10 Background of Maintenance 2015

(c) 2015 by Edy Suwondo 1

AE4170:Rekayasa Perawatan Pesawat Udara(Aircraft Maintenance Engineering)

Dr. Edy SuwondoE-mail: [email protected]

[email protected]/WA: 081 22 000 785

Aircraft Design, Operation and Maintenance Research GroupFaculty of Mechanical and Aerospace Engineering

Institute Technology Bandung

Peraturan Kuliah

Sistem kuliah:Ceramah dan PR/Tugas

Evaluasi: Kuis 10 kali PG(?), dijadwal, dipakai semua (90%)PR (3 buah) 10% (jika terlambat -20%/minggu)

Tidak ada toleransi terhadap kecurangan dalam kuis.Tidak ada kuis susulan, UTS, UAS atau Rev.

A>84, 84AB>77, 77B>70, 70BC>62, C54, 54>EHP SILENT!!


Course DescriptionShort Description:Overview on aviation safety and operating costs, review on probability theory and models, failure density functions, discussion on maintenance concept, Reliability-Centred Maintenance, MSG-3, Regulations and Organisation, and Reliability Program.

Tujuan Instruksional Umum (TIU):Kuliah ini memberikan pemahaman tentang latar belakang perlunya perawatan, pemodelan keandalan, konsep perawatan, metode pembuatan program perawatan, peraturan yang berlaku dan metode pemantauan dan evaluasi program perawatan yang sedang berjalan. Mahasiswa diharapkan mampu menerapkan pemahaman tersebut pada studi kasus di pesawat udara.

Related Courses and ReferencesRelated Courses:1. AE2201: Statistika (Pre-requisit?)2. AE3180: Aircraft Systems (Co-requisit?)

References/Bibliography:1. John Moubray, Reliability-centred Maintenance, Butterworth-

Heinemann, 2nd ed., 19972. F. Stanley Nowlan and Howard F. Heap, Reliability-Centered

Maintenance, United Airlines, 19783. ATA MSG-3, SAE JA 10114. Diktat kuliah: Manajemen Perawatan Pesawat, oleh Edy

Suwondo, 20015. Reliability Eng. Handbook, Dimitri Kececioglu, vol1, 20026. AC 120-17A: Maint. Control by Reliability Method, FAA, 19787. Aircraft Maintenance Management, C.H. Friend., 1992


Pilih jawabanyangbenar (bisa beberapa atau tidak ada,tulis nomor soal dan jawaban saja).1. Probabilitas sebuah sistemuntuk TIDAKmemenuhi fungsinyapada waktu dankondisi operasi

tertentu dinyatakan dengan fungsi:a.Keandalan b.Laju kegagalanc.Densitas kegagalan d.Denstitas kegagalan kumulatif

2.Bathtubcurve (kurva bak mandi)merupakan kurva antara umur itemdengana.Keandalan b.Probabilitas densitas kegagalanc.Probabilitas kegagalan kondisional d.Denstitaskegagalankumulatif

3.PernyataanhubunganberikutiniyangBENARadalah:a.Fungsi densitas sama dengan negatif turunan pertama keandalan.b.Laju kegagalan sama dengan fungsi densitas dibagi keandalan.c.Keandalan sama dengan exponensial pangkat negatif integrallaju kegagalan terhadap waktu.d.Probabilitas kegagalan kondisional sama dengan exponensial pangkat negatif integralkeandalan

terhadap waktu.4.YangBUKANsyarat dapat diterapkannya tugas perawatan OnCondtion (OC)adalah:

a.Kegagalan potensial dapat didefinisikanb.Laju kegagalan meningkat dengan tajam setelah umur tertentu.c.Mudah untuk mendeteksi kegagalan potensial d.PFintervalkonsisten dan panjang.

5.Jika PFinterval6bulan,sedangkan Nett PF1bulan,maka intervalinspeksi adalah:a. 2bulan b.2,5bulan c.1bulan d.5bulan.

Course ProgramWk Topik Sub Topik TIK Act.1 Overview on

aviation safety and operating costs

Accidents and incidents which may be prevented by maintenance

Peserta dapat mengidentifikasi penting-nya perawatan bagi keselamatan penerbangan dan pengurangan biaya perawatan total, serta potensi bisnis MRO

K, T

2 &3

Review on probability theory and models

Bath tub curve,Failure data plotting, distribusi eksponensial, normal, dan Weibull

Peserta dapat menentukan fungsi distribusidari sekumpulan data kegagalan, menurunkan hubungan fungsi-fungsi yang digunakan, serta menjelaskan karakteristiklaju kegagalan

KPR

4 Maintenance concept

Model degradasi prestasi dan bentuk distribusi pada strategi perawatan

Peserta dapat menjelaskan strategi perawatan yg sesuai berdasarkan bentuk degradasi prestasi dan distribusi kegagalan

Q1, K

4, 5&6

RCM Tujuh pertanyaan RCM,Fungsi, kegagalan fungsi, efek dan dampak kegagalan

Peserta dapat menjelaskan fungsi dan kegagalan fungsi, serta klasifikasi konsekuensi kegagalan dan kriteria efektivitas tugas perawatan

Q2, K

7 RCM Metode penentuan tugas perawatan

Peserta dapat memilih tugas perawatan yang 'applicable', efektif dan efisien.

Q3, K

8 RCM Tindakan standar Peserta dapat menentukan tindakan standar yang sesuai untuk tiap kategori konsekuensi kegagalan

Q4,K


Wk Topik Sub Topik TIK Act.

9 RCM Contoh penerapan pada sistem dan mesin

Peserta dapat mengaplikasikan RCM untuk sistem mesin pesawat.

Q5, K, PR

10 RCM RCM untuk structure pesawat dan contoh penerapannya

Peserta dapat menentukan penyebab kegagalan struktur dan ratingnya.

Q6, K

11&12

MSG-3 MSG-3 untuk Systems and Power Plant, and Structure

Peserta dapat menjelaskan perbedaan MSG-3 dengan RCM dan logika khusus MSG-3 untuk struktur

Q7, K

13 Regulasi dan Organisasi.

FAR 25 dan 135Advisory Circullar's

Peserta dapat menjelaskan regulasi yang berkaitan dengan perawatan dan dampaknya pada organisasi dan proses pembuatan dokumen perawatan pesawat.

Q8, K

14 Reliability Program Proses dan data yang diperlukan.

Peserta dapat menjelaskan proses pemantauan prestasi program perawatan.

Q9,K

15 Reliability Program Bentuk-bentuk evaluasi Evaluasi dan tindakan perbaikan K, Q10

Course Program (contd)

What is Maintenance?

All activities subjected to technical systemsto keep the condition (Preventive)

or to bring to the condition (Corrective)which is required to fulfill specified functions


What is Maintenance?

unavailable state

Perf

orm

ance

leve

l/co

nditi

on/

res

ista

nce

to fai

lure

Initial Condition

Potential failure condition

Functional failure condition

TimeDefect

available state

Maintenance

Modification

9Maintenance Organization should achieve the goal in a efficient way.

9Maintenance also contributes to Airlines profit by minimizing its cost and maximizing aircraft availability

Objectives (ver. MSG3-2002):

To ensure realization of inherent safety To achieve the targeted availability and reliability (Mengindentifikasi adanya kebutuhan modifikasi) To minimize total maintenance cost

Aircraft Maintenance Overview


DefinisiAirplane Accident (Boeing, ICAO, NTSB): An occurence associated with the operation of an airplane that takes place between the time any person boards the airplane with the intention of flight and such time as all such persons disembarked, in which: the airplane sustains substantial damage, or the airplane is missing or is completely inaccessible, or death or serious injury results from being in the airplane, or direct

contact with the airplane or anything attached thereto, or direct exposure to jet blast.

Exluding fatal and nonfatal injuries from natural causes, and fatal and nonfatal self-inflicted injuries or injuries inflicted by other person, and nonfatal injuries resulting from atmospheric turbulence, normal maneuvre, loose object, boarding, disembarking, evacuation, maintenance and servicing.

Not considered as accident: result of experiment test flight, sabotage, hijack, terrorism, and military action.

TerminologiDestroyed: the estimated or likely cost of repair would have exceeded 50% of the new value of the airplane had it still been in production at the time of accident (NTSB: not economically repairable; Hull Loss = totally destroyed)Fatal injury: any injury that results in death within 30 days of the accidentMajor accident: an accident in which any of the thee conditions is met:- the airplane was destroyed, or- there were multiple fatalities, or- there was one fatality and the airplane was substantially damaged

Serious injury: an injury that is sustained by a person in an accident and that requires hospitalization > 48 hrs, commencing within 7 days after injury, or results in a fracture of any bone (except simple fracture of fingers, toes, nose). etc.Substantial Damage: damage of failure which adversely affects the structural strength, performance, or flight characteristics of the airplane, which normally require major repair.


Any means or combination of overhaul, repair, inspection, replacement, or defect rectification of an aircraft and or aircraft components

The alteration of an aircraft and or aircraft component in conformity with an approved standard

Repairables Rotables Consumables

Airframe

Engine

Component

Line A-C Checks Higher Checks

29%

46%

25%

8%7%14%

What is Maintenance

Aviation Safety StatisticsUSA Passenger fatalities per billion passenger miles 20002009[Ian Savage, in The Economics of Transportation Safety, July 2013]

Riding a motorcycle 212.57Driving or passenger in a car or light truck 7.28Passenger on a local ferryboat 3.17Passenger on commuter rail and Amtrak 0.43Passenger on urban mass transit rail (20022009)a 0.24Passenger on a bus (holding more than 10 passengers transit, inter-city, school, charter)

0.11

Passenger on commercial aviation 0.07a While onboard a train including assault and violent acts.


SOME A/C ACCIDENTS:Beech BE-1900D (RIGGING)Tupolev TU-154 (NUT)A310, braking system failure

Database accidents:http://www.skybrary.aero/


AirDisaster.ComAirbus A310-324, Sibir Airlines, 09 July 2006, on a scheduled

passenger flight from Moscow, veered off runway 30 after reportedly carrying out a normal landing, smashed through several buildings,

and exploded in flames, at Irkutsk, Russia.


Maintenance StrategyHow an Airline perform its aircraft maintenance

Pooling (Component & Engine): charge based on Flight Hours (Power By the Hour)

Individual Repair/Overhaul: time and material basis (Cost +)

Contract Maintenance Partly done in-house, the rest outsourcing

Garuda (in terms of cost): 30% in house, 70% outsource

Outsourcing

Aircraft Maintenance Overview


Innovative Cooperative Actions of R&D in EUROCONTROL Programme CARE INO III, Dynamic Cost Indexing

The Amount of Usage or Demand for Aircraft OperationsThe level of maintenance is directly related to the amount of usage in that it is the operation of aircraft which creates the wear on equipment.

Government Policy Government policy sets the basic ground rules under which

the industry operates

In many ways it creates the open market for maintenance, for example RVSM (Reduced Vertical Separation Minima) modification, ACAS 2 (Airborne Collision Avoidance System) modification mandated by the government authority.

MRO Industry


The Big PlayersAirframe Maintenance Engine Maintenance Component Maintenance

Tramco/BF Goodrich Lufthansa Technick SAS ComponentsLufthansa Technick General Electric Tramco/BF GoodrichSR Technick General Electric Strother Lufthansa TechnickKLM Pratt & Whitney Allied SignalFLS Aerospace Rolls Royce SR TechnickHAECO SR Technick Air FranceAir France Greenwich HoneywellTimco Volvo Nordam GroupBoeing Aerospace KLM Rockwell CollinsTeam AER Lingus Air France British AirwaysAir Canada Air New Zealand IAI / BedekAmerican Airlines Aviall Boeing AerospaceBritish Airways GE Caledonian Celcius AviocomDelta Airlines MTU FLS LtdFinair Snecma Services Qantas

MRO Industry


http://www.mcgraw-hillhomelandsecurity.com/events/html/mas10/Day2%20Opening.BUDIHADIANTO.pdf


Opportunity of Cooperation - Engineers/Technicians

Newtechniciansbyregion20142033

Region TechniciansAsiaPacific 238,000Europe 101,000NorthAmerica 113,000MiddleEast 66,000LatinAmerica 47,000CIS 22,000Africa 22,000

Total 609,000

39%

19%

10%

7%4%4%

17%

609,000

Source:BoeingPilot&TechnicianOutlook2014,GMF2015

Morethan

http://www.mcgraw-hillhomelandsecurity.com/events/html/mas10/Day2%20Opening.BUDIHADIANTO.pdf


Three Phases of RCM-Based Maint Program[Neil B. Bloom, RCM implementation made simple, 2006]

Phase 1: Identification of important items for safety, operation, or asset protection.

Phase 2: Specification of the required tasks for the items above.

Phase 3: Properly executing the tasks above.

Tugas 1 (3% NA, 25 Agustus 2015)Cari (di mana saja) dua makalah/laporan/publikasi aplikasi

perawatan untuk mencegah kecelakaan pada alat transportasi(bebas). Deskripsi harus teknis. Paling lama publikasi tahun2013.

Ketentuan:1. Sertakan print out (fotocopy) makalah (halaman pertama saja,

non-cover)2. Buat ringkasan halaman A4 per makalah (boleh terjemah

abstrak) tulis tangan3. Buat ulasan/analisis dan rekomendasi maksimum 1 halaman A4

tulis tangan rapi/terbaca (yang diketik nilai dikurangi 30%)4. Diekerjakan sendiri2, yang nyontek, nilai dibagi bersama5. Dikumpulkan Sebelum Kuliah minggu berikutnya (Selasa, 1

Sept. 2015).

Documents

10 Background of Maintenance 2015