMV 31 Corrective action for 11 out of 12 failure modes defined
Rotor winding improvements Introduced Mar 03
- HPSOV 26 Field program progressing nicely
EEC 49 PSS modification SB 73-065. Improved ATP in place.
Program improvements being monitored – MTBUR 18,000 hrs
Starter 43 P09 rework SB 80-006 issued (new turbine seal Assy)
P10 - turbine stack improvements - SB 80-007 issued
Fuel Filter delta P switch 29 Potted switch improvement S/B 73-042
1 flight allowance added to DDPG MMEL
MTBUR at 70,000 hours
Ignition System 29 Ignition lead/exciter ... no anomalies
Power switching relay available for Aircraft incorp.
Soft time recommendation not universally incorp’d
Utilize improved EEC S/W troubleshooting capability - Fleet
Highlights published Feb 02

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CFM56-7 Scorecard Data through December 2003

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