2000 SAP AG European A&D Information Forum 2000, March 14./15.2000 / 1 Jens Schoeneberg (E2) Jens Schöneberg Solution Architect MRO/M&E Rotable Management

2000 SAP AG European A&D Information Forum 2000, March 14./15.2000 / 1 Jens Schoeneberg (E2)

Jens SchönebergSolution Architect MRO/M&E

RotableManagement



SAP Solution22

Rotable Management in Aerospace11

SAP Future Focus33

Content



SAP Solution22


SAP Future Focus33

Content



Repairable Part Serialized Long Life Cycle Expensive Components Big / Complex Components Life Limit Controlled

What is a Rotable?



Rotable Management Cycle

Stock

ServiceableServiceable UnserviceableUnserviceable

ProcurementScrapping

In-house Repair

Aircraft

Subcontracting


Scenarios with/without Intermediate Storage

WarehousePart(s)

Replacementpart(s)

Part(s)

Part(s)

Technicalobject

Repairprocess

Part(s)

Part(s)

Technicalobject

Repairprocess

Open-loop scenario

Closed-loop scenario


Rotable Management Requirements

Support of maintenance/repair processes

In-house

Subcontracting

Documentation of all maintenance tasks performed

Traceability of rotable parts back to birth

Inventory

Configuration (production site)

Repair shop (shop floor) / Subcontractor

Handling of rotable part status

Tracking of rotable part conditions

Part number change due to modification

Handling of exchange parts from subcontractors

Valuation according to parts condition

Businessrelated

Businessrelated

AviationAuthority

related

AviationAuthority

related


SAP Solution22


SAP Future Focus33

Content



Func-tionallocation

Equip-ment/Serialnumber

Technicalobjects

As-Maintained Configuration

Assem-bly

Material


Serial Number and Equipment

Equipment master record

Serial data

Material E-2002Material E-2002

Serial number 1351Serial number 1351

• Stock information

• Serial number history


Rotable Exchange Process

(1) Rotable exchange process


Return of serviced partReplacement part

Removal of part Shipment of part

(2) Repair process(2) Repair process

WarehouseWorkshop /

Subcontractor


Life Controlled Rotables I

Flight HoursFlight Hours

Take-offs/LandingsTake-offs/Landings

Chracteristics ofClassification System

Chracteristics ofClassification System

CounterReading

Flight hours 2351CounterReading

Landings 511

Input Sources:- Manually via R/3- Intranet/Internet- PM-PCS Interface

Technical ObjectTechnical Object

CounterCounter


Aeroplane counter

12.02. 350 Take-offs/landings

20.02. 360 Take-offs/landings

Landing gear counter for tires

12/02. 20 Take-offs/landings

20/02. 30 Take-offs/landings

Difference of 10 take-offs/landings carried forward

Life Controlled Rotables II


Automaticcreation

Update onFlight Hours

RotableMaintenancePlan R/3

Pump P111

PM/CSPM/CSOrderOrder

PM/CSPM/CSOrderOrder

Rotable Exchange

1 4 5 3

P111

Hours

Aircraft ConfigurationAircraft Configuration

Manualcreation

Discrepancy found

LifeContolledRotable

PM/CSPM/CSNotificationNotification

PM/CSPM/CSNotificationNotification

Trigger/InitiateRotable

Exchange


Usage list

G-BIKAG-BIKA

Installation 01.03.98Removal 20.09.98

01.03. - 20.09.98 G-BIKA01.03. - 20.09.98 G-BIKA

Traceability of Rotable within As-Maintained Configuration


PurchasingPurchasing

Ser. No. 1Ser. No. 1

Ser No.-1New

New

Ser. No. 1Unservice-

able

Ser No. 1Service-

able

Sub-contractor

In-house

Ser No. 1

Ser No.-1

ShippingShipping

ReceiptReceipt

Rotable Traceability witin Inventory


Materialwith valuation type A

(condition-basedvaluation)

Materialwith valuation type A

(condition-basedvaluation)

Valuation typeNEW

$ 3,000.00

Valuation typeNEW

$ 3,000.00

Valuation typeSERVICE

$ 2,200.00

Valuation typeSERVICE

$ 2,200.00

Valuation typeUNSERVICE $ 1,280.00

Valuation typeUNSERVICE $ 1,280.00

Valuation Based on Parts Condition


In-house Repair Process





(2) In-house repair process

(2) In-house repair process

WarehouseIn-house

Workshop


Refurbishment Order

Maintenance order 800175Order type: PM04

Material P-2001 Fuel pumpQuantity 3Serial number 53, 81, 27

From UNSERVICEPlant:0001 SLoc: 0002

To SERVICEPlant: 0001 SLoc: 0001

StockStockPlantPlant 00010001SLocSLoc 00020002


UNSERVICE

Goods issuewith movement

type 261

Goods issuewith movement

type 261



SERVICE

Goods receiptwith movement

type 101

Goods receiptwith movement

type 101SLoc = Storage location


Material P-2001Serial number 53

Plant 1000Storage location0001BatchSERVICE

Material P-2001Serial number 53

Plant 1000Storage location0002BatchUNSERVICE

EnjoySAP - Refurbishment

StockStockStockStock

UNSERVICE

StockStockStockStock

SERVICE

Refurbishmentorder

Refurbishmentorder

Object list:- Serial number 1- Serial number 2- Serial number 3

Object list:- Serial number 1- Serial number 2- Serial number 3

Goods issue

Goods issue

Automatic change of valuation type during goods movementAutomatic change of valuation type during goods movement

Proposal of serial numbers during goods issueProposal of serial numbers during goods issue


Subcontracting Process





(2) Subcontracting process

(2) Subcontracting process

New withIS A&D 4.6New with

IS A&D 4.6

Warehouse Subcontractor


Purchase Order for Subcontracting

SubcontractorSubcontractorMRO ProviderMRO Provider

10 L 1pc DISC SerNr 471pc DISC SerNr 472pc BLADE

DISC Serial Number 47

Purchase OrderPart that will be receipt back

Parts that will be providedto the subcontractor

+


Warehouse

xxxxxxxxxxxxxxxxxxxxxx

xxxxxxxxxxxxxxxxxxxxxx

xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx

Purchase orderSubcontracting

DISC 1pcBLADE 2pc

SC vendor SUBC1

SC inventory monitor

DISC BLADE

(1) Create SDdelivery

(2) Post goodsissue for P/O

Picking, Packing, Shipping

Vendorstock

SC = Subcontracting


SC vendorSC vendor

1)1) Goods receipt for theGoods receipt for theserviced rotableserviced rotable

2)2) Component consumptionComponent consumption

Purch. Orderhistory

Comp.: DISC

Goods receiptof rotable

Goods Receipt

Warehouse

SC = Subcontracting


Goods receipt of servicable parts

Part number change Serial Number change

Valuation change

Consumption of parts from

SC vendor stock

Goods Receipt

Three scenarios are supported at the time of the goods receipt:

Rotable with the same material and serial number is received

Material number of rotable changes (due to upgrade), but serial number remains the same

Subcontractor sends back replacement part, with different serial number

The new parts condition might require a valuation change

For traceability reasons, the history for a specific serial number must be complete

SC = Subcontracting


Warranty Assignment

Master warranty

• Description

• Warranty services

• Warranty counter

Tail G-BIKA

• Valid from 5.1.1998

• Measuring point:Flight hoursCycles

Tail C-678

• Valid from 12.10.1998

• Measuring point:Flight hoursCycles

Assignment


SAP Solution22


SAP Future Focus33

Content



EnjoySAP - Rotable Exchange Process

Replacement part

Removal of part

Warehouse

Easy-to-use transaction for exchange of rotable part during line maintenance

Supported functions

Creation of PM/CS notification to document discrepancies and which is used as rotable part traveller

IPC access to identify replacement part

Configuration update at time of removal / installation

Configuration completeness check

Automatic goods movement postings for

Goods receipt/issue

Change of ownership

Change of parts condition

Valuation change


Initial Provisioning / Follow up Procurement*

No of Aircraft

No of Parts per Aircraft

Flying hours per Aircraft a Day

Mean Time Between Removal

Turn Around Time

Service Level

....

No of Locations

Turn around time per Location

Stock transfer time

Budget

Costs (have to be calculated)

Optimal Stockper location

Repair Float required

per location

Repair Float required

Level 1Level 1 Level 2Level 2 Level 3Level 3

* Depends on client funding


Integrated Planning for Rotables Using APO*

Fulfillment SystemR/3

Fulfillment SystemR/3

Historical dataHistorical data

Maintenance planMaintenance plan

PM/CS orderPM/CS order

InventoryInventory

Refurbishment orderRefurbishment order

P.O. new partP.O. new part

P.O. subcontractingP.O. subcontracting

SynchronizeP.O. = Purchase order

Planning SystemAPO

Planning SystemAPO

Detailed PlanningSNP

Detailed PlanningSNP

Fullfillment PlanningPP/DS

Fullfillment PlanningPP/DS

ForecastDP

ForecastDP

* Depends on client funding


Reliability Monitoring in BW

Development of Extractors for the following Key Performance Indicators (KPIs):

Mean Time Between Removal (MTBR)

Mean Time Between Unscheduled Removal (MTBUR)

Mean Time Between Failure (MTBF)

Documents

2000 SAP AG European A&D Information Forum 2000, March 14./15.2000 / 1 Jens Schoeneberg (E2) Jens Schöneberg Solution Architect MRO/M&E Rotable Management