CFM56 Project Overview

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CFM Proprietary Information 2
CFM56 Project Department Team
T. Shuttleworth, Administrative Associate
R. McAfee
M. Schwartz
J.A. Agnew
W.H. Benham
P. J. Busken
B.P. Davey
P. G. Gruber
R. Goodall
P.C. Kolbe
E.B. Martin
T. McClary
A. P. Mihalchik
J. Milam
R. L. Nebuda
B. Quinn
R. Smith
M. Wandersee
CFM56
Project General Manager
W. S. Clapper
CFM56
Project General Manager
W. S. Clapper
CFM56-5
Program
General Manager
K.J. Foley
CFM56-5
Program
General Manager
K.J. Foley
CFM56-2/-3/-7
Program
General Manager
R. W. Adams
CFM56-2/-3/-7
Program
General Manager
R. W. Adams
CFMI e-Business and
Product Support Integration
Director
S. Pawlikowski
CFMI e-Business and
Product Support Integration
Director
S. Pawlikowski
CFM56
Product Support
Engineering Manager
D. N. Poli
CFM56
Product Support
Engineering Manager
D. N. Poli
CFM56
Manufacturing
Programs Manager
R.W. Adams
CFM56
Manufacturing
Programs Manager
R.W. Adams
CFM56 Upgrades
Program Leader
L.J. Baran
CFM56 Upgrades
Program Leader
L.J. Baran
CFM56
Project
Master Black Belt
S. O’Day
CFM56
Project
Master Black Belt
S. O’Day
CFM Proprietary Information 3
CFM56 in ‘02: The World’s Best-Selling
Engines
Greatest aviation partnership in the world
– 5,000 CFM-powered aircraft
– 200,000 passengers every day
– ~600 orders in ‘02 / 55% orders share
First flight on A318
First flight of -5C/P on A340 testbed
CFM56-3 Time on Wing upgrade
– Entered service Oct. ‘02 at Southwest
Excellent progress on Project TECH56
CFM Proprietary Information 4
CFM56 in ‘03: New Platforms, New
Upgrades
Certify / launch upgrades
- CFM56-5B acoustic upgrade
- CFM56-5C/P for A340
Define technology insertion for -5B & -7
Deliver reliable new products
– CFM56-5B on A318 … Frontier, July ‘03
– CFM56-5C/P on A340-300 … Swiss, Oct. ‘03
Execute 737-900X strategy with Boeing
Manage fleet issues
…HPT blade durability , -5C reverser
CFM Proprietary Information 5
CFM56-7
1997
CFM56-5B/P
1996
Generation
4
• Wide chord fan blades
• Powder metallurgy
• Low emissions
• 3-D aero
2000
Thrust (1000 pounds)
1970
•High bypass
•Hydromechanical
controls
Generation
1
• Static composites
• Containment tech
• Noise reduction
Generation
2
CFM56-2
CFM56-3
1984
25
30
35
CFM56-5C
1993
CFM56-5A
1988
•FADEC
•Active clearance
•Advanced turbine materials
and coatings
Generation
3
CFM56-5C/P
2002
CFM56 Engine Family:
How the Best Keeps Getting Better
B737-300
B737-400
B737-500
A319
A320
A340 A318
A319
A320
A321
B737-600
B737-700
B737-800
B737-900
DC-8
Military
Incorporating Advanced, Proven Technology
CFM Proprietary Information 6
Animation
CFM56-3 Core Upgrade Program
CFM56: Product Upgrades
 3D aero in compressor and new HPT hardware
 Benefits:
– Longer on-wing life
– Lower operating cost
– Lower maintenance costs
– Enhanced durability
 13 engines delivered to Southwest Airlines in 2002
– 7 engines are in-service flying on 6 aircraft
Southwest Airlines is already experiencing the
benefits
CFM Proprietary Information 7
CFM56: Product Upgrades
 Objective - Meet Stage 4 (Stage 3 – 10.0 EPNdB) @ 95% confidence
for 93-ton A321
– Stage 4 approved by ICAO general assembly
– In effect January 1, 2006 for new and derivative aircraft
– Existing models grand-fathered
 Certification of acoustics and hardware 2nd quarter 2003
– Thrust Reverser
 Mechanical certification complete – currently in production for A321
 Acoustic certification 2nd quarter 2003
– Chevron Nozzle
 Mechanical and acoustic certification 2nd quarter 2003
– Inlet – certification 4th quarter 2004 if necessary
 Decision to include inlet will be made after acoustic data has been
completed for Thrust Reverser and Chevron Nozzle
 Certification testing showed 1.6dB improvement
CFM56-5B Acoustic Program
CFM Proprietary Information 8
 Major engine certification program in conjunction with
aircraft improvements
 Benefits:
– Completely interchangeable with current -5C
– 1% SFC improvement
– 13°C lower EGT
 10% lower maintenance costs
– Maintains current CFM56-5C noise (26 EPNdB margin)
– Uses the existing nacelle
 Market for 500 engines/upgrade kits
 Engine certification October 2003
 EIS November 2003
CFM56: Product Upgrades
CFM56-5C/P for Airbus A340-200/300
CFM Proprietary Information 9
Snecma
• Swept fan
• Light-weight structures
• Low pressure turbine
• High speed bearing
GE
• High pressure compressor
• TAPS combustor
• High pressure turbine
• Brush sealing
Jointly
•Turbine interaction
• Acoustics
• Engine controls
• Testing
TECH56 Technology Programs
CFM Proprietary Information 10
• Swept Fan Blade 
- Hollow design
- Second generation for additional acoustic improvement
• TAPS Maturation 
- Optimize NOx vs. CO; demonstrate durability
• Six-Stage Compressor 
- Mature next-generation 3-D aerodynamics; optimize loading
• Acoustics 
- Demonstrate additional acoustic improvement
- Chevrons, acoustic liners, 2nd generation swept fan blade
• High Efficiency LPC and LPT Technology
Technology Maturation Plan 2001-2003
 Engine test planned
CFM Proprietary Information 11
CFM Project TECH56: The Next Phase
Technology maturation
 Program has met all objectives to date
– Technology development has been overwhelming success
– Time to take TECH56 to next level
 Focus for 2001 - 2003:
– Drive lower total cost of ownership
– Reduce maintenance costs
– Develop even simpler, more robust designs
– Optimize engine cycle
– Develop new controls technology
– Improve systems integration
Whatever the Market Needs, TECH56 Has the Answer
CFM Proprietary Information 12
Driving Reliability and Satisfaction
 The whole CFM team is involved
 Communication and sharing information
– Field Reporting
– Scorecards and Digital Cockpit
– WTT/Focus Teams
 Driving Improvements using Six Sigma
– Cluster teams to analyze
– Cluster teams to implement
Driving Customer Satisfaction with CFM team
involvement, communication and Six Sigma
CFM Proprietary Information 13
Raj Varadarajan
Jerry Otto
Marketing
Kent Weden
Product Support
Vince VanDenBriel
Quality
Bill Clapper
General Manager
Wayne Adams
CFM56-3/-7 Programs
Manufacturing & Quality
Ken Foley
CFM56-5 Program
Shawn O’Day
Master Black Belt
Scott Pawlikowski
CFM e.Business and
Product Support
Integration
Debbie Poli
CFM56 Product
Support Engineering
Rebecca Goodall
Compliance
Len Baran
CFM56 Upgrades
Services Integration
Bruce Mills
Engineering
John Mericle
Business Operations
The CFM56 Team
CFM Proprietary Information 14
Issue Identification
-
-
Fleet Experience
Hours: 18,566,940
Cycles 2,928,473
Engines 975
Customers 31
Customer Sensitivities
• Kuwait - HPT blades
• Air Canada - No.4 Bearing / SV Planning
• Cathay - Shop visits / LOTC
• LanChile -- Engine durability / Starter
• AFR -- Nacelle
• CSW -- Hung starts
• IBE / GFA / CCA / TAP/ -- Engine SV
planning
Issues Status Corrective Action
• HPT blades SB 72-462 and 72-469 released
• No. 4 bearing New material available June 10.
• Performance Overhaul task force driving
improvements
• VSV LVDT Faults Engine test / component test in process
to identify root cause of events
• LOTC rate Investigating all known causes
New N2 sensor 72-422
New T25 sensor 73-013
• Starter ring gear Date code inspection (SB 80-0011)
• Soft starter pawls AOW has been sent to operators.
SB 80-0012 approved
Total Shop Visit Rate
Goal 0.100
Current rate 0.068
Total ATO Rate
Goal 0.001
Current rate 0.008
Total IFSD Rate
Goal 0.003
Current rate 0.0070
Total Dispatch Reliability
Goal 99.85
Current rate 99.67
June Airbus Data
CFM56-5C Propulsion System Scorecard
Total IFTB/Diversions
Goal 0.008
Current rate 0.0126
Fleet Leading Indicators
• IBE Fins Erosion
• High Oil consumption
• Starter FOD -- Airbus issue
Y
Y
R
Y
G
G
Total UER
Goal 0.040
Current rate 0.040
G
It all begins with field reporting…
• Scorecard data comes from field event
reporting
• Leading indicators are identified
through event reports and field
feedback
• Prioritization and field fixes are based
on data analysis
CFM Proprietary Information 15
CFM… Top Repeatable Processes
CFM56-5C Top UER
cause – HPT Blades CFM International Proprietary information
Top Unscheduled Engine Removal Causes
(Last 12 months)
Cause Quantity Corrective Action
HPT Blades 41 SB 72-0469- Improved HPT blade durability
High EGT / Performance 18 Performance restorat-io-Fnocus su-bteams
driving recommendations and improvements
Number 4 bearing 14 New Outer Race Material
CESM 009- bearing shop practices
High Oil Consumption 14 SB 72-0464- Introduction of new LPT seals
Additional causes under investigation
HPC Blades 12 FOD caused events
Oil Leaks 6 Several engines under investigation
Combustion Chamber 2 SB 72-0412-New outer cowl
AGB Mounting pad 3 Loose hydraulic pump pad studs replaced
N2 Vibrations 2 Improved shop practices.
Several engines under investigation
Data through September 30, 2002
UER’s – Repeatable Process – Data depends on field
reporting
CFM Proprietary Information 16
Q1 Analysis
Total Restored Shop Visits in Q1
0
1
2
3
4
5
6
7
8
9
10
11
Perf. Det.
HPT Blade
#4 Bearing
O Rings
High Oil
Consumption
Dome
Number of Events
2001
HPT Blade • Q1 is d• epartment-wide initiative
• Performed on all CFM models
• Understand shop visit causes in Q1
- HPT blades driving removals for short-haul
–5C customers
• Drive field actions through customer teams
0
5000
10000
15000
20000
25000
1996 1997 1998 1999 2000
Engine Flight Hours
Minimum
Q1
Mean
Q3
Maximum
CFM56-5C Shop Visit Q1 Analysis – Restored Shop Visit
Stability Factor: .56
Implementing Corrective
Actions to Reduce Variation
CFM Proprietary Information 17
Goals:
• Closer integration with Field
Service
• Drive Field improvements
and airline implementation
Product Cluster Strategy
-
-
Top CFM56-5C Projects - Status
Field Programs: - The Pipeline
Cluster Projects: - The Execution
Description
Americas Asia SA Region
HPT Blade BSI Video Implementation on trac k
Waterwash Barriers identified / plan in place
Reduction of delays c/b fuel leaks Barriers identified / recovery plan required
N2 Sensor upgrade More data required
Primary TR lock lubing
#4 Bearing implementation
Status
BPTS #: Title Leader Metrics Impacted W&C Budget Impact? Status
2001-10-024569CFM56-5C Blade HPT Root TE CrMac. kWinagnBdeSrIsVeiedeoATO, IFSD, High cost failure Yes Implementation
2001-11-026141CFM56-5C Waterwash B. Vermillion TOW No Implementation
2001-12-02816R0eduction of delays caused by fuelSle.aPkaswlikowski D&C No Implementation
2002-05-012207N2 Sensor Upgrade S. Pawlikowski IFSD / LOTC Events No Implementation
2002-11-023139CFM56-5C TSM Improvements E. Martin LOTC / IFSD / UER No Analyze / Improve
2002-11-022400CFM56-5C / P Development A. Kemp TOW / UER Yes Improve
2001-08-01948C6 FM56-5C Inlet lip cracking durabiJli.tyCimallparnodveermentD&C / Maintenance cost No Improve/Control
2002-11-023261CFM56-5C Nacelle Cluster K. Foley Nacelle Maintenance cost Yes Analyze / Improve
Fleet Experience
Hours: 18,566,940
Cycles 2,928,473
Engines 975
Customers 31
Customer Sensitivities
• Kuwait - HPT blades
• Air Canada - No.4 Bearing / SV Planning
• Cathay - Shop visits / LOTC
• LanChile -- Engine durability / Starter
• AFR -- Nacelle
• CSW -- Hung starts
• IBE / GFA / CCA / TAP/ -- Engine SV
planning
Issues Status Corrective Action
• HPT blades SB 72-462 and 72-469 released
• No. 4 bearing New material available June 10.
• Performance Overhaul task force driving
improvements
• VSV LVDT Faults Engine test / component test in process
to identify root cause of events
• LOTC rate Investigating all known causes
New N2 sensor 72-422
New T25 sensor 73-013
• Starter ring gear Date code inspection (SB 80-0011)
• Soft starter pawls AOW has been sent to operators.
SB 80-0012 approved
Total Shop Visit Rate
Goal 0.100
Current rate 0.068
Total ATO Rate
Goal 0.001
Current rate 0.008
Total IFSD Rate
Goal 0.003
Current rate 0.0070
Total Dispatch Reliability
Goal 99.85
Current rate 99.67
June Airbus Data
CFM56-5C Propulsion System Scorecard
Total IFTB/Diversions
Goal 0.008
Current rate 0.0126
Fleet Leading Indicators
• IBE Fins Erosion
• High Oil consumption
• Starter FOD -- Airbus issue
Y
Y
R
Y
G
G
Total UER
Goal 0.040
Current rate 0.040
G
Implementation
tracked and
reported at
Quality Meeting
CFM Proprietary Information 18
6
Warrantees &
Concessions Q1 Analysis
Project Clusters
HPT Blade
ANOVA Weibull
WTT &
Focus Teams
UERs
Design of Experiments
Box Plots Cause & Effect
Pareto Trend Analysis
Mini Tab
Implementation – HPT Blade Example
CFM Proprietary Information 19
B. Clapper - Cluster Leader
CFM56 HPT Blade Programs
Project #: 2002-02-002501
M. Wandersee - Leader
CFM56-5A ANA P08 HPTB
Dovetail Cracking
2001-05-012202
CFM56-5C - 2D
Root/Trailing edge crack
2001-05-012203
Implemented
CFM56-5B/P HPT Blade
Shank Separation
2001-05-012205
CFM56-5BP/-7 HPTB
Trailing Edge Separation
2002-02-003122
CFM56-5BP/-7 HPTB
Trailing Edge Separation
2002-02-003122
Design Improvements Repair Development Programs
T. Norris - Leader
CFM56-5A S1 HPTB
Improved Durability Blade
2001-10-023245
Implemented
CFM56-7, -5B/P S1 HPTB
MXX Design Durability
Improvement
2001-10-023260
Implemented
Various - Leaders
Shank Strip of CFM56-7B,-
5B/P HPT Blades
– Eight projects
2002-01-001353
2002-08-016872
2002-08-016874
2002-08-016875
2002-08-016870
2002-082-016867
2002-08-016864
2002-04-010030
Implemented
Matt Saylor -Leader
Modified PtAl Process for
CFM56-7 HPT Blade
2002-01-000908
Various - Leaders
Shank cracking of CFM56-
7B,-5B/P HPT Blades
- Four projects
2002-08-016862
2002-03-007565
2002-08-016884
2002-08-016886
Implemented
Field Programs
Various - Leaders
Shank cracking of CFM56-
7B,-5B/P HPTB
-Two projects
2002-08-016878
2002-09-019040
Implemented
Tingfan Pang -Leader
HPTB For CFM56-5CP
(thru TG6)
2002-04-008488
Implemented
DFSS CFM56-5C/P
Optimum Accelerated
Durability Test Definition
2002-11-022400
-5C/P HPT Blade –
TG7 thru Certification
2002-11-023679
Scott Carson - Leader
Tapered Tip HPTB
2002-02-003305
Ys:
Two-run HPT Blade
No HPTB-caused IFSDs
CFM56 HPT Blade Cluster
CFM Proprietary Information 20
$0
$5,000,000
$10,000,000
$15,000,000
$20,000,000
$25,000,000
$30,000,000
CFM56-3 CFM56-5A CFM56-5B CFM56-5C CFM56-7B
0
10
20
30
40
50
60
70
80
CFM56 Concessions - Analysis
CFM56-5C is biggest
contributor to CFM
concession volume & cost
One-way Analysis of Variance
Analysis of Variance
Source DF SS MS F P
Factor 4 2.889E+12 7.224E+11 4.36 0.002
Error 261 4.322E+13 1.656E+11
Total 265 4.611E+13
Individual 95% CIs For Mean
Based on Pooled StDev
Level N Mean StDev ----------+---------+---------+-
-----
CFM56-3 67 166097 290803 (-----*------)
CFM56-5A 21 176623 199922 (-----------*----------)
CFM56-5B 34 161682 281807 (--------*--------)
CFM56-5C 71 372221 673451 (------*-----)
CFM56-7B 73 105548 185192 (-----*-----)
----------+---------+---------+-
-----
Pooled StDev = 406924 150000 300000 450000
CFM56-3
20%
CFM56-5A
7%
CFM56-5B
10%
CFM56-5C
49%
CFM56-7B
14%
CFM Proprietary Information 21
CFM56-5C Concessions by Hardware - Analysis
$0
$1,000,000
$2,000,000
$3,000,000
$4,000,000
$5,000,000
$6,000,000
$7,000,000
$8,000,000
$9,000,000
#4 Brg #3 Brg HPT
Blade
HPC
Case
IGB HMU Other Perf EGT
Probe
Fuel
Pump
Air/Oil
Sep
LPT
Shroud
C-Clip Unknown Upgrade HPC
Vane
0
5
10
15
20
25
HPT Blade is Top Cause for CFM56-5C Concessions
CFM Proprietary Information 22
HPT Blade Cluster… Driving Improvements
• Field Control Program
Customer training video
Reduce borescope interval
Cancel repairs
Rotables availability for quick turns
Critical Xs:
• New Blade Design
DFR Scoring
Accelerated endurance testing
Leading indicators
Optimized cooling
1000 10000
0.1
1
2 3 5
10
20
40
60
80
99
Percent
UERreq.
Cycle:3800
DPMO:6210
ScrapReq.
B10:3800
B50:6000
11000
M73P02 LCFPred..
M73P02Rupture
M60P01Rupture
M60P01 LCF
CFM56-5C4 Fleet
Asia Fleet
Gulf Fleet
Cycles to failure / removal
CFM Proprietary Information 23
Summary
 Communication from you
All data analysis is based on field data
 Events
 Customer Sensitivities
 Field Fix Effectiveness
 Involvement from entire team is required
Cluster Teams
 FSE Reporting
 PSE Identifying issues/leading indicators
 Teams using Six Sigma tools for analysis
 PSE communicates control program implementation
 FSE driving implementation
 Communication to you
Digitization to share information
 WTT/Focus Team information
 CFM Weekly News
 Livelink Presentation Files
 Digital Cockpit and Scorecards
Maintain communications … Feedback is critical to Reliability
and Customer Satisfaction

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CFM56 Project Overview