Eliminate CFM56-7B27B1 HMU HPSOV Switch Failures at American Trans Air

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Six Sigma -- Define/Measure/Analyze/Improve/Control Phases GE Aircraft Engines
GE Proprietary Information GE Aircraft Engines
g GE Aircraft Engines
Six Sigma Project
Eliminate CFM56-7B27B1 HMU HPSOV
Switch Failures at American Trans Air
BPTS # 2002-11-022509
Amandio Morais
ATA Field Service Program Manager
November 2002
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Six Sigma -- Define/Measure/Analyze/Improve/Control Phases GE Aircraft Engines
GE Proprietary Information GE Aircraft Engines
g GE Aircraft Engines
Project Summary - Page 1
Area/Location: Indianapolis, IN Cluster ID:
Title: Eliminate HMU HPSOV Switch failures at ATA BPTS ID: 2002-11-022509
Who is the
customer?
American Trans Air
Why is this
important?
1) #1 Cause of Engine-Related Delays
2) Effecting ATA¡¦s Reliability Rate
What do I want to
improve?
1) Incorporate Latest HPSOV Switch Into HMU
2) Engine Reliability at ATA
How will I measure
the problem?
1) Monitor engine-related delays related to HMU HPSOV switch failures
2) Check status in event summary
Can I trust the
process output (Y)
data?
Yes
Timing: Start: 9/7/01 Complete: 11/19/02 Implement: 11/19/02
Leader Org.: GCFS
Sponsors: Sponsors: Rod Jarvis Process Owner: American Trans Air
Resources: Project Leader: Amandio Morais MBB/Mentor: Scott Kopczynski
Required for Project Approval Required for Project Closure Optional
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Six Sigma -- Define/Measure/Analyze/Improve/Control Phases GE Aircraft Engines
GE Proprietary Information GE Aircraft Engines
g GE Aircraft Engines Project Summary - page 2
Project Summary - Page 2
How good am I
today?
Z = 0.565949
How good do I need
to be?
Z = 6
Variation Source Summary
Vital X Impact on Average/Variation of your Y Improvement Plan
HMU HPSOV Switch Failures 100%
Incorporate S/B on-wing
Control Plan Summary
Vital X Control Plan to insure Improvement is Sustained
S/B Incorporation Monitor engine-related delays
Have I reached my
Goal?
Yes (no engine-related HMU HPSOV delays since April 13, 2002)
Required for Project Approval Required for Project Closure Optional
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Six Sigma -- Define/Measure/Analyze/Improve/Control Phases GE Aircraft Engines
GE Proprietary Information GE Aircraft Engines
g GE Aircraft Engines Project Summary - page 3
Action Plan - Complete if project has open actions
Open Action Items Person Responsible Est / Actual Completion Date
Functional Implementation Status (Excel spreadsheet - double click to open)
Group1 Group2 Group3 Group4 Group5
Engagement Status Committed Plan to Commit Plan to Commit Committed Committed
Committed
Plan to Commit
Does Not Support
Leveragable Project
Where can this project be immediately leveraged? How?
Comments / Lessons Learned
Cost/Benefit Profile (Excel spreadsheet - double click to open)
QX QX QX QX Total
Expenditures 61,986 $61,986.00
Savings
Indirect $0.00
Avoidance 106,260 $106,260.00
Total $168,246.00
Required for Project Approval Required for Project Closure Optional
5
Six Sigma -- Define/Measure/Analyze/Improve/Control Phases GE Aircraft Engines
GE Proprietary Information GE Aircraft Engines
g GE Aircraft Engines Define - Project Summary
Problem Statement:
¡E ATA has experienced several HMU
HPSOV switch failures in the fleet.
¡E #1 cause for engine-related delays
Defect(s) Definition:
¡E HMU HPSOV switch failure
Critical Metric Affected:
1) Customer Satisfaction Issue
2) At The Customer, For The Customer
Project
3) Effects Reliability metrics
Team:
Amandio Morais - Field Service PM
Jim Smith ¡V ATA Powerplant Manager
Jeremy Ubelhor - ATA Powerplant Engineer
Zach Bolt - CSM
CFM56-7 Product Team FSE¡¦s
Leadership:
BB: Scott Kopczynski
Sponsor(s): Rod Jarvis
Goal/Objective:
¡E Eliminate all future HMU HPSOV
switch failures
Issues / Concerns:
¡E Time involvement to incorporate S/B
into ATA¡¦s fleet
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Six Sigma -- Define/Measure/Analyze/Improve/Control Phases GE Aircraft Engines
GE Proprietary Information GE Aircraft Engines
g GE Aircraft Engines Measure ¡V Event Report Spreadsheet
71 888417 1/31/02 1904 918 N302 1 IND
SAGE Data
Scatter No No T49.5 Probe Removed P/N TC296-02
72 888441 2/26/02 1830 907 N303 2 PIE HMU HPSOV
Yes - 38
Minutes No None Not Applicable
73 888568 3/2/02 1300 599 N307 2 LAS HMU HPSOV
Yes - 19
Minutes No None Not Applicable
74 888742 3/3/02 610 293 N314 2 MDW HMU HPSOV
Yes - 41
Minutes No None Not Applicable
75 888470 1/31/02 1459 726 N304 2 MDW
Broken DMS
Detector No No DMS Detector
Removed S/N 6109-3
Installed S/N 6237-H
76 888843 3/7/02 3 1 N317 1 IND DMS No No None Not Applicable
77 888741 3/7/02 641 311 N314 1 DFW
Oil Filter Bypass
Light
Yes - 61
Minutes No
Oil Filter DP
Switch Not Available
78 888843 3/14/02 67 37 N317 1 DFW Control Light No Yes EEC
Removed S/N
LMDN7120; Installed
S/N LMDN6616
¡E All Field Events Are Tracked Via FSE¡¦s Spreadsheet
¡E Data is collected daily from ATA¡¦s America system (hard copy)
HMU HPSOV Failures
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Six Sigma -- Define/Measure/Analyze/Improve/Control Phases GE Aircraft Engines
GE Proprietary Information GE Aircraft Engines
g GE Aircraft Engines Measure ¡V Pareto Chart
HMU H PSO V
Co n t ro l Lig h t
O il Filte r B y pa s s L ig h t
Engin e No S ta rt Fa ile d To In c re a s e En gine Pow e r
A c o us tic a l Pa n e l Dama ge
DMS
Fa n B lad e Re p a ir
FO D
Fu e l Filte r B y pas s Ligh t
Fu el L eak age
No Eng ine V ib ra tio n In dic a t ion
O th e rs
14 13 7 4 2 1 1 1 1 1 1 1 2
29 27 14 8 4 2 2 2 2 2 2 2 4
29 55 69 78 82 84 86 88 90 92 94 96 100
0
1 0
2 0
3 0
4 0
5 0
0
2 0
4 0
6 0
8 0
1 0 0
De fe c t
C o unt
P e rce nt
C um %
Percent
Count
ATA E n g in e-Related Delay s S um m ary (s in ce Day 1 of O p eration )
¡E First airplane into revenue service in June 24, 2001
¡E Total of 49 engine-related delays (FOD, airframe systems not included)
¡E Total cost of HMU HPSOV delays $61,986 (24%); Total cost of ATA 73 delays $254,475
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Six Sigma -- Define/Measure/Analyze/Improve/Control Phases GE Aircraft Engines
GE Proprietary Information GE Aircraft Engines
g GE Aircraft Engines Measure ¡V Delay Cost Data
¡E Cost of delays data was retrieved from ATA¡¦s Reliability Dept.
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Six Sigma -- Define/Measure/Analyze/Improve/Control Phases GE Aircraft Engines
GE Proprietary Information GE Aircraft Engines
g GE Aircraft Engines Analyze ¡V Z Score Before Fix
Description: Classify units as defective or non defective, traditionally uses the Binomial distribution formula listed below.
Glossary: Mean Average
Sigma Standard Deviation
p(d) Probability of Defects
Enter Numbers Below
Formulas:
Enter Numbers Above
p(d) = 1-FTY "=>" 0.285714
Z = 0.565949
FTY= 0.714286
14
49
p(d)= 0.285714
No. of Bad Units
Total No. of Units
p(d)= "=>"
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Six Sigma -- Define/Measure/Analyze/Improve/Control Phases GE Aircraft Engines
GE Proprietary Information GE Aircraft Engines
g GE Aircraft Engines
C FM I P rop rie ta ry In fo rm a tion
A TA C FM 5 6 -7 T e c h Re v iew M a rc h 2 0 0 2
H M U /H P SO V Sw itc h
B a c kg ro u n d
¡E H P SO V sw itc h le a d in g c a u s e o f H M U rem o v a ls a n d D & C ¡¦s
- O n -win g s witc h re p la c em e n t in p la c e fo r c o n ta inm e n t
- C om m itte d to o p e ra to rs to in tro fix b y 4Q ¡¦0 1
¡E J o in t C FM I/B o e in g /H o n e yw e ll te am h a v e s tu d ie d d e s ig n
a lte rn a tiv e s to in c re a s e re lia b ility to a c c e p tab le le v e l
- S P S T sw itc h with A /C m o d ific a tio n s e le c te d
¡E S P S T sw itc h e lim in a te s p re d om in a n t fa ilu re m o d e v ia ru n
re e d d e le tio n
- ¡§L a tc h o n s h u td own ¡¨ c o n s titu te s 9 0% o f rem o v a ls
- O th e r switc h c h a ra c te ris tic s m a in ta in e d a s ris k a b a teme n t
¡E N ew HM U P /N (P 0 8 ) c re a te s o n e -w a y e n g in e /a irc ra ft
in te rc h a n g e a b ility
- S P S T sw itc h re q u ire s re v is e d P 5 -2 c a rd ; re v is e d c a rd
c om p a tib le with c u rre n t o r p ro p o s e d switc h
Q u a lific atio n T e s tin g S tatu s
¡E C om p re h e n s iv e te s t p ro g ram c om p le te d th a t a d d re s s e d
p o te n t ia l f ie ld fa ilu re m o d e s
¡E E n d u ra n c e te s tin g fo r b o th ru n a n d s h u td ow n m o d e s
¡E B o u n c e te s tin g c om p le te d a t 1 .2 5 X e n g in e ¡§ g ¡¨ le v e ls w ith
B o e in g P 5 -2 c a rd
- N o ¡§flic k e rin g ¡¨ lig h t o b s e rv e d .
¡E P ro to ty p e sw itc h in s ta lle d o n d e v e lo pm e n t e n g in e fo r
e n d u ra n c e c y c lin g
- 4 0 0 0 c yc le e n d u ra n c e te s t with p e rio d ic switc h m o n ito rin g
s u c c e s s fu lly c om p le te d
NC
NO
Arm
N C
N O
A rm
P ro p o s e d Sw itc h C o n fig u ra tio n
C u rre n t D o u b le T h row
P ro p o s e d S in g le T h row
R u n co n ta c t e lim in a te d
In tro d u c tio n L o gis tic s
¡E C FM I/B o e in g /H o n e yw e ll la u n c h te am fo rm e d . C h a r te r:
In s u re a ll d o c um e n ta tio n , h a rdwa re , s e rv ic e b u lle tin s a re
a v a ila b le fo r sm o o th in tro d u c tio n o f th e re v is e d H P SO V
in d ic a tio n s ys tem in to p ro d u c tio n a n d in -s e rv ic e a irc ra ft
¡E In tro d u c tio n p o in ts c h o s e n
- P 5 -2 C irc u it c a rd :
- A /C lin e N o 1 0 4 7 (c omp le te )
- S P S T S w itc h (P 0 8 H MU ):
- A /C lin e N o 1 0 7 7 -- F e b . ¡¥0 2 A irc ra ft d e liv e ry
C o n tro ls a n d A c c e s s o rie s
Analyze ¡V HMU HPSOV Overview
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Six Sigma -- Define/Measure/Analyze/Improve/Control Phases GE Aircraft Engines
GE Proprietary Information GE Aircraft Engines
g GE Aircraft Engines Analyze ¡V HMU HPSOV Overview
CFM56-7 All Operators Conference - April 17 - 19, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 6
Current SPDT Switch
N S
NC
NO
Arm
Shutdown Position
HPSOV Switch
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Six Sigma -- Define/Measure/Analyze/Improve/Control Phases GE Aircraft Engines
GE Proprietary Information GE Aircraft Engines
g GE Aircraft Engines
CFM56-7 All Operators Conference - April 17 - 19, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 9
SPST Switch Concept
NC
NO
Arm
N S
Shutdown Position
HPSOV Switch
Analyze ¡V HMU HPSOV Overview
13
Six Sigma -- Define/Measure/Analyze/Improve/Control Phases GE Aircraft Engines
GE Proprietary Information GE Aircraft Engines
g GE Aircraft Engines Improvement ¡V Incorporate New S/B
„h HPSOV switch changed to single-pole, single throw (SPST) switch to eliminate ¡§latch on
shutdown¡¨ failure mode by removing ¡§run¡¨ reed
¡V Switch faults have historically driven D&C¡¦s and HMU removals
¡V New switch introduced to production in February, 2002; HMU P/N rolled to ¡§P08¡¨
¡V No switch faults on HMU¡¦s shipped from factory as P08¡¦s
„h P08 HMU creates one-way engine/aircraft interchangeability limitations
¡V SPST switch requires revised P5-2 cockpit card; revised card compatible with
current or proposed switch
„h P5-2 cards and SPST switches field retrofit program on-going
¡V SB 73-0067R1¡K.Program communicated via All Ops, Fleet Highlites messages
¡V Cards and switches can be ordered via ¡§No charge purchase order¡¨
¡V On-wing switch change will also be provided ¡§free of charge¡¨ by Honeywell field
service
„h HPSOV switch improvement program in place
New
single pole switch in P08 HMU
Capable
of on-wing replacement
- Field program Service Bulletins issued
- Boeing SB 737-28-1179
- CFM SB 73-067
- Overall going well, some recent issues
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Six Sigma -- Define/Measure/Analyze/Improve/Control Phases GE Aircraft Engines
GE Proprietary Information GE Aircraft Engines
g GE Aircraft Engines
Symptom: Improper indication of cockpit P5-2 light
Fault Code: None
Average Monthly Removals for this Issue: 3.2
Root cause:
„h Rev K SPDT switch not performing
„h Fixes to improve the SPDT design did not improve
primary switch failure mode.
¡V Switch sticking on shutdown
Long Term Resolution:
„h Replace/modify P5 panel in the cockpit
„h Replace SPDT switch with SPST switch on-wing
ATA first to complete the retrofit - Thank you
Control ¡V Honeywell Feedback
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Six Sigma -- Define/Measure/Analyze/Improve/Control Phases GE Aircraft Engines
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„h HMU HPSOV Failures Were The #1 Cause For Engine
Related Delays at American Trans Air
„h Boeing S/B 737-28-1179 & CFM S/B 73-067 Were Applied
To All Engines In The Fleet
„h Once The S/B¡¦s Were Incorporated Into The Fleet, All HMU
HPSOV Failures Were Eliminated
„h ATA¡¦s cost summary: $61,986 in delays
„h ATA¡¦s cost avoidance: $61,986 / 7 months = $8,855/month
x 12 months = $106,260 (could be more if actual airplane
delivery is taken into consideration)
„h First delay occurred on 9/17/01, and the last delay
occurred on 4/13/02
„h Majority of modifications occurred in April/May/June
timeframe
Control ¡V Summary

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Eliminate CFM56-7B27B1 HMU HPSOV Switch Failures at American Trans Air