a guideline to improve reliability and operational...
TRANSCRIPT
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A Guideline to Improve Reliability and Operational Availability of Scorpène Submarines defining the way to
manage Logistic Effort with the goal of better performance
Master of Sciences in Asset Management Control
Dissertation
Student: Carlos BLAMEY
Professor: Michel KUIJER
22-12-2011
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1. Introduction
2. Problem’s description
3. Current situation, “Gateways” and their impact in the
reliability and operational availability
4. Prioritizing improvement opportunities
5.Methods which may drive submarines’ proposed
improvement
6. Conclusions
AGENDA
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1. Introduction
2. Problem’s description
3. Current situation, “Gateways” and their impact in the
reliability and operational availability
4. Prioritizing improvement opportunities
5.Methods which may drive submarines’ proposed
improvement
6. Conclusions
AGENDA
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1.- The “Neptuno Contract” was signed 1997 between the Chilean Navy and
the Scorpene Consortium for the construction of 2 Last Generation
Conventional Submarines which have been incorporated to the service
on 2005 and 2006 respectivelly.
Introduction.
2.- During the first 5 years in service, Scorpène Submarine have suffered the
failure of their critical systems, achieving a lower reliability and
operational availability than the defined one on the Technical
Specifications.
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O’Higgins’ availability reduction during the first years in operation
0
50
100
150
200
250
20052006
20072008
2009
TiempoProyectado(días)
Tiempo RealReparaciones(días)
Δ = 82%
Introduction.
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Introducción.
“This submarine is the most performing war machine I’ve never crew; it can be hard injured but it persist in fighting” (Bravo, 2008)…..
(Bravo, 2008)
But this argument wasn’t in line with the following caricature which shows the daily headaches of this Commanding Officer.
• Maintenance Plan• Budget• Spare parts• Supply Chain• Unexpected failures• Skills• Design
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1.- El Contrato Neptuno, fue firmado en 1997 entre la Armada de Chile y el
Consorcio Constructor en un proceso que generó un gran debate.
2.- Durante los primeros 5 años de servicio, los Submarinos Scorpène han
evidenciado una menor confiabilidad y disponibilidad operacional que la
especificada, producto de fallas en sus sistemas críticos.
3.- Those failures are not linked with the “Genetic Code” of their
equipments and, in general, they correspond to causes which are
not related to those identified by the suppliers in the ARM
analysis.
Introduction.
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Introduction.
The nature of the failures, which is not exactly proper to equipment’snature, forces us to look for cost-effective solutions in the explitation of ournaval assets.
The Maintenance Gateways (Nikolowski)
We have an opened gateway to failures!
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1.- El Contrato Neptuno, fue firmado en 1997 entre la Armada de Chile y el
Consorcio Constructor en un proceso que generó un gran debate.
2.- Durante los primeros 5 años de servicio, los Submarinos Scorpène han
evidenciado una menor confiabilidad y disponibilidad operacional que la
especificada, producto de fallas en sus sistemas críticos.
3.- Estas fallas no están necesariamente asociadas al “Código Genético” de
sus equipos, sino que en general corresponden a distorsiones del
análisis ARM.
4.- In the other hand, we can suppose that the budgetary situation
will no change in coming years.
Introduction.
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Introduction.
During the last decade, chilean GDP has grown notably.
But in the same period of time, Defense Budget has remain almost constant, so it is not foreseeable any significant budgetary improvement in the immediate future.
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1. Introduction
2. Problem’s description
3. Current situation, “Gateways” and their impact in the
reliability and operational availability
4. Prioritizing improvement opportunities
5.Methods which may drive submarines’ proposed
improvement
6. Conclusions
AGENDA
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Problem’s description.
How can be reliability and operational availability improved in order to achieve a better effectiveness of Scorpène Submarines during their exploitation phase?
Additionally, the following subsidiary questions may guide this Thesis:
• How can be identified the criticality of key systems which may impact operational availability of Scorpène?
• What causes the decreasing of systems availability?
• What can be done in order to decrease down time?
• Which should be the efforts to be done to improve reliability and operational availability?
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1. Introduction
2. Problem’s description
3. Current situation, “Gateways” and their impact in the
reliability and operational availability
4. Prioritizing improvement opportunities
5.Methods which may drive submarines’ proposed
improvement
6. Conclusions
AGENDA
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Current situation, “Gateways” and their impact in the reliability and operational availability
Operational availability is defined at the design of the asset, considering personal, logistic and material matters.The operator adopts it according with their culture and other considerations.
Often, we care about operational matters without caring ILS implications and their impact in the life cycle of the assets.
Priorities have been centred in the purchase without regarding on support.
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Financial effort is centered in acquisition.
Current situation, “Gateways” and their impact in the reliability and operational availability
The submarine’s ILS was built under a logic which didn’t consider obsolescence, lack of skills, or infrastructure.
It is not previewed extra budget to complement the ILS, nevertheless the sole budgetary assign is not enough….we have to prioritize.
An ILS without budgetary support implies several weakness during the life cycle..
During the operational phase, those requirements have to be duly evaluated, being one between several requirements for the Navy.
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Way of OperatingDecisions under pressureShort time vision.
DesignBas maintenance specificationsLack of toolsChange of materialsSupplying mistakesBad informationPoor communication
Maintenance errorsData qualityData interpretation
Bad quality of the air-Water contaminationExtreme ambiance conditions
Situación actual, “Gateways” y su impacto en la confiabilidad y disponibilidad operacional
The Maintenance Gateways (Nikolowski)
“Unforced errors” of our equipments…..
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Current situation, “Gateways” and their impact in the reliability and operational availability
Reliability:
Ao = Uptime
Uptime + Downtime
R(t) = e-λt
λ = number of failures
total uptime hours
We have to look for simple and feasible solutions to improve reliability and operational availability of our submarines.
To improve reliabilitywe have to reducethe number offailures
Operational availability:
To improve availabilitywe have to reducedowntime
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Summary of Failures v/s CriticalityFramework of 5 Years
0
50
100
150
200
250
Intern
al Communic
ation
sHull S
tructu
reProp
ulsion
Electric
Gene
ration
Integ
rated Plat
form C
&M
Hull Ins
tallat
ions &
Accomoda
tions
Weapon
s Ope
ration
Safety
DiveNavig
ation
Air & S
urfac
e Dete
ction
Tactic
al Exp
loitat
ion
Operat
ional
Enviro
nmen
t
External
Commun
icatio
n
Technical Function
Dow
ntim
e
0
100
200
300
400
500
600
700
Crit
ical
ity
Number of FailuresCriticality
Current situation, “Gateways” and their impact in the reliability and operational availability
From SALINO we got the number of failures, downtime and criticality.
Discarding short downtime failures, we had evaluate Causes and Duration as a way to evaluate their impact on reliability and operational availability
Criticality: how much a system contributes to mission..
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Current situation, “Gateways” and their impact in the reliability and operational availability
Availability matrix let us discover the “Gateways”, it means were we have given room to failures, without duly coming with solutions to mitigate the downtime.
(1) Causes of the Failure
Env
ironm
ent
Qua
lity
of D
esig
n
Man
ufac
turin
g D
efec
t
Deg
rada
tion
Bad
Spe
c. o
f Mat
eria
ls
Mai
nten
ance
Indu
ced
Bad
Ope
ratio
n
Tota
l
%
(2) C
ause
of t
he d
elay
Needs Manufacturer Support 6 32 20 9 1 0 0 68 40,48
Long Lead Items 17 4 0 9 6 0 1 37 22,02
Needs DesignEvolution 8 8 3 0 3 6 0 28 16,67
Lack of Tools & Facilities 1 1 0 1 0 2 1 6 3,57
Problem of Access 10 0 0 2 0 0 0 12 7,14
Lack of Budget 5 3 0 5 0 0 0 13 7,74
Obsolescence 1 0 0 3 0 0 0 4 2,38
Total 48 48 23 29 10 8 2 168 100
% 28,57 28,57 13,69 17,26 5,95 4,76 1,19 100
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1. Introduction
2. Problem’s description
3. Current situation, “Gateways” and their impact in the
reliability and operational availability
4. Prioritizing improvement opportunities
5.Methods which may drive submarines’ proposed
improvement
6. Conclusions
AGENDA
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We could know what to do, but how to do it if needs are greater than budgetand if we know that we are not going to got any special budget?
Prioritizing improvement opportunities
Where to start?
ParetoFactor
0
500000
1000000
1500000
2000000
2500000
3000000
3500000
BH OO DB DY UA BB BC RC EN FG RH RD FH GV HX BT DA
ParetoFactor
We will focus on the 20% of the failures with more availability impact, taking into consideration their criticality, their frecuency and their downtime.
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Prioritizing improvement opportunities
How to prioritize budgetary effort?
We have to built a ranking taking into consideration:
• Availability Impact
• Budgetary effort
• Confident
If we have USD 1M.How can I be more cost-effective?
All the money in one, two ore more problems? On which solutions?
ParetoFactor
0
500000
1000000
1500000
2000000
2500000
3000000
3500000
BH OO DB DY UA BB BC RC EN FG RH RD FH GV HX BT DA
ParetoFactor
Are we really sure on that?
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Prioritizing improvement opportunities
Following this method, the next is the ranking that should been follow in order to come with cost-effective solutions.
Installation Installation Description Cause/DowntimeAvailability
Impact Number Effort Confidence Focus
KO Combat Mgt. System Quality/Manufacturer 2 3 2 12
BM Diesel Cooling System Quality/LLI 1,8 2 3 11
BD Diesel Engines Degradation/Manufacturer 1,6 3 2 9,4
DP Steering Console Quality/Manufacturer 0,9 3 3 8,3
ME Electric Propulsion Motor Degradation/LLI 0,8 3 3 7,4
GS Attack Periscope Degradation/Manufacturer 0,7 3 3 6,2
BH Air Induction Environment/Evolution 3 2 1 6,1
AvailabilityImpact
BudgetaryImpact
Confident
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1. Introduction
2. Problem’s description
3. Current situation, “Gateways” and their impact in the
reliability and operational availability
4. Prioritizing improvement opportunities
5.Methods which may drive submarines’ proposed
improvement
6. Conclusions
AGENDA
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Methods which may drive submarines’ proposed improvement
1. 40% of the failures that needsmanufacturer support….
What should be done to reduce ……?
• Technology transfer:
- SAGEM: Level 4 maintenance- Thales: SUBTICS- DCNS : Setting to Work, External connectors
• Development of Special Tools to support Logistic Process:
- Information Portals- Logistic Perfornance Indicators- Needs’ satisfaction indicators
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Methods which may drive submarines’ proposed improvement
1. 40% of the failures that needsmanufacturer support….
What should be done to reduce ……?
• Technology transfer:
- SAGEM: Level 4 maintenance- Thales: SUBTICS- DCNS : Setting to Work, External connectors
• Development of Special Tools to support Logistic Process:
- Information Portals- Logistic Perfornance Indicators- Needs’ satisfaction indicators
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Methods which may drive submarines’ proposed improvement
2. 22% of failures affected by long leaditems…….
What should be done to reduce ……?
• Benchmarking:
- Joint purchasing process- Common Stock- Maintenance plans revision- COTS management policies
• Improvement of inventory management methods:
- Replacement of the zero stock policy (since 1988) by a new one basedon criticality stock levels.
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Methods which may drive submarines’ proposed improvement
2. 22% of failures affected by long leaditems…….
What should be done to reduce ……?
• Benchmarking:
- Joint purchasing process- Common Stock- Maintenance plans revision- COTS management policies
• Improvement of inventory management methods:
- Replacement of the zero stock policy (since 1988) by a new one basedon criticality stock levels.
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Methods which may drive submarines’ proposed improvement
3. 40% of failures affected by design ofmanufacure…….
What should be done to reduce ……?
• Multidisciplinary Teamwork including the most skilled people in order to propose ballanced solutions:
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Methods which may drive submarines’ proposed improvement
3. 17% of failures caused by degradation ofcritical components..….
What should be done to reduce ……?
• Long Term Agreements:
- Availability based contracts for specific sistems.
• Review of the design and the maintenance plans.
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1. Introduction
2. Problem’s description
3. Current situation, “Gateways” and their impact in the
reliability and operational availability
4. Prioritizing improvement opportunities
5.Methods which may drive submarines’ proposed
improvement
6. Conclusions
AGENDA
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Conclusions:
1. Scorpène submarines have evidenced lower reliability and operationalavailability than the one defined in the Contract.
2. This situation comes from open “Gateways” caused by failures on ILS….Logistic products haven't been purchased at the due time.
3. Failures which more impact into reliability and operational availability arethose which needs the support of the manufacturer, those affected bylong lead items and also those derived from design and manufactureaffected by the effect of the exposition to extreme pressure (operationdepth).
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4. We have already implemented solutions, by duly integrating pragmaticcriteria in order to come with cost-effective mitigating solutions, based onthe effect on performances.
5. There are also long term solutions which might be implemented throughusers clubs, as inventory management improvements, joint purchaseprocess in order to benefit of volume, common stocks, etc.
6. The good, transparent and consensuated priority definition…….
Conclusions