Alaska Airlines CFM56-7B HMU Caused HMU Disruption Improvement

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1 GE Transportation
Project Description:
Reduce Alaska Airlines Operational disruptions due to unscheduled HMU removals
Voice of Customer:
The reliability of the HMU is having a negative effect on our departure reliability
Project Leader:
Stuart Kramlich - GEAE Field Service
Team Members:
Paul Deutchle – GEAE CSM
Keith Megargle – Alaska Power Plant Engineering
Dave Fox – Honeywell Field Service Engineer
BB Mentor:
Jeff Milam – GEAE ACFC BB
Defect:
- Any HMU related operational disruption
caused by a known failure mode that is
addressed by an available product
improvement
Customer Metric:
- ATO and D&C
- Maintenance burden
Alaska Airlines CFM56-7B HMU Caused
HMU Disruption Improvement BPTS#: 2004-06-010448
DMAIC Step 0
2 GE Transportation
DMAIC Steps 1 & 2
CFM PROPRIETARY INFORMATION
Through March 2004
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
% Successful Departures
CFM Goal
Total Dispatch Reliability
CFM PROPRIETARY INFORMATION
Through March 2004
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
% Successful Departures
CFM Goal
Total Dispatch Reliability
CFM PROPRIETARY INFORMATION
D&C Top Causes (Basic engine last 12 months) Through March 2004
Cause Quantity Corrective Action
HMU (158): MTBUR -- 15,200 hours
- TBV 81 EHSV product improvements incorporated Feb 2003
- FMV 46 Corrective action for 12 out of 13 failure modes defined
Rotor winding improvements Introduced Mar 2003
- HPSOV 14 Field program progressing nicely
EEC 66 PSS modification SB 73-065. Improved ATP in place.
Program improvements being monitored – MTBUR
18,000 hrs – Individual Pressure transducers failing
Starter 55 P09 rework SB 80-006 issued (new turbine seal
assembly) P10 - turbine stack improvements - SB 80-007
issued
Fuel Filter Delta-P switch 36 Potted switch improvement S/B 73-042
1 flight allowance added to DDPG MMEL
MTBUR at 70,000 hours
Ignition System 28 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
6
5
3
9
7
CFM PROPRIETARY INFORMATION
D&C Top Causes (Basic engine last 12 months) Through March 2004
Cause Quantity Corrective Action
HMU (158): MTBUR -- 15,200 hours
- TBV 81 EHSV product improvements incorporated Feb 2003
- FMV 46 Corrective action for 12 out of 13 failure modes defined
Rotor winding improvements Introduced Mar 2003
- HPSOV 14 Field program progressing nicely
EEC 66 PSS modification SB 73-065. Improved ATP in place.
Program improvements being monitored – MTBUR
18,000 hrs – Individual Pressure transducers failing
Starter 55 P09 rework SB 80-006 issued (new turbine seal
assembly) P10 - turbine stack improvements - SB 80-007
issued
Fuel Filter Delta-P switch 36 Potted switch improvement S/B 73-042
1 flight allowance added to DDPG MMEL
MTBUR at 70,000 hours
Ignition System 28 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
6
5
3
9
7
HMU related D&Cs
top driver for
CFM56-7B fleet
DMAIC Steps 1 & 2
3 GE Transportation
Fleet Statistics - Operational Impact
HMU Reliability is Critical ttooCCFFMM5566--77BBDD&&CCRRaattee
SOURCE: Honeywell HMU return data
Delays and Cancellations
HMU Caused
Feb 1998 through Mar 2004
173
100 97
71
66
41 39
31 30
25
20 20
12
4 4 2 2
0
20
40
60
80
100
120
140
160
180
200
HPSOV
TBV DMD and POS Disagree (SAC)
FMV POS Out of Range
FMV POS Disagree
Unknown
VBV Current Out of Range
TBV DMD and POS Disagree (DAC)
Vibration
Leak
No Start/Hung Start
Flameout Uncommanded Throttle
LPTACC DMD and POS Disagree
Engine Control Light
Precautionary
Service Bulletin
No Fault
Mech Ovespd Protec Out of Range
* * * * * * * * *
* Denotes modification in place
DMAIC Steps 3
4 GE Transportation
ASA - HMU Removals per Month
0
1
2
3
4
5
6
Jan 03
Feb 03
Mar 03
Apr 03
May 03
Jun 03
Jul 03
Aug 03
Sep 03
Oct 03
Nov 03
Dec 03
Jan 04
Feb 04
Mar 04
Chi-Square Test Hypotheses:
Ho: All groups the same
Ha: At least one different
Group Count N Expected Chi-sq
A 3 20000 0.973 4.223
B 33 720000 35.027 0.117
Totals--------> 36 740000
4.340 <-------Chi-Sq
df---> 1 3.841 <---------Critical Chi-Sq
0.037 <--------- p-value
A = ASA monthly experience
B = CFM56-7B fleet experience
ASA Experience
Similar to fleet
HMU removal
experience
DMAIC Step 3
5 GE Transportation
0
2,000
4,000
6,000
8,000
10,000
12,000
14,000
16,000
18,000
Apr-00
Jun-00
Aug-00
Oct-00
Dec-00
Feb-01
Apr-01
Jun-01
Aug-01
Oct-01
Dec-01
Feb-02
Apr-02
Jun-02
Aug-02
Oct-02
Dec-02
Feb-03
Apr-03
Jun-03
Aug-03
Oct-03
Dec-03
Feb-04
P08
"New HPSOV"
(Feb-02)
P09
"FMV/TBV/BSV"
(Jun-03)
P07
"Rumble"
(May-99)
CFM56-7B Fleet Statistics - Reliability Performance
Reliability PPeerrffoorrmmaanncceeCCoonnttiinnuueess ttoo IImmpprroovvee
MTBUR: 15,266 hrs.
MTBUR = (12 Month Flight Hours) / (12 Month Removals)
“On-wing”
HPSOV Switch
Replacements
(Mar-00)
ASA MTBUR
9200
DMAIC Step 4&5
6 GE Transportation
CFM56-7 HMU - Time to First Removal
PPoossiittiivvee TTrreenndd
Average Hours at First HMU Removal
0
1,000
2,000
3,000
4,000
5,000
6,000
7,000
8,000
9,000
10,000
1998 1999 2000 2001 2002 2003 2004
ASA’s
average time
for removal is
6200 hours
DMAIC Step 4&5
7 GE Transportation
Alaska HMU Removals Jan 03 – Mar 04
Alaska Airlines HMU removal Causes
0
2
4
6
8
10
12
FMV NCFR Fuel
Leak
TBV chafed
wire
OSG
# Removals
Current Configuration
P09 Config
Current MTBUR 9245.667
P09 Potential MTBUR 18491.33
DMAIC Step 6
8 GE Transportation
High Pressure Shutoff Valve (HPSOV) Switch 
Wire Chafing Resulting in Wrap Faults 
Burner Staging Valve (BSV) &
Main Staging Valve (MSV) Faults 
Fuel Leakage
Increased Removals Partially Due to AFSO Switch
Replacement
Fuel Metering Valve (FMV) Feedback Faults 
Fuel Metering Valve Resolver
Demand / Feedback Faults 
Transient Bleed Valve (TBV) EHSV 
CFM56-7 HMU Removal Drivers DMAIC Step 6
9 GE Transportation
0
10
20
30
40
50
60
70
80
Jan-00
Mar-00
May-00
Jul-00
Sep-00
Nov-00
Jan-01
Mar-01
May-01
Jul-01
Sep-01
Nov-01
Jan-02
Mar-02
May-02
Jul-02
Sep-02
Nov-02
Jan-03
Mar-03
May-03
Jul-03
Sep-03
Nov-03
Jan-04
Mar-04
0
100,000
200,000
300,000
400,000
500,000
600,000
700,000
800,000
Unknown / Misc.
Chafing / Wrap Fault
BSV
Leakage
HPSOV Switch
DMD/FDBK (TBV)
FMV F/B
Monthly Usage (Right Axis)
CFM56-7 HMU - Removal Drivers
Removals Decreasing Despite IInnccrreeaasseeddUUttiilliizzaattiioonn
Monthly Removals
(12 Month Rolling Average)
Monthly Removals
(12 Month Rolling Average)
Monthly Removals
Monthly Usage (hours)
DMAIC Step 7 & 8
10 GE Transportation
3012
177
300
P07/P08
New P09
Upgraded to P09
70,000
336,000
27,844,000
Total Fleet
3,489 HMU抯
28,250,000 Hours
( 86%)
( 9%)
( 5%)
Fleet Statistics - Fielded Configurations
CFM56-7 HMU Fleet
By Part Number
CFM56-7 HMU Fleet
By Part Number
CFM56-7 HMU Fleet hours
By Part Number
CFM56-7 HMU Fleet hours
By Part Number
AAllaasskkaa’’ssPP0099PPeenneettrraattiioonn aatt4422%%
DMAIC Step 8
11 GE Transportation
CFM56-7 MTBUR
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
11000
12000
13000
14000
15000
16000
17000
18000
19000
20000
7/24/1998
2/9/1999
8/28/1999
3/15/2000
10/1/2000
4/19/2001
11/5/2001
5/24/2002
12/10/2002
6/28/2003
1/14/2004
8/1/2004
2/17/2005
9/5/2005
3/24/2006
10/10/2006
4/28/2007
Month/Year MTBUR (
Hours)
Projected: No Changes
Duane Growth Model
12 Month Actual
Projected: 'P09 Changes
Projected: 'P0' and P11
Crowe AAMSA Model - MTBUR to Date and Projected
Projected HMU Reliability Growth
(Honeywell data)
P07 & P08 - ‘recent’ incorporations = wire grid & SPST switch
P09 = FMV resolver module, TBV EHSV, BSV solenoid modifications
P10 = proposed BSV solenoid elimination
P11 = proposed fluorocarbon fuel-to-air seals
Month/Year
DMAIC Step 9
12 GE Transportation
Go Forward plan (Steps 10 thru 12)
• ECO written to proactively introduce p09 HMU’s -- Complete
•Continue to drive p09 penetration
» currently 2/month may increase based
on recent commercial discussions with
Honeywell -- In Work
• Working with Alaska’s reliability group to monitor
reliability improvements -- In Work
•Leverage PFM approach to other reliability drivers
- i.e., Starter oil leakage

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Alaska Airlines CFM56-7B HMU Caused HMU Disruption Improvement