Maintenance For Financiers

Transcription

1 GE - Aviation Maintenance For Financiers The information contained in this document is GE proprietary information and is disclosed in confidence. It is the property of GE and shall not be used, disclosed to others or reproduced without the express written consent of GE, including, but without limitation, it is not to be used in the creation, manufacture, development, or derivation of any repairs, modifications, spare parts, designs, or configuration changes or to obtain FAA or any other government or regulatory approval to do so. If consent is given for reproduction in whole or in part, this notice and the notice set forth on each page of this document shall appear in any such reproduction in whole or in part. The information contained in this document may also be controlled by the U.S. export control laws. Unauthorized export or re-export is prohibited.

2 Outline The Core Life Limited Parts Scheduled and Unscheduled Events 2

3 The Core 3

4 Engine Maintenance A Perfect World Operators enjoy a long on-wing life When the engine has a maintenance event there are accrued funds to cover the cost The engine is maintained to original equipment specifications The engine can easily be transferred between owners and operators 4

5 Engine Maintenance The Challenges Operators enjoy a long on- wing life When the engine has a maintenance event there are accrued funds to cover the cost The engine is maintained to original equipment specifications The engine can easily be transferred between owners and operators Operators don t want to pay for events they don t have Who holds the fund s? How much should be retained? Who makes this decision? What impact does that decision have? What happens when utilization, flight leg, and operating environment change? 5

6 The First Shop Visit New engines have been designed for low cost per hour. 8 7 Time on Wing A typical CFM56 coming in for its first visit stayed on wing more than 7 years Years 75% to 80% of engines 3 delivered will be on wing 10 years or more. 2 1 Shop Visit cost is directly proportional to time on wing (P) 6

7 The Workscope Decision Time Work scope choice reflects the future time on wing of the engine. Minimal work scope is a short term strategy the drives lower time on wing. Extended work scopes can be costly and not achieve the lowest operating cost Optimal work scopes need to be proposed and fit to operating requirements and long term strategy CFM56 7B CFM56 7B Cat Cat A A Removal Removal Scenario Scenario Options Options Low Thrust Engines Limiter 20K Low Thrust Engines Limiter 20K 1.8 Hours per Flight (P04 DISK) 1.8 Hours per Flight (P04 DISK) B20 to B24 Engines Limits Fan * HPC HPT LPT B20 to B24 Engines Limits 30.0 Fan 20.0 * HPC 18.9 HPT 25.0 LPT Removal * with extension cause Removal * with extension Intro TI HPT blades cause CFM56 7B Intro TI HPT blades Scenario CFM56 7B Cat Cat B B Removal Removal Scenario Scenario Options Options Reduced Stub Scenario Life High Thrust Engines Limiter 18K 2.4 Hours per Flight Reduced Stub Life High Thrust Engines Limiter 18K 2.4 Hours A1 per Flight B26 Engines Limits A1 Room to Fan Improve * HPC SV HPT LPT B26 Engines Limits Room Cost to 30.0 per Fan Improve HR 18.6 * HPC 18.0 SV HPT 25.0 LPT Removal * with extension Cost 30.0 per HR cause 18.9 Removal PERF& * with extension cause 40 Cycles x PERF& 6.1 Intro TI HPT 5 blades TI HPT 10 blades Cycles x 1000 Scenario Intro TI HPT blades TI HPT blades CFM56 7B Reduced Stub Scenario Life Intro TI HPT blades & CFM56 7B Cat Cat C C Removal Removal Scenario Scenario Options Options B1 Reduced Stub Life Scenario WO Event Intro TI HPT blades High & Thrust Engines Limiter 18K 2.4 Hours Scenario per B1 Flight Room to Improve SV WO Event High Thrust Engines Limiter K 2.4 A2 Hours per Flight Room Cost to per Improve HR SV Reduced SV Nb B27 [16 18] Engines A2 Limits Cost Fan * per HPC HR HPT LPT 16 [16 18] B27 Engines 34 Cycles x 1000 Reduced Limits SV Nb 30.0 Fan 18.6 * HPC 18.0 HPT 25.0 Removal * with extension LPT LPT at 25K 18.9 cause 25 Cycles x Removal (Event) PERF& * with extension LPT at 25K 18.9 Event cause 6.1 (Event) 25 PERF& 13.9 Intro TI HPT blades With TI set 38.9 Cycles x Event 6.1 Intro TI set + TI HPT blade 13.9 Intro TI HPT blades With TI set Cycles x 1000 Scenario Scenario W Events Intro TI set + TI HPT blade Reduced Stub Scenario Life Event / Scenario W Events TI HPT blades Recommended Event / B2 C1 Reduced Stub Life LPT achieved 25K Intro TI HPT blades & TI HPT blades Scenario 12 Recommended B2 W Events C1 Room to Improve SV LPT achieved 25K Intro TI HPT blades & Scenario W Events Room Next SV in 12K Cost to per Improve HR SV [11 12] [11 12] A Optimized TOW Next SV in 12K Cost per HR [11 12] [11 12] A3 36 Cycles x 1000 Cycles 6 Reduced x 1000 Optimized Cost per TOW HR Cycles x 1000 Cycles [ ] Reduced LPT x 1000 Cost at 16K per HR Event or With TI set [ ] Event 14 Perf PERFO Intro TI set + TI HPT blade LPT at 16K 30 6 With 36 TI Cycles set x Event or Event 14 Perf PERFO 6 Cycles x 1000 Recommended Intro TI set + TI Intro HPT blade TI set + TI HPT blade Scenario W Events Recommended 105 th CFM56 PRM March 15, 2007 Intro TI CFM set International + TI HPT blade Proprietary Information For Internal Use Only Scenario W Events Scenario W Events , th CFM56 PRM March 15, 2007 CFM International Proprietary Information For Internal Use Only Scenario Optimized W TOW Events C LPT achieved 25K , B3 LPT Optimized not achieved TOW 25K C LPT achieved 25K B3 LPT not Next achieved 25K SV in 12K [11 12] Next SV in Next 25K SV in 12K [11 12] Next SV in 25K 12 [11 12] [11 12] Cycles x Cycles x Cycles x 1000 Cycles x th CFM56 PRM March 15, 2007 CFM International Proprietary Information For Internal Use Only Event or Perf PERFO PERFO Recommended 105 th CFM56 PRM March 15, 2007 CFM International Proprietary Information For Internal Use Only Event or Perf Intro TI set + TI HPT blade PERFO PERFO Scenario Recommended W Events Intro TI set + TI HPT blade Scenario Optimized W TOW Events C3 LPT Optimized not achieved TOW 25K C3 LPT not achieved 25K Next SV in 25K [11 12] Next SV in 25K 12 [11 12] Cycles x Cycles x th CFM56 PRM March 15, 2007 CFM International Proprietary Information For Internal Use Only 105 th CFM56 PRM March 15, 2007 CFM International Proprietary Information For Internal Use Only 7

8 Changes What Now? Moving aircraft from region to region effects maintenance cost Dust Storms Other factors are: Flight Leg Utilization Flight Operations Line Maintenance Practices 8

9 On Point Customer collaboration and OnPoint flexibility Defined requirements Desired time on wing (TOW) Ownership Horizon Life limited parts () build standard Used material preferences Financial & operational goals Optimized solution Intelligent workscope TOW management USM content optimization & buy-back Repair capability Spare engine coverage with guaranteed results 9

10 The Money Engines accrue maintenance expense each hour they operate. No exceptions somebody will pay to return the engine to service. Maintenance Reserves is a method to account for this. Annual Customer Cash Flow $1,400,000 $1,200,000 $1,000,000 $800,000 $600,000 $400,000 $200,000 $/EFH Year No Upgrade Upgrade Must have, a good forecast of cost that accounts for variation Determination of payment timing Each Hour Each Event Customer Cash Flow at Shop Visit $1,400,000 $1,200,000 $1,000,000 $800,000 $600,000 $400,000 $200,000 $/SV Year No Upgrade Upgrade 10

11 Life Limited Parts 11

12 What is a Critical Rotating Part? High-energy parts that cannot be contained if they fail, parts whose failure could create a hazard to the aircraft Definition resides in CFM/GE/SNECMA Procedure and agency regulations Disks, Seals, Spools, Shafts Classification invokes specific technical and operator responsibilities 12

13 Things to keep in Mind about Separate maintenance reserves are usually collected for tends to come in waves (or spikes) are high dollar parts. Used serviceable may be able to help defray the cost (depending on build standard of course). parts tend to be largest part of engine valuation. OEM parts, Proper Records,ensure easier transfer from one operator to another. 13

14 Scheduled and Unscheduled Events 14

15 Delivering asset productivity GE and CFM engines 655 million flight hours and growing A takeoff every 2 seconds Delivering beyond expectations Increasing departures decreasing events 15

16 Keeping aircraft flying 120% 100% 80% 60% 40% 20% GE and CFM departures 105% increase 0% (Cumulative averages) Dec-97 Dec-99 Dec-01 Dec-03 Dec-05-20% -40% -60% GE and CFM events 54% decrease 16

17 Diagnostics services Asset healthcare using advanced technology Data analyzed 24 hours a day, 7 days a week Anomalies reported via within 15 minutes Access, analyze and manage alerts via the internet Customer Notification Reports (CNR) with corrective actions recommended in 2 hours Storage of data engine life Web access to the GE Customer Web Center (CWC) 17

18 DEGT N155AW_2_721 TrendData 25 Nov Jan M ar Apr Jun Aug S ep Nov J an Fe b A pr Jun Jul S ep No v Dec EG THDM C GGW D_1_811149_01/ 24/2001 TRENDDATA Low alert 24 Jan Feb M ar M ar Ap r M ay M ay Jun Jul Jul GWFM N77261_2_ TRENDDA TA Diagnostics reduces engine operational cost more savings Increased Use of Derate Derate Frequency Figure 2 Fleet Derate Distrib ution for May 2004 Mean Shop Cost Minimized CRUISE DELTA EGT Thrust Derate (%) Data analysis for customer s A319 fleet revealed low average derate and wide variation in use of derate Flight Operations engaged Airline on benefit of derate Additional Diagnostics 3% derate Alerts use detect yields performance significant savings shift indicative over the of hot product section distress life On wing BSI confirms HPT Shroud Burn Early Engine Removal Prevented DEG T Customer operating cost reduction $3MM+ Customer shop visit cost reduced $ k/shop visit Customer saves outstation removal ~$25K Customer Benefit - Decreased Operating Cost by $3MM FLIGHT_DATETIME C GG WD_ 1_ _01/24/200 1 E GTHDM vs. FLIGHT_DATE TIME E GT Hot Da y Margin at Take off On-wing action driven by alerts Engine removed while HPT identifies blades still and corrects broken upper repairable 1 EGT harness GE Transportation Cost of Ownership Lowered Through HPT Blade Repair ~ 1.3% recovery in $200K $500K Savings/SV FLIGH T DAT versus ETIME Blade Replacement Diagnostics Alerts identify rapid takeoff EGT deterioration Fuel Burn Efficiency Restored N77261_2_ GWFM vs. FLIGHT_DATETIME DELTA FUEL FLO W AT CRUISE EGT exceedance leading to unnecessary engine removal Diagnostics avoided Alerts detect performance shift indicative of Clearance Control Reduced Line Maintenance cruise Fuel Flow malfunction GE Tran sportation Cost of Ownership Lowered Through On Wing Action Total Cost of Outstation FLIGHT DATETIME Engine Removal ~$25K Delta Pressure (psi) 2 Engine not in danger of exceeding OFDP Trend at Take Off operating limits HPTACC valve changed on wing enabling Fuel Flow recovery Airline maintenance strategy of Hard time limits for GE90 oil filter replacements 2A 4A 2A USL Proc es s Data 3 GE Transportation Target * LSL * Cost of Ownership Lowered Mean Through On Wing Action Sample N 739 StDev (ST) (Fuel Savings StDev (LT) = $2/EFH) USL S T LT Customer fuel savings = $2/EFH+ Diagnostics Alerts drive oncondition oil filter replacements Oil Filter changes reduced from 240 to 20 per year Customer savings = $50K+ 90%+ reduction in potential maintenance errors GE Transportation Reduced Maintenance = $50K plus Engine Run Savings PLUS... 92% Reduction in Potential Maintenance Errors 5 GE Transportation 18

19 Additional diagnostics services Comprehensive Assigned Diagnostic Manager Regular engine health reviews Takeoff and cruise data trend monitoring and analysis Weekly performance summary (EGT Margin), highlight reports & plots Customer notification & recommended actions of impending events Engine removal forecasting Fleet trending for customized workscope $1000/eng/yr Real Time Fault processing / alert generation Exceedance processing / alert generation Alert notification Real time troubleshooting Oil consumption monitoring ~$3000/eng/yr 19

20 Maintenance for your ownership requirements Offering flexible products and solutions Lowering ownership cost GE and CFM material Providing excellent customer support Delivering through GE s operational excellence 20

21 Summary The Core Life Limited Parts Scheduled and Unscheduled Events 21