Scorecard/Fleet Experience

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CFMI PROPRIETARY INFORMATION
Data through December 2001
Scorecard/Fleet Experience
CFMI PROPRIETARY INFORMATION
Data through December 2001
ATO Rate
Goal 0.010
Current rate 0.012
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 and Flight Line Issues
Current month
Previous month
Fleet Experience
Hours: 10,741,308
Cycles: 5,582,418
Engines: 2,137
Aircraft 1,004
Issue Status
• HPSOV Switch
• Oil/Fuel Delta P Switch
• Fan Disk
• Platform Aft Pin
• LPT Blade (DAC)
• N1 Vibration - Flight Line
• EEC
• HPT Blades
• HMU - FMV
• AGB - N2 hand cranking pad gear
• MSV position faults
• N2 Tone - Flight Line
CFM56-7 Scorecard
Total IFSD Rate
Goal 0.003
Current 0.003
Total ATO Rate
Goal 0.020
Current 0.028
Total SV Rate
Goal 0.100
Current 0.024
Total UER rate
Goal 0.040
Current 0.015
Issue Leading Indicators
Booster Spool FWD Flange Wear
VBV Guide Pad Delamination
Booster Abradable Corrosion
Fan Platform Life
LPT2 Nozzle Cracking
R
G
G
Y
Y
R
G
G
G
Y
Y
R
CFMI PROPRIETARY INFORMATION
Data through December 2001
• Air Algerie (7)
• Air Berlin (24)
• Air China (7)
• Air Europa (12)
• Air Pacific (3)
• Alaska (21)
• Aloha (5)
• Amiri Flight (4)
• American (76)
• American Transair (14)
• ARAMCO (5)
• Axon (2)
• Azzura (2)
• Braathens (11)
• Britannia (5)
• BWIA (6)
• City Bird (3)
• Continental (116)
• COPA (8)
• China Airlines (9)
• China Southwest (7)
• China Wuhan (2)
• China Yunnan (3)
• Delta (61)
• Easyjet (9)
• El Al (5)
• Euralair (6)
• Futura (7)
• Germania (10)
• GOL Transportes (7)
• Hainan (7)
• Hamburg Intl (3)
• Hapag-Lloyd (27)
• Helios Airways (2)
• Jet Airways (19)
• Kibris (3)
• KLM (17)
• Korean (15)
• Lauda (6)
• LAPA (8)
• Maersk (7)
• Mandarin (3)
• Midway (10)
• North American (2)
• Novair (3)
• Pegasus (11)
• RAM (9)
• Ryanair (17)
• Sahara (3)
• SAS (53)
• Shanghai (6)
• Shenzen (6)
• South African (14)
• Southwest (115)
• Sterling (6)
• Suncountry (6)
• Sunexpress (6)
• TAROM (3)
• Transaero (2)
• Transavia (14)
• THY (25)
• Tunis (8)
• US Navy (4)
• Varig (7)
• Virgin Blue (6)
• Westjet (4)
• Xiamen (6)
• Xinjiang (5)
• BBJ (62)
• Others (23)
737-6/-7/-8/-900 Customers and Fleet Size
CFMI PROPRIETARY INFORMATION
Data through December 2001
Age Distribution - Hours
0
50
100
150
200
250
0
50
100
150
200
250
Number of Engines
ETSN Distribution
CFMI PROPRIETARY INFORMATION
Data through December 2001
Age Distribution - Cycles
0
50
100
150
200
250
300
350
0
50
100
150
200
250
300
350
Number of Engines
ECSN Distribution
CFMI PROPRIETARY INFORMATION
Data through December 2001
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
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 2001
IFSD Causes - Total Last 12 Months
Cause Quantity Corrective Action
Oil Temperature Sensor 4 Redesign insert incorp’d in production (88T-481)
June 01, Field containment issued SB 72-A336
TEO system logic revised in - SB 72-064 (S/W
7.B.M1) to preclude invalid oil pressure indication
Fleet plan defined: Rework or replace at shop visit
No 3 brg 2 No active program (3 failures in 10 million Flt hours)
Ps3 Line 1 Safety wire introduced to production engines -
June 01, and SB 72-333 introduces lock wire at
shop visit. Safety wire provisions introduced into
EEC SB 73-062R1
No 4 brg Suspect 1 New outer race material 1st Qtr 02
Radial Drive Shaft 1 Under Investigation
Separation
Starter Failure (P08) 1 Under Investigation - Turbine bearing failure
Engine Controls 1 EEC PSS flex failure CH B (CFMSB 73-0065) along with a VSV
out of range fault on CH B of the HMU
Engine controls 1 HMU under investigation - Eng. Stuck at 85% N1
Data for total rate:
Lightening strike 1 Under investigation - DFDR and EEC received
Maintenance error 1 IDG not properly secured after IDG replacement
Oil filter bypass 1 Chips in oil filter … previous starter failure - AMM improvements
FOD - Bird Strike 1 No Active Program
CFMI PROPRIETARY INFORMATION
Data through December 2001
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
ATOper 1000 departures.
Basic 12 mo Rolling
Total 12 mo Rolling
CFMI PROPRIETARY INFORMATION
Data Aborted Takeoff Causes - Last 12 monththsrough December 2001
Cause Quantity Corrective Action
Data for basic rate:
MSV position fault 8 Cell 58 testing continues. Solenoid driver output not enough
to activate solenoid under certain conditions. Containment
and improvement options being defined
Eng Control light 4 Fleet highlights published, maintenance hand book
(No faults recorded) developed to aid mtc im FMC-CDU interrogation
TBV Position fault 3 Under Investigation
Oil/fuel Filter DP 2 New FFDP design P/N QA7995 field penetration
progressing .. further mechanical switch improvements being
evaluated
HMU - FMV 2 Product improvements for 12 of 13 known issues
Evaluating revising EEC SW fault logic from 2 to 4
degrees to alleviate position & signal disagree faults
HPT Blade 1 HPT blade Airfoil separation - Telemetry Test completed -
Evaluating the results
Eng Control light 1 HPTACC TC fault - 7.B.M1 SB 73-064 Issued
Fuel Pump 1 Failure to attain T/O power - Fuel pump fault confirmed
HMU - No response to 1 Manufacturing defect in HMU’s shutoff shuttle valve
thrust lever input
Data for total rate:
Bird strike 4 N/A
Operation 2 N/A
Fumes in cabin - Mtnc 2 N/A
HPC Blade Lock liberation 1 Assembly error: preventive actions in place
A/C system APU Fumes 1 N/A
CTAI Valve 1 Ref regulator improvements in work - 2nd qtr 2002
CFMI PROPRIETARY INFORMATION
Data through December 2001
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
199712
199803
199806
199809
199812
199903
199906
199909
199912
200003
200006
200009
200012
200103
200106
200109
200112
Shop Visit per 1K hours
12 Month Rolling Average
CFMI PROPRIETARY INFORMATION
Data Shop Visit Causes - Total engine Last 12 montthhrsough December 2001
Cause Quantity Corrective Action
LPT Blade 42 DAC unique. Control actions in place. New blade 2Qtr 02
Proactive No 4 brg removal 14 Bearings from suspect lot of 47
Maintenance 9 N/A
FOD/Other 6 N/A
HPT Blade Evaluation 6 Sampling program to evaluate HPT blade shank cracks
Fan Disk replacement 5 CESM 005 and S/B 72-253 issued, New AMM limits issued
TEO sensor 4 Redesign inserts for additional robustness. TEO system logic revised in S/W 7.B.M1 - SB 72-064 to
preclude invalid oil pressure indication. Field containment for housing issued 72-A336
VBV Pad disbondment 3 Bonding process improvement incorp’d into production. EEC software improvements 2 Qtr 02
No. 3 Bearing 2 No active program
No. 4 Bearing 2 MCD Inspection - SB 72-180, New outer race material 1st Qtr 02
Combustor distress 2 Secondary swirler material loss - Under investigation
AGB hand cranking pad 2 In investigation
brg
HPT Blade separation 1 In-investigation, telemetry test scheduled Oct 2001
Core vibration 1 Top case core balance procedure developed.. Rotor stack improvements
incorp’d into production.
Oil Leak 1 Oil leak into fan disk and booster - Assy error
Metal in HPT 1 HPT air manifold spalsh plate --- CFM56-7 S/B 72-167
Air manifold
HPC stg 4 blade lock 1 Assembly error. Assembly planning to require set screw drop measurement.
separation
Fan abradable shroud 1 Attributed to quality issue - audit & corrective actions complete
dsibondment
Fan Blade Platform 1 Fan blade platform pin undertorqued
No 1 brg 1 Under Investigation
CFMI PROPRIETARY INFORMATION
Data through December 2001
Total Unscheduled Engine Removals
CFM56-7B Unscheduled Engine Removals
0.000
0.010
0.020
0.030
0.040
0.050
0.060
0.070
0.080
199712
199803
199806
199809
199812
199903
199906
199909
199912
200003
200006
200009
200012
200103
200106
200109
200112
UERs per 1k hours
CFMI PROPRIETARY INFORMATION
Data through December 2001
CFM56-7 Dispatch Reliability
99.700
99.750
99.800
99.850
99.900
99.950
100.000
199712
199803
199806
199809
199812
199903
199906
199909
199912
200003
200006
200009
200012
200103
200106
200109
200112
Successful Departures
12 Month Rolling Average
CFMI PROPRIETARY INFORMATION
Data Delay and Cancellation Top Causesthrough December 2001
(basic engine last 12 months)
Cause Quantity Corrective Action
HMU:
- FMV 42 Under investigation
- HPSOV 45 SB 73-067 to issue Feb 02 - Introduces SPST switch
Ignition System 40 Ignition lead/exciter ... no anomalies
Power switching relay available for Aircraft incorp.
Soft time recommendation not acknowledged
Utilize improved EEC S/W troubleshooting capability
Fuel delta pressure switch 30 Potted switch improvement S/B 73-042
1 flight allowance added to DDPG MMEL
PALL offering discount on switch upgrade
Starter 30 50 % oil leaks and 50 % mechanical failures
EEC 21 PSS modification SB 73-065. Improved ATP in place.
Program improvements being monitored
Oil delta P switch 20 Under Investigation
N1 Vibration 19 Vibration Maint. Action published - CESM 007
issued
Engine Control light 13 Under Investigation - Need airline FDR data
(No Fault Codes)
HPTACC Valve 10 Improved LVDT S/B 75-002. TCC thermocouple
input eliminated in EEC S/W 7.B.M1 - SB 73-064
CFMI PROPRIETARY INFORMATION
Data through December 2001
CFM56-7B Revenue Service Status
Entry into service December 1997
Operators/aircraft in service 115/1004
Cumulative engine hours/cycles 10,741,308/
5,582,418
Daily utilization hours/cycles 9.5/4.9
Average flight leg 1.92
High time and cycle engines: hours/cycles 16,326 / 10,324
Total SVR (per 1,000 EFH) .024
Total IFSD rate (per 1,000 EFH) .003
Dispatch reliability 99.96
Meeting or Exceeding Reliability Goals

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CFM56-7B TRAINING MANUAL ENGINE FAN TRIM BALANCE

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Scorecard/Fleet Experience