In-Service Scorecard Through August 2004

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CFM PROPRIETARY INFORMATION
In-Service Scorecard
Through August 2004
Bill Benham
CFM56-3/-7 Model Leader
CFM56 Product Support Engineering
CFM PROPRIETARY INFORMATION
Dispatch Reliability
Goal 99.95
Current 99.95
Fleet Statistics
• 12 Month Rolling Average Previous Month Current Month
CFM56-7 Scorecard
Total IFSD Rate
Goal 0.006
Current 0.002
Total ATO Rate
Goal 0.020
Current 0.011
Total SV Rate
Goal 0.100
Current 0.018
Total UER rate
Goal 0.040
Current 0.018
Experience
Hours: 31,485,174
Cycles: 16,387,586
Engines: 3,308
Aircraft: 1,560
Operators: 145
In-Service Issues
Issue Status
Leading Indicators
• Fuel Nozzle Distress • HPT Blade: SB 72-115R2, 72-326
• Fan Frame Shroud Cracks: SB 72-0440R4 Mar-04
SB 72-0495R2 Oct-04
• Aft Scavenge Nipple Crack: All Reps Wire Jan –04
• VSV Inner Bushing Wear SB 72-0515 Oct- 04
• HMU Leaks (FS o-ring) Viton – Prod Oct-04
Y
Y
G
G
G
CFM PROPRIETARY INFORMATION
64 737 New Gen Operators With at Least 4 Airplanes:
* AEROMEXICO-AEROVIAS DE MEXICO S.A. (12) * KENYA AIRWAYS (4)
* AIR ALGERIE (12) * KLM ROYAL DUTCH AIRLINES (18)
* AIR BERLIN (33) * KOREAN AIRLINES (28)
* AIR CHINA INTL CORP. (16) * LAUDA AIR (8)
* AIR EUROPA (17) * MAERSK AIR A/S (9)
* AIR HORIZONS (6) * MALEV (12)
* AIRTRAN AIRWAYS INC (5) * MIAMI AIR INTERNATONAL (6)
* ALASKA AIRLINES (34) * NEOS (4)
* ALOHA (13) * OMAN AIR (5)
* AMERICAN AIRLINES (77) * PEGASUS AIRLINES (11)
* ARAMCO SERVICES (5) * QANTAS (23)
* ATA AIRLINES (33) * ROYAL AIR MAROC (12)
* BRAATHENS (9) * RYANAIR (57)
* BWIA INTERNATIONAL AIRWAYS LIMITED (7) * SAHARA AIRLINES LIMITED - INDIA (7)
* CHINA AIRLINES (11) * SCANDINAVIAN AIRLINES SYSTEM (50)
* CHINA EASTERN AIRLINES (11) * SHANGHAI AIRLINES (14)
* CHINA SOUTHERN AIRLINES (18) * SHENZHEN AIRLINES (18)
* CHINA SOUTHWEST AIRLINES (12) * SOUTH AFRICAN AIRWAYS (21)
* CHINA YUNNAN AIRLINES (4) * SOUTHWEST AIRLINES (181)
* CONTINENTAL AIRLINES (138) * STERLING EUROPEAN AIRLINES (11)
* COPA-PANAMENA DE AVIACION S.A. (18) * SUN COUNTRY (4)
* DELTA AIR LINES (71) * SUNEXPRESS (11)
* EASY JET (31) * TRANSAVIA AIRLINES (25)
* EL AL ISRAEL AIRLINES LTD. (6) * TRAVEL SERVICE (5)
* ETHIOPIAN AIRLINES CORP (4) * TUNIS AIR (7)
* EUROCYPRIA AIRLINES (4) * TURKISH AIRLINES INC. (28)
* EXCEL AIRWAYS (6) * U. S. NAVY (7)
* FUTURA INTERNATIONAL (10) * VIRGIN BLUE (46)
* GERMANIA FLUGGESELLSCHAFT MBH (10) * WESTJET AIRLINES LTD. (35)
* GOL TRANSPORTES AEREOS (22) * XIAMEN AIRLINES (10)
* HAINAN AIRLINES (22) * XINJIANG AIRLINES (4)
* HAPAG LLOYD FLUG (30) * OTHER NEW-GEN OPERATORS (94)
* JET AIRWAYS PRIVATE LTD (27)
CFM PROPRIETARY INFORMATION
Age Distribution by Hours
CFM PROPRIETARY INFORMATION
Age Distribution by Cycles
CFM PROPRIETARY INFORMATION
CFM56-7B Fleet Leaders
CFM PROPRIETARY INFORMATION
In Flight Shut Down 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
199802
199805
199808
199811
199902
199905
199908
199911
200002
200005
200008
200011
200102
200105
200108
200111
200202
200204
200207
200210
200301
200304
200307
200310
200401
200404
200407
IFSD per 1K hours
120 Minute ETOPS Threshold
Basic 12 Month Rolling Average
Total 12 Month Rolling Average
180 Minute ETOPS Threshold
CFM Goal (0.006)
0.001
0.002
CFM PROPRIETARY INFORMATION
IFSD Causes - Total Last 12 Months
Cause Quantity Corrective Action
No 4 bearing 1 New outer race material introduced - SB 72-0352 Issued Oct. 17, 2002
AGB Bearings: 1 On-going investigation on AGB bearings; suspect abusive grinding and lack of
- line 3 (1event) burn off checks during manufacturing process.
SB 72-0368 issued for specific population of line 3 bearing NDT for
Hardness check
Aft Sump Oil Leak 2 Cracked Scavenge line nipple All reps Jan-04
Starter Failure (P08) 1 1 – Needle Bearing Failure
No 3 bearing 1 Engine Test for Offset-Bearing – New part number to identify new offset
HPT Blade Shank Failure 1 M10P01 HPT blade in production, all removed blades to have shank coating
stripped
MFP-to-AGB seal 1 Oil Leak - Seal Replaced
HMU 1 Rollback – uncommanded fuel flow reduction – investigation
Main Fuel Pump 1 Inner stage failure (no impeller rotation)
Data For Total:
Maintenance 3 Oil loss (MCD), Spinning Fuel Filter, Hand Cranking Pad N/I
Bird Strike 2 Fan Blade Damage
Aircraft System 1 Spar Valve.
Operation 2 2 – Shutdown due to “Fuel Imbalance.” Procedures not followed
1
1
1
CFM PROPRIETARY INFORMATION
Aborted Takeoff Rate
CFM56-7 ATO Rate
0.000
0.005
0.010
0.015
0.020
0.025
0.030
0.035
0.040
199802
199805
199808
199811
199902
199905
199908
199911
200002
200005
200008
200011
200102
200105
200108
200111
200202
200205
200208
200211
200302
200305
200308
200311
200402
200405
200408
ATO per 1000 Departures
Basic 12 Month Rolling Average
Total 12 Month Rolling Average
CFM Goal
CFM PROPRIETARY INFORMATION
Aborted Takeoff Causes - Last 12 months
Cause Quantity Corrective Action
Data for basic rate:
HMU - TBV 2 Corrective action introduced – EHSV feedback spring
HMU – FMV 1 FMV Control Current Out Of Range
HMU – Fuel Flow Decrease 1 DFDR data shows fuel flow decreasing when EEC is opening FMV
under Investigation
FFDP 1 Fuel Filter Impending Bypass during T/O.
Data for total rate:
FOD/Bird strike 12 1 – HPC damage to stage 1-8 : others N/A
Misc. A/C Indications 5 (1) Thrust Reverser, (2) MLG Brake indication, Door Prox, MLG
indication, Pitot Probe Blocked
Operation 6 2 occurrences of Pitot probe heat not turned on. EEC S/W
version 7.B.P (Jan 30, 2004) to address timer in logic.
(2) No Cause – (1) Master caution (1) N1 split false alarm
Fuel Contamination 1 Contamination of the OSG system in the HMU
Smell in Cabin – Water Wash 2 Dry out procedures not being followed…
Maintenance 1 Fuel Tube Not Properly Installed
1
1
1
1
1
CFM PROPRIETARY INFORMATION
Shop Visit Rate
CFM56-7 Total Shop Visit Rate
0
0.02
0.04
0.06
0.08
0.1
0.12
199712
199803
199806
199809
199812
199903
199906
199909
199912
200003
200006
200009
200012
200103
200106
200109
200112
200203
200206
200209
200212
200303
200306
200309
200312
200403
200406
Shop Visit per 1K hours
CFM Goal
CFM PROPRIETARY INFORMATION
Shop Visit Top Causes - Last 12 months
Cause Quantity Corrective Action
HPT Blade
T/E cracks 63 SB 72-115 R1 issued to retire P05 blades at first shop visit. SB 72-326
recommends a 1000 cycle BSI interval
Shank Separation 1 M10P01 HPT blade in production, all removed blades to have shank
coating stripped
Fan Shroud Cracks 17 Fleet inspection SB 72-0440R4, issue Feb 04 (24% fallout), TIG repair
developed for piece part. -103 panel being removed. CFM Doubler
repair submitted for FAR25 Sept 2004.
FOD/Bird strike 4 N/A
Fan Disk replacement 6 CESM 005 and S/B 72-253 issued. In-service wear limits approved
(0.011 inch). Limits issued.
No. 4 Bearing 1 New outer race material introduced - SB 72-0352 Issued Oct. 17, 2002
Aft Sump 15 9 cracked scavenge lines
5 aft sump cover o-rings – o-ring RR procedure added to AMM
Design/O-ring material change under review – All Reps Wire Jan 2004
No. 3 Bearing 4 Engine Test Complete – New part number to identify new offset
2 Precautionary removals
Fan Blade Platform 1 Fan blade platform pin torque check SBs issued: 72-374 and
Liberations 72-386. SB revision to increase all torques – Sept 04
Combustor 6 1 – Combustor Distress : 3 Outer Cowl Missing Material :1 OC Wire
1 – Cracked
HPC Blade Damage 7 Multiple stages – 2 caused engine stall
5
1
2
3
1
1
1
CFM PROPRIETARY INFORMATION
Total Unscheduled Engine Removals
CFM56-7 Unscheduled Engine Removals
0.000
0.010
0.020
0.030
0.040
0.050
0.060
0.070
0.080
199801
199804
199807
199810
199901
199904
199907
199910
200001
200004
200007
200010
200101
200104
200107
200110
200201
200204
200207
200210
200301
200304
200307
200310
200401
200404
200407
UERs per 1k hours
CFM Goal
CFM PROPRIETARY INFORMATION
CFM56-7 Total 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
200404
200408
%Successful Departures
CFM Goal
Total Dispatch Reliability
CFM PROPRIETARY INFORMATION
D&C Top Causes (Basic engine last 12 months)
Cause Quantity Corrective Action
HMU (178): Software version 7BQ to address TBV and FMV
- TBV 98 TBV EHSV product improvements incorporated MAR-03
- FMV 69 Corrective action for 12 out of 13 failure modes defined
Rotor winding improvements Introduced MAR-03
- HPSOV 11 Field program progressing nicely
Engine Control Light 14 Engine Control Light – No fault code reported
EEC 63 PSS modification SB 73-065. Improved ATP in place.
Program improvements being monitored
– Individual Pressure transducers failing
Starter 62 P09 rework SB 80-006 issued (new turbine seal
assembly) P10 - turbine stack improvements - SB 80-007
issued
Fuel Filter Delta-P 42 Potted switch improvement S/B 73-042
1 flight allowance added to DDPG MMEL
Ignition System 25 Ignition lead/exciter ... no anomalies
Power switching relay available for Aircraft
incorporation. Soft time recommendation not
universally incorporated. Utilize improved EEC S/W
troubleshooting capability - Fleet Highlights published
Feb 2002 – WTT Investigation Feb 2004
FOD and Bird Strike 70 Nothing specific to address – Evidenced during walk around
Fuel Leaks 86 11-VSV; 8-HPTACC; 7-TBV; 31-MFP; 29-HMU
3
10
1
2
20
16
9

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In-Service Scorecard Through August 2004