phm experience at utc and pratt & whitney: challenges and ... · pw4000 engine removed prior to...
TRANSCRIPT
This document is the property of United Technologies Corporation (UTC). You may not possess, use, copy or disclose this document or any information
in it, for any purpose, including without limitation to design, manufacture or repair parts, or obtain FAA or other government approval to do so, without
UTC’s express written permission. Neither receipt nor possession of this document alone, from any source, constitutes such permission. Possession,
use, copying or disclosure by anyone without UTC’s express written permission is not authorized and may result in criminal and/ or civil liability.
Pratt & Whitney Proprietary
PHM Experience at UTC and Pratt & Whitney:
Challenges and Opportunities
Steve O’Flarity
The PHM Society
1 October 2009
1 October 2009page 2
Click to edit Master subtitle style
Focus
United Technologies PHM Overview
Pratt & Whitney PHM Overview
Defining Value…It’s Not Easy
Lessons Learned (and some we’re all still working on)
1 October 2009page 3
Click to edit Master subtitle style
Public Access Data
United Technologies Corporation
1 October 2009page 4
Click to edit Master subtitle style
A Tradition Of Innovation
Willis CarrierWillis Carrier
Thomas HamiltonThomas Hamilton
Elisha Graves OtisElisha Graves Otis
David SundstrandDavid Sundstrand
Igor SikorskyIgor Sikorsky
Charles ChubbCharles Chubb
Fred RentschlerFred Rentschler
Walter KiddeWalter Kidde
1 October 2009page 5
Click to edit Master subtitle style
Broad UTC PHM Experience
United Technologies Research Center
Multi-Spectral Diagnostics
UTC Power
Fuel Cell Remote Diagnostics
Sikorsky Aircraft
Usage-Based Lifing
Sikorsky Aircraft
HUMS
Pratt & Whitney
EHM, ADEM
PW625PW625
UTC Fire & SecurityCarrier
Otis
Pratt & Whitney Rocketdyne
Remote Building Monitoring and Diagnostics
Remote Elevator Monitoring
Hamilton Sundstrand
Health Monitoring
P&W Canada
Health Monitoring
Diagnostic Sensor FusionHealth Monitoring
1 October 2009page 6
Click to edit Master subtitle style
Pratt & Whitney
Public Access Data
Military EnginesLarge Commercial
Engines
Small Engines SpacePower Systems
1 October 2009page 7
Click to edit Master subtitle styleMaterial and
Repair ServicesService
Solutions
EngineServices
New Engines
Experience and Engineering Excellence
Over 80 Years of Aircraft Engine Design & Maintenance
1 October 2009page 8
Click to edit Master subtitle style
Complete MRO Services
Engine Leasing
PW4000
JT9D
CFM56
PW2000
JT8D
V2500
PW6000
Repair
Customer Training
Overhaul
Water WashHealth Management
$/FH MonitoringLine Maintenance
Fleet Management$/FH Overhauls
24-Hr Help Center
1 October 2009page 9
Click to edit Master subtitle style
Customer Issues are MRO Issues
Example assumes $2M purchase price and $100 / EFH direct maintenance cost (DMC) at 3,500 EFH / yr
Fuel
Emissions
Availability
$0.0
$5.0
$10.0
$15.0
$20.0
$25.0
0 5 10 15 20 25 30 35 40 45 50 55Year
DM
C ($M
)
Cum Maintenance Cost
PURCHASE
1 October 2009page 10
Click to edit Master subtitle style
Automatically process dataDetect issues before failuresPerform troubleshooting
AnalyzePlan maintenanceTurn aircraft
RecommendInspectionMaintenance
ManageLife cycle costsForecastingSupply chain
Engine Health ManagementIntegral to managing operations
1 October 2009page 11
Click to edit Master subtitle style
Confirm
Isolate
Communicate
Maintain
1-1
Document
Customer
Engine Management Programs (EMPs)Closed loop alert notification and disposition process
Review
1 October 2009page 12
Click to edit Master subtitle style
Key Lessons / Challenges
What’s the business case?
How do we get data?
How do we support small customers, mobile customers (leasing)?
How do we solve more of our customers’ problems?
1 October 2009page 13
Click to edit Master subtitle style
A Generalized PHM Value ModelCREATEVALUE
OBJECTIVE
RECIPIENT
VALUE PROP
BUS. PROP
OFFERING
METRICS
1 October 2009page 14
Click to edit Master subtitle style
A Generalized PHM Value ModelCREATEVALUE
PROVIDERVALUE
CUSTOMERVALUE
OBJECTIVE
RECIPIENT
VALUE PROP
BUS. PROP
OFFERING
METRICS
1 October 2009page 15
Click to edit Master subtitle style
A Generalized PHM Value ModelCREATEVALUE
PROVIDERVALUE
CUSTOMERVALUE
REDUCEDMAINTENANCE
COSTS
REDUCEDOPERATING
COSTS
INCREASEDAVAILABILITY
OBJECTIVE
RECIPIENT
VALUE PROP
BUS. PROP
OFFERING
METRICS
RELIABILITY
OUTSOURCE ADDITIONALCAPABILITIES GUARANTEES
AVAILABILITY
OPERATINGCOSTS
ASSET /RESIDUAL
VALUE
MAINTENANCEPLANS
MONITORINGPLANS
BETTERFLEET
MAINTENANCECOSTS
1 October 2009page 16
Click to edit Master subtitle style
A Generalized PHM Value ModelCREATEVALUE
GENERATEREVENUE
REDUCECOSTS
GUARANTEEDMAINTENANCE
COST
IMPROVERELIABILITY
PROVIDERVALUE
CUSTOMERVALUE
WARRANTYMITIGATION
MONITORINGPROGRAMS
USAGE BYTHE HOUR
MAINTENANCECOST
GUARANTEES
BUNDLED /ADJACENTSERVICES
REDUCEDMAINTENANCE
COST
ADDITIONALSALES
REDUCEDMAINTENANCE
COSTS
REDUCEDOPERATING
COSTS
INCREASEDAVAILABILITY
REDUCEDWARRANTY
COSTS
OBJECTIVE
RECIPIENT
VALUE PROP
BUS. PROP
OFFERING
METRICS
BETTERPRODUCT
ADDITIONALSALES
ADDITIONALSALES
VARIOUSMODELS
VARIOUSPOSSIBILITIES
RELIABILITYINCREASEDAVAILABILITY
OUTSOURCE ADDITIONALCAPABILITIES GUARANTEES
AVAILABILITY
OPERATINGCOSTS
ASSET /RESIDUAL
VALUE
MAINTENANCEPLANS
MONITORINGPLANS
BETTERFLEET
MAINTENANCECOSTS
1 October 2009page 17
Click to edit Master subtitle style
Define and Quantify the Metrics!CREATEVALUE
GENERATEREVENUE
REDUCECOSTS
GUARANTEEDMAINTENANCE
COST
IMPROVERELIABILITY
PROVIDERVALUE
CUSTOMERVALUE
WARRANTYMITIGATION
MONITORINGPROGRAMS
USAGE BYTHE HOUR
MAINTENANCECOST
GUARANTEES
BUNDLED /ADJACENTSERVICES
REDUCEDMAINTENANCE
COST
ADDITIONALSALES
REDUCEDMAINTENANCE
COSTS
REDUCEDOPERATING
COSTS
INCREASEDAVAILABILITY
REDUCEDWARRANTY
COSTS
OBJECTIVE
RECIPIENT
VALUE PROP
BUS. PROP
OFFERING
METRICS
BETTERPRODUCT
ADDITIONALSALES
ADDITIONALSALES
VARIOUSMODELS
VARIOUSPOSSIBILITIES
RELIABILITYINCREASEDAVAILABILITY
OUTSOURCE ADDITIONALCAPABILITIES GUARANTEES
AVAILABILITY
OPERATINGCOSTS
ASSET /RESIDUAL
VALUE
MAINTENANCEPLANS
MONITORINGPLANS
BETTERFLEET
MAINTENANCECOSTS
1 October 2009page 18
Click to edit Master subtitle style
Diagnostics and Prognostics Mitigate RisksReliability typically trades with cost and weight
PHM improves reliability, reduces costCatch small events early before becoming big cost
Turn UERs into pre-planned removals
Forecast trends that can be managed on wing
Determine overhaul workscope on wing
Extend life – usage-based lifing
Our PHM analysis tool is ADEM – Advanced Diagnostics and Engine Management
ADEM drives hardware and systems technologiesGas path and subsystem sensor coverage
Access to operational performance and usage data
Accurate engine simulation models
Reporting
Fault Trending
Alerting
Watch Lists
Data Visualization
1 October 2009page 19
Click to edit Master subtitle style
Health Management Provides Quantifiable Value
Savings vary by service level, customer, fleet, etc., and do not include significant productivity improvement typically realized.
Time on wing extension
Shop visit cost reduction
Fuel consumption reduction
Operational cost reduction
0%5%
10%15%20%25%30%35%
TOW SVC Fuel Operational
0%
5%
10%
15%
20%
25%
30%
35%
Bleed
HPCHPT
EGT Mgmt.
Instr.
TCC
Oil Sys. Fan
Value Summary
Event Value
1 October 2009page 20
Click to edit Master subtitle style
Trend plots point to HPT
Isolation indicates HPT Borescope inspectionrevealed T1 blade damage
Engine removed prior toincurring additional damage
PW4000 engine removed prior to additional damage
Customer Value – HPT Damage Detected
Estimated Savings: $700K (UER potential – $Million+ / Event)Estimated Savings: $700K (UER potential – $Million+ / Event)
Alerts triggered
1 October 2009page 21
Click to edit Master subtitle style
Industry Health Management Value Stream
ACQUIREDATA
DELIVERDATA
ANALYZE+ REPORT
EXECUTEACTIONS
STRONGWEAK
1 October 2009page 22
Click to edit Master subtitle style
Improve Data Collection and Delivery Technologies
Current technologies are poor: ACARS, sneaker-net
PHM critically needs various field data for…Warranty / guarantee mitigation
$/FH risk mitigation
LLP usage-based life extension
Interval and cost estimation forecasting
Revenue through health services
Emerging issue detection
Fuel conservation services and consumption guarantees
Emissions tracking – ETS, U.S. “Cap & Trade”
BA
ND
WID
TH
LATENCYPOST
FLIGHTREALTIME
HIG
HLO
W
REACTIVEDIAGNOSTIC
PROACTIVEPROGNOSTIC
2.4-64 Kbits/sec
432K-30M bits/sec
100
Kbits
/ sec
As it happensDelayed 1-5 days
0 Kb
its/ s
ec30
Mbi
ts/ s
ec
ACARS
FLIGHTCOUPONS
QAR /SNEAKER NET
BROADBANDSATELLITE
BA
ND
WID
TH
LATENCYPOST
FLIGHTREALTIME
HIG
HLO
W
REACTIVEDIAGNOSTIC
PROACTIVEPROGNOSTIC
2.4-64 Kbits/sec
432K-30M bits/sec
100
Kbits
/ sec
As it happensDelayed 1-5 days
0 Kb
its/ s
ec30
Mbi
ts/ s
ec
ACARS
FLIGHTCOUPONS
QAR /SNEAKER NET
BROADBANDSATELLITE
Commercial Engine Data Delivery
1 October 2009page 23
Click to edit Master subtitle style
57%
23%
13%
6% 1%
How Do We Address Small / Lease Operators?
57% of world’s operators fly 10 or fewer engines
10 or less engines
11 - 30 engines
31- 100 engines
101-500 engines
500+ engines
Customers flying >100 engines mostly captive
Profitability?Portability?
1 October 2009page 24
Click to edit Master subtitle style
Algorithms /
Analysis
Algorithms /
Analysis
Basicsensors Basic trend monitoring Manual
calculations
Expandedinstrumentation
Oil condition, sub-systems
Custommodels
Isolation techniques
Work scope / operationsoptimization
Electronic enginecontrols
Anomaly detection
Condition-based maintenance
Operational improvements
How Can We Address More Problems?Sen
sors
/ DataSen
sors
/ Data
Technology advancements drive value
Part lifealgorithms
Expanded flight data
Usagebasedlifing
1 October 2009page 25
Click to edit Master subtitle style
A Holistic Systems Approach
Integrated vehicle health and data management
100% pylon-on-down (POD) supportThrust Reverser with
Variable Area Fan Nozzle
Fan Cowls
Primary Exhaust Nozzle
Exhaust Plug or Cone
Engine Mounts
Pylon and Attaching Hardware
Aft Pylon FairingInlet
Engine and Engine Build-Up
BFE (Generators, Hydraulic Pumps, Fire
Protection, etc.)
Environmental Control System
APUGuided Troubleshooting