An Airline Maintenance Manpower Planning

Aircraft Health Monitoring
&
Maintenance Costs
KEITH FERNANDES
Manager, Fleet Engineering
15 September 2016, IATA MCC 2016
AGENDA
AHM & Maintenance Costs

AHM - The Basics
VAA – AHM System & Infrastructure
AHM Application to Maintenance Programs
Maintenance Task: Escalations using AHM
 Task Analysis
 Cost Benefit
 Justifications
Summary & What's Next?

2
Aircraft Health Monitoring (AHM) – The Basics
 Modern aircraft are data-rich and designed with significant advancements
in digital technologies
 Data transmitted from these modern-talking aircraft can be harnessed to

enhance the aircraft health monitoring and prognostic maintenance
capabilities
 Data streams into the AHM system can also be applied to optimise aircraft
maintenance programs; and consequently a reduction in related
maintenance costs
3
VAA AHM SYSTEM: AHEAD PRO
 VAA utilises the functionality of AHEAD PRO - a system developed by

Embraer to continuously monitor the status of aircraft in real time
 A computational web-based platform developed to support Health

Monitoring processes within the airline operation, from data acquisition to
time-to-failure prognosis
4
Source: Customer AHEAD Pro Presentation by Embraer (2014)
AHEAD PRO System Architecture
5
Source: Customer AHEAD Pro Presentation by Embraer (2014)
AHM Application to Scheduled Maintenance
 AHEAD PRO is integral to VAA aircraft health management processes with

functionalities integrated as active features:
 ACARS enabled aircraft receives Real-Time information while aircraft is still in

flight – CAS & CMC messages
 Display Aircraft fault messages in a real-time user-friendly Interface
 System Trend monitoring via QAR data
 VAA utilized the functionality of the AHM system to analyse & implement an
escalation of a candidate scheduled maintenance program task interval based on:
 the accuracy of the AHM transmitted data

 the real time availability
 continuous assessment of system fault conditions
6
Maintenance Task Escalation using AHM
The following MPD task was selected and analysed for interval escalation using the real
time health monitoring offered by the AHM system.
Task Description:
MPD 72-00-00-001: Visual Check of the Master Chip Detector Indication on the MFD
(Multi-Functional Display)
Current MPD Interval: 120 FH

VAA Approved Task Interval: 250 FH*
* Optimised to align with a scheduled maintenance opportunity 7
Task Escalation : Analysis
Task interval escalation subjected to a comprehensive analytical review process.
Engineering – Technical analysis

 Verified all previous messages were reported
 Verified all reported events originated with 72-00-00-001 and simultaneously
visible through VA AHM system
 Verified the effectiveness of the AHM system
AHM - Framework Analysis

 Confirmed chip detection metric is captured by AHM system
 Confirmed relevant ‘Alerts’ set up to advise if chip detected
 Work instruction set up for maintenance action when fault message is received
Engineering - Reliability Analysis

 Compliance, Yield and findings were analysed
 Reviewed unscheduled findings related to task 8
Task Escalation : Cost Benefit
Existing functionality within the AHM resulted in a reduction in maintenance cost
Cost Benefit:
Fleet of 18x aircraft
 Savings of 195x scheduled maintenance events
 Overall (annual) savings of 97.5 MH
9
Task Escalation : Justification
Escalating the task MPD 72-00-00-001 was therefore substantiated and regulatory
approved by the following key elements:
1. Analysis process confirmed that the AHM system was designed to reliably detect
faults and communicate the alerts in real time.
2. Cost benefit analysis indicated a savings in MH requirements with no risk to ongoing
continuing airworthiness.
3. Introduction of a new process to address the fault condition into bench level work
instructions, including maintenance actions to be initiated on identification of the
Chip Detector Alert.
10
Task Selections: Further Escalation Candidates
VAA proved the internal concept with the candidate task – Maintenance inspections and
associated costs can be effectively reduced by the accuracy of AHM functionality when
set up to generate real time fault alerts.
The next set of candidate tasks have been identified to analyse for potential escalation of
task intervals based AHM functionality:
MPD Task # Task Description Task Interval (MPD) Task Man Hours
21-51-01-001 RST - PACK FLOW CONTROL VALVE FILTER 7500 FH 0.9
21-51-10-001 RST - PACK BYPASS VALVE FILTER 3000 FH – P/N 820914-5 2.8
7500 FH – P/N -6 AND ABOVE
21-62-05-001 RST - TRIM AIR MODULATING VALVE FILTER 7500 FH 0.9
30-11-01-001 RST - WING ANTI-ICE VALVE 6000 FH 2.04
30-31-01-001 OPC - AIR DATA SMART PROBE (ADSP) HEATING - 16,087 FH 2.08
49-00-00-001 VCK - APU SYSTEM FAULT CODES 750 FH 0.5
71-00-00-002 VCK - ENGINE FAULT MESSAGES - 750 FH 0.5
36-10-01-001 RST - CROSS BLEED VALVE SUPPLY FILTER - 7500 FH 1.2
36-11-01-001 RST - HIGH STAGE BLEED VALVE FILTER - 7500 FH 0.64
36-11-06-001 RST - TORQUE MOTOR CONTROLLER FILTER 12,000 FH 3.00
36-11-09-001 RST - FAN AIR VALVE FILTER 7500 FH 0.82
11
AHM as a Method to reduce Maintenance Costs!
 AHM technology deliver succinct technological advantages that provide

effective and real-time aircraft health monitoring functionality.
 When these digital data streams are combined with reliable infrastructure
set-ups, airlines can extract well defined credits for scheduled maintenance
tasks as well as efficient prognostic defect management of aircraft systems
and components.
12
What’s Next?
With clear operational and costs benefits for airlines, the industry
stakeholders must :
 Consider tapping on the significant volumes of reliable aircraft digital

data
 Develop policies, techniques and maintenance solutions
 Create AHM Data based maintenance program concepts
 Initiate an ISC stakeholder process to update the existing MSG-3

framework to include AHM capabilities 13
Thank you !
14

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Aircraft Health Monitoring

AHM & Maintenance Costs

VAA – AHM System & Infrastructure

AHM Application to Maintenance Programs

Maintenance Task: Escalations using AHM

Summary & What's Next?

 Data transmitted from these modern-talking aircraft can be harnessed to

 VAA utilises the functionality of AHEAD PRO - a system developed by

 A computational web-based platform developed to support Health

 AHEAD PRO is integral to VAA aircraft health management processes with

 ACARS enabled aircraft receives Real-Time information while aircraft is still in

 the accuracy of the AHM transmitted data

Current MPD Interval: 120 FH

Engineering – Technical analysis

AHM - Framework Analysis

Engineering - Reliability Analysis

 AHM technology deliver succinct technological advantages that provide

 Consider tapping on the significant volumes of reliable aircraft digital

 Develop policies, techniques and maintenance solutions

 Create AHM Data based maintenance program concepts

 Initiate an ISC stakeholder process to update the existing MSG-3

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