Presentation on theme: "Complex Maintenance, Repair, and Overhaul Overview"— Presentation transcript:
1Complex Maintenance, Repair, and Overhaul Overview
2ObjectivesAfter completing this module, you should be able to do the following:Discuss the key functionality available in Oracle cMRO
3Maintenance, Repair and Overhaul (MRO) At-a-Glance Tear-Down& InspectRepair / ReplaceRe-InstallPlanned & Unplanned MaintenanceImproved Aircraft ReliabilityMajor Overhauls, Unscheduled Repairs and Inspections, Condition MonitoringConfiguration ManagementRegulatory ComplianceMaintenance, Repair & Overhaul is the process of executing a maintenance activity to improve aircraft reliability. This includes both planned and unplanned maintenance activities such as:Overhauls of major components such as engines or APUsScheduled maintenance activities such as Letter Checks, routine inspections or standard maintenanceUnplanned maintenance activities that are the result of problems during operation, issues logged by the flight crew or issues discovered by service technicians during inspections.By analyzing aircraft performance and usage and planning maintenance activities associated with the results, aircraft reliability can be improved, meaning the aircraft spends less time on the ground and more time in the air generating revenue.
4Business Pressures Aircraft on Ground Cost Containment How do I minimize the effects of unscheduled repairs?How do I decrease asset turn around time?Cost ContainmentWhere are my highest inventory and capital expenses?How can I improve maintenance productivity?Tear-Down& InspectRepair / ReplaceRe-InstallRegulatory ComplianceHow do I ensure compliance to FAA / JAA regulations?How do I ensure audit trail visibility and availability?Multi-Site Planning & SchedulingHow do I aggregate/assign inventory and resources?How do improve fleet-level planning?
5Operational Challenges PlanningOperational ChallengesSingle, linear planning cycle that ignores cost / skills requirementsMaintenance RequirementsSpares ManagementCost / Skills AnalysisIsolated Planning and ExecutionReactive MaintenanceManual ProcessesIsolated View of InventoryScheduleExecutionMaintain multiple master configuration versions for similar unitsSerial #Tail #1AoG*Serial #Tail #1AoG*Maintenance RequirementsRepair / ReplacementDocument UpdatesConfiguration Updates*Aircraft on Ground
7Foundation: Unified Information Architecture DevelopCommon data model enables a single source of truthComprehensive suite of applications designed to work togetherRobust set of integration services based on open standardsModular deployment by business flowSingle global instance implementationsContractsMarketProjectsSellHROrderCustomers,Suppliers,Products, …FinancePlanMaintainProcureServiceMakeFulfill
10Oracle Complex MRO Enables you to… Maintain Complex Configurations Effectively Plan Enterprise-Wide OperationsOptimize Maintenance ExecutionCentrally Manage All Engineering Data…for Line Maintenance, Base Maintenance, and Engine / Component Overhaul
11Maintain Configuration Control Manage Configuration Changes and History Master Configuration“Allowable Configuration”Unit Configuration“As Installed” / “As Maintained”References AllowableConfig.Tail #SystemSerial #Serial #ComponentComponentSerial #Serial #Serial #Serial #PrimaryAlternatePrimaryAlternateSerial #Serial #Serial #Serial #Allowable Assembly TemplateManage Constraints and RulesLink to Maintenance RequirementsSupport Sub-Master ConfigurationsTrace Installation / Removal HistoryTrack Unit Specific InformationUpdate Applicable Configurations with Single Entry
12Maintain Configuration Control Manage Configuration Changes and History Master Configuration“Allowable Configuration”Unit Configuration“As Installed” / “As Maintained”References AllowableConfig.Tail #SystemSerial #Serial #ComponentComponentSerial #Serial #Serial #Serial #PrimaryAlternatePrimaryAlternateSerial #Serial #Serial #Serial #Allowable Assembly TemplateManage Constraints and RulesLink to Maintenance RequirementsSupport Sub-Master ConfigurationsTrace Installation / Removal HistoryTrack Unit Specific InformationUpdate Applicable Configurations with Single EntryNow let’s look at the Unit Configuration:The unit configuration is the As Installed / As Maintained template of structure assembly information, specific to each unit. It can be maintained at any designated level (aircraft, engine, components, etc.) and will track serial numbers for each level. Through the unit configuration you can:1. Track component installation/removalProvides Material Management informationAssociates child units to parent unitsMonitors life of any component – where it is today and where it has been2. Track “Unit Specific” informationSupports Engineering / Maintenance Planning informationce requirements (fleet program / log book) and maintenance history3. Update applicable configurations with a single entryWith an established tree structure, searches for other configurations with the same part/component and automatically updates as appropriate.Additionally, the unit configuration refers to the allowable configuration for change approvals (as the arrow in the picture shows). It check for items such as:New parts installedModification rulesEngineering updates
13Maintain Fleet Configuration Automatically Link Unique Characteristics List All Units in FleetProvide Logical Grouping or HierarchyManage at the Unit LevelLink Directly to Fleet Maintenance ProgramSand FilterCorrosion InhibitorOceanDesertTail #Site 1Site 2Site 3FleetProduct Classification, which is part of Configuration Management, provides you with the flexibility to create logical groupings of units. This allows you to tailor the solution to your specific business needs. Examples include:Fleet - series - modelFamily - model - versionDifferent environments change the maintenance needs of an asset. Just detach a unit from one branch of the classification tree and attach it to another and that unit is automatically re-assigned to the maintenance requirements of the new branch.Example: As the picture shows, two planes maintained in different environments (desert vs aircraft carrier) will require different needs when parts are sent back for repair / warranty work. Keeping track of these requirements, and reassigning is easy to do with Oracle’s Complex MRO solution. When you reassign a plane, the basic maintenance requirements will stay with the tail number, but the plane will automatically be reassigned maintenance requirements to fit the new location.No one else offers this type of solution. Other products may say they do, but they require manual transfer of maintenance requirements. Only Oracle’s Complex MRO solution allows you to rapidly re-deploy assets and their associated maintenance with one tail number transition.
14Component Tracking Trace Rotables Throughout Their Life OEM(Jan ’88)Active Unit(Oct ’88)Shop(Feb ’92)Airframe(Dec ’96)TPM(May ’01)A-1FP1A105RepairA125RetrofitA-1FP2B225ReplaceA145CalibrateB-1CP1B255ModifyB225ModifyD-1FP4C135B255D-1FP5C195C185Provide visibility to work history of tracked componentsAllow purchasing to control capital expendituresImprove predictive maintenance for engineering changesThe management of Rotables is a major issue in capital costs. Complex MRO provides life-cycle history of every tracked component from when it is entered into the system until it is retired from the business. Complex MRO maintains all information on a component from where it is (installed in an active unit, in repair or in inventory) to where it has been throughout its life, who worked on it, what was done to it and when, current version and versioning history.Further, this tracking provides total asset visibility to reduce capital expenditures as you know what you have and where it is before spending for unneeded components that were in inventory but not visible in the system.
15Provide Complete FAA Compliance for Every Configuration Support Regulatory Compliance Provide Tracking and Traceability of All Asset DataSerial #Tail #Complete Configuration HistoryMaintenance DataRepair / Check HistoryProblem / Failure ReportsReliability DataQuality InformationAirworthiness Directives / Service BulletinsEngineering Change Orders / Modification OrdersComplex MRO provides compliance tracking for all configuration information to ensure adherence to all Regulatory, Environmental and Safety regulations that effect your assets and operations. Additionally, Complex MRO will archive this information indefinitely so you have a reliable and consistent audit trail if required in the future.Provide Complete FAA Compliance for Every Configuration
16Oracle Complex MRO Enables you to… Maintain Complex Configurations Effectively Plan Enterprise-Wide OperationsOptimize Maintenance ExecutionCentrally Manage All Engineering DataLet’s now discuss Effectively Planning Enterprise-Wide Operations...
17Plan at all Horizons Automatically Flow Requirements to All Plans Fleet & LocationsFleet Maintenance ProgramDefine frequency and content of maintenance checks for all aircraftLong Term PlanForecast resource requirements; analyze and assign capacityContinuous UpdatesScope / CoverageUnit Maintenance PlanBaseOverhaulAssign due dates to maintenance requirements for each aircraftVisit Work PackageEstablish tasks to be performed during next aircraft visitOracle’s solution allows you to plan at all time horizons and flow the information to each level as plans change. We’ll go into each of these plans in detail in the following slides.AircraftDaysPlanning Time FrameYears
18Create Single, Tailorable Plan for Entire Fleet; Ensure Compliance LineBaseOverhaulFleet Maintenance Program Define Frequency and Content of Maintenance ChecksIdentify maintenance requirements based on OEM specifications for each asset typeDefine intervals, thresholds and effectivity for all requirementsLink requirements to associated documents and routesTrack dependent relationships and flag affected componentsCapture changes from Airworthiness Directives (ADs) or Service Bulletins (SBs)The Fleet Maintenance Program capability enables you to establish the frequency, effectivity and content of all aircraft maintenance requirements. By creating a single plan for the entire fleet, dependent relationships can be tracked and affected components can be flagged when changes occur to a linked component. This tailorable solution enables users to modify needs as additional requirements are identified through Airworthiness Directives or Service Bulletins, for example.Create Single, Tailorable Plan for Entire Fleet; Ensure Compliance
19Long Term Planning Forecast Needs Across Entire Organization LineBaseOverhaulLong Term Planning Forecast Needs Across Entire OrganizationIdentify tools / equipmentForecast spares / material requirementsIncorporate needs into inventory planningEstablish manpower needs based on skillsEstimate total man-hoursLong Term PlanResourcesAnalyze capacity to maximize utilizationAnalyze scenarios to determine optimal schedulesCreate reservations at assigned locationsIdentify excess capacityVisit 1Visit 2Visit…Capacity / LocationThe fleet plan can then be leveraged to create a Long Term Plan, which forecasts maintenance requirements by location and enables users to create scenario / capacity analysis models and determine optimal schedules to maximize utilization. Resources such as spare parts, personnel and equipment can be identified in advance, ensuring availability when needed.
20Unit Maintenance Plans Integrate Fleet and Unique Needs for Each Unit BaseOverhaulUnit Maintenance Plans Integrate Fleet and Unique Needs for Each UnitTail #001Tail #002Tail #003Tail #004Aircraft EnvironmentCondition MonitoringFMP RequirementsAircraft UsageLog Book ItemsChecksOne-Time ModificationsOut-of-Phase InspectionsDeferred ItemsList All Open Maintenance Requirements for Each AircraftCalculate Due Dates Based on Time Remaining and Forecasted UsageAutomatically Flow Deferrals Back to Unit Maintenance PlanThe Unit Maintenance Plan generates due dates for each of the maintenance requirements for a unit based on the thresholds and usage forecasts.Unit Maintenance Plans capture all inputs (product requirements such as OEM specifications, usage-based requirements such as number of takeoffs/landings and environmental conditions) to create maintenance plans for each individual aircraft.Unit MaintenancePlan
21Global Order Promising Inventory Optim- ization LineBaseOverhaulMaterial Planning Footprint Effectively Manage Spares Planning and AllocationFlight patternsHistorical planned requirementsComplex MROHistorical unplanned requirementsFleet additionsDemandPlanningUMPFuture requirementsFuture requirements from visitPlanned VisitsExceptionsGlobal Order PromisingCustomer service levelAdvanced SupplyChain PlanningInventory Optim- izationDemandFulfillmentBudgetRecommendationsTransferProcureServiceTime-phased echelon stocking recommendationsBy locationBy itemBecause Complex MRO is integrated with the rest of the Oracle E-Business Suite, this complete flow allows you to effectively manage your spares inventory by providing a comprehensive solution for spares planning and logistics.Inventory holding min / max
22Oracle Complex MRO Enables you to… Maintain Complex Configurations Effectively Plan Enterprise-Wide OperationsOptimize Maintenance ExecutionCentrally Manage All Engineering DataLet’s now talk about Optimizing Maintenance Execution…
26Line Maintenance Execution Transit Technician selects or creates Line Maintenance VisitViews work Orders in context of Line Maintenance VisitCreates Non Routine Work OrdersRequests Deferrals where neededCan log in / log out to create resource transactions or data clerkRecords time after the work is performedTechnician can close visit after completing and recording workOracle provides a seamless execution work flow for all processes, creating an efficient process from establishing demand to closing a work order and releasing/shipping the product.
27Base Maintenance Execution - User logs into “My Work Orders” UISees only work orders assigned to self or qualified to work onUser is guided through process by “smart defaulting” buttons.(parts change icon is only active if a parts change is required.QA Icon is only enabled if QA Plan needs to be recorded)User performs:Parts ChangeRecords Quality Data / Sign OffLogs Non RoutineAccesses Relevant DocumentsAdds additional Material RequirementsOracle provides a seamless execution work flow for all processes, creating an efficient process from establishing demand to closing a work order and releasing/shipping the product.
28Overhaul Maintenance Execution - Mechanic chooses primary and secondary disposition forremoved Part based on the condition and further actionsA non routine work order will be generated for componentsWhich require inspection, repair, or scrapThe off/on log is automatically updated based on theremoval and Installation detailsOracle provides a seamless execution work flow for all processes, creating an efficient process from establishing demand to closing a work order and releasing/shipping the product.
29Oracle Complex MRO Enables you to… Maintain Complex Configurations Effectively Plan Enterprise-Wide OperationsOptimize Maintenance ExecutionCentrally Manage All Engineering DataFinally, let’s discuss how Complex MRO Centrally Manages All Engineering Data…
30Complete Document Repository Provide Easy Access, Traceability for Compliance Register all technical documentsCentralize revision controlProvide subscription and distribution informationReference maintenance objectsLink to legacy electronic publication systemsSchematicsVoice / VideoOnline AccessAll documents can be stored in a single, secure location with Complex MRO’s Document Index. Any document, regardless of the type (drawings, schematics, voice or video images, text/scanned data) can be registered and version control maintained. Oracle’s solution can be linked to legacy systems to capture all historical data as needed. Access can be controlled and monitored through subscription and distribution management capabilities.Text / Scanned
31Route Management Leverage Common Work Steps to Increase Efficiency Create Work / Task CardsDefine Work InstructionsEstablish Resource NeedsType & TitleNumber / Revision ControlWorkflow-Driven ApprovalsQuality PlansTemplates / Established Work StepsEngine & Component Overhaul Disposition ActionsAssociated DocumentsLabor SkillsTools and EquipmentSpare PartsIn Route Management work cards are created for the different jobs requires in a maintenance requirement. Documents from the Document Index can be associated to a route as well as labor and material requirements. Routes can also be broken down into subcomponents or operations. As with a route, any pertinent documentation can be associated to an operation. A quality plan can be defined and associated to a route for quality inspections and sign-offs when the work is completed.Standardize Best Practices and Streamline Workflow
32Capture and Analyze Data at All Levels Ensure Quality at the Source PartnersYour Company3rd PartyComponent SuppliersMaintenance ProvidersOEMsOperatorRole-Based AccessCollect / aggregate dataAnalyze informationDistribute resultsClosed loop Corrective actionIntegrated Enterprise RepositoryWith a single enterprise data repository, product information can be captured at any level in the supply chain. By capturing all information in a single location, accurate analysis can be performed on quality results, and corrective action can be taken to improve products where needed.
33Task: Air Filter Change Task: Wheel Inspection Reusable Templates - Routes Leverage Template Data to Improve ProductivityTask: Air Filter ChangeOperation 2.3.5Xxx Xxx Xxx Xxx Xxx XxxXxx Xxx Xxx Xxx XxxOperation 2.3.6Xxx XxxTask: Wheel InspectionOperation 1.5.5Operation 1.5.6Task: APU OverhaulOperation 4.23Operation 4.24Create template for single operation or series of operationsAutomatically create templates from operations in new processLeverage templates for unrelated processes with the same operationEliminate Need to Re-Enter Information or Perform System QueriesTo improve efficiency and reduce manual labor, Oracle Complex MRO leverages reusable templates for creating operations or a series of operations. The templates work both ways – existing templates can be used to create steps or, if new processes are created, templates can be automatically created based on the new process.
34Oracle Complex MROIntegrated configuration and component lifecycle trackingMaintain Complex ConfigurationsComprehensive fleet and unit-based maintenance planning and schedulingEffectively Plan Enterprise-Wide OperationsComplete execution management for all scheduled, unscheduled, and overhaul activitiesOptimize Maintenance ExecutionTotal route management with reusable templates and an integrated document indexCentrally Manage All Engineering DataLet’s summarize the key capabilities of Oracle’s Complex MRO solution.
35Oracle Complex MRO Total Control of Complex Configurations Effective Enterprise-Wide PlanningOptimized Maintenance ExecutionCentralized Engineering Data ManagementIn Summary, Oracle provides… (summarize points in slide)Thank you very much for your time and attention today.Are there any questions I can answer relative to the Complex MRO product?
36Summary You should now be able to do the following: Discuss key functionality in Oracle cMRO