A Guideline to Improve Reliability and Operational ...academy.amccentre.nl/thesis/presentatie/Presentation_C_Blamey.pdf · A Guideline to Improve Reliability and Operational Availability

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A Guideline to Improve Reliability and Operational Availability of Scorpène Submarines defining the way to

manage Logistic Effort with the goal of better performance

Master of Sciences in Asset Management Control

Dissertation

Student: Carlos BLAMEY

Professor: Michel KUIJER

22-12-2011

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1. Introduction

2. Problem’s description

3. Current situation, “Gateways” and their impact in the

reliability and operational availability

4. Prioritizing improvement opportunities

5.Methods which may drive submarines’ proposed

improvement

6. Conclusions

AGENDA

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1. Introduction






improvement

6. Conclusions

AGENDA

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1.- The “Neptuno Contract” was signed 1997 between the Chilean Navy and

the Scorpene Consortium for the construction of 2 Last Generation

Conventional Submarines which have been incorporated to the service

on 2005 and 2006 respectivelly.

Introduction.

2.- During the first 5 years in service, Scorpène Submarine have suffered the

failure of their critical systems, achieving a lower reliability and

operational availability than the defined one on the Technical

Specifications.

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O’Higgins’ availability reduction during the first years in operation

0

50

100

150

200

250

20052006

20072008

2009

TiempoProyectado(días)

Tiempo RealReparaciones(días)

Δ = 82%

Introduction.

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Introducción.

“This submarine is the most performing war machine I’ve never crew; it can be hard injured but it persist in fighting” (Bravo, 2008)…..

(Bravo, 2008)

But this argument wasn’t in line with the following caricature which shows the daily headaches of this Commanding Officer.

• Maintenance Plan• Budget• Spare parts• Supply Chain• Unexpected failures• Skills• Design

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1.- El Contrato Neptuno, fue firmado en 1997 entre la Armada de Chile y el

Consorcio Constructor en un proceso que generó un gran debate.

2.- Durante los primeros 5 años de servicio, los Submarinos Scorpène han

evidenciado una menor confiabilidad y disponibilidad operacional que la

especificada, producto de fallas en sus sistemas críticos.

3.- Those failures are not linked with the “Genetic Code” of their

equipments and, in general, they correspond to causes which are

not related to those identified by the suppliers in the ARM

analysis.

Introduction.

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Introduction.

The nature of the failures, which is not exactly proper to equipment’snature, forces us to look for cost-effective solutions in the explitation of ournaval assets.

The Maintenance Gateways (Nikolowski)

We have an opened gateway to failures!

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1.- El Contrato Neptuno, fue firmado en 1997 entre la Armada de Chile y el

Consorcio Constructor en un proceso que generó un gran debate.

2.- Durante los primeros 5 años de servicio, los Submarinos Scorpène han

evidenciado una menor confiabilidad y disponibilidad operacional que la

especificada, producto de fallas en sus sistemas críticos.

3.- Estas fallas no están necesariamente asociadas al “Código Genético” de

sus equipos, sino que en general corresponden a distorsiones del

análisis ARM.

4.- In the other hand, we can suppose that the budgetary situation

will no change in coming years.

Introduction.

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Introduction.

During the last decade, chilean GDP has grown notably.

But in the same period of time, Defense Budget has remain almost constant, so it is not foreseeable any significant budgetary improvement in the immediate future.

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1. Introduction






improvement

6. Conclusions

AGENDA

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Problem’s description.

How can be reliability and operational availability improved in order to achieve a better effectiveness of Scorpène Submarines during their exploitation phase?

Additionally, the following subsidiary questions may guide this Thesis:

• How can be identified the criticality of key systems which may impact operational availability of Scorpène?

• What causes the decreasing of systems availability?

• What can be done in order to decrease down time?

• Which should be the efforts to be done to improve reliability and operational availability?

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Problem’s description.

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1. Introduction






improvement

6. Conclusions

AGENDA

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Current situation, “Gateways” and their impact in the reliability and operational availability

Operational availability is defined at the design of the asset, considering personal, logistic and material matters.The operator adopts it according with their culture and other considerations.

Often, we care about operational matters without caring ILS implications and their impact in the life cycle of the assets.

Priorities have been centred in the purchase without regarding on support.

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Financial effort is centered in acquisition.


The submarine’s ILS was built under a logic which didn’t consider obsolescence, lack of skills, or infrastructure.

It is not previewed extra budget to complement the ILS, nevertheless the sole budgetary assign is not enough….we have to prioritize.

An ILS without budgetary support implies several weakness during the life cycle..

During the operational phase, those requirements have to be duly evaluated, being one between several requirements for the Navy.

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Way of OperatingDecisions under pressureShort time vision.

DesignBas maintenance specificationsLack of toolsChange of materialsSupplying mistakesBad informationPoor communication

Maintenance errorsData qualityData interpretation

Bad quality of the air-Water contaminationExtreme ambiance conditions

Situación actual, “Gateways” y su impacto en la confiabilidad y disponibilidad operacional

The Maintenance Gateways (Nikolowski)

“Unforced errors” of our equipments…..

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Reliability:

Ao = Uptime

Uptime + Downtime

R(t) = e-λt

λ = number of failures

total uptime hours

We have to look for simple and feasible solutions to improve reliability and operational availability of our submarines.

To improve reliabilitywe have to reducethe number offailures

Operational availability:

To improve availabilitywe have to reducedowntime

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Summary of Failures v/s CriticalityFramework of 5 Years

0

50

100

150

200

250

Intern

al Communic

ation

sHull S

tructu

reProp

ulsion

Electric

Gene

ration

Integ

rated Plat

form C

&M

Hull Ins

tallat

ions &

Accomoda

tions

Weapon

s Ope

ration

Safety

DiveNavig

ation

Air & S

urfac

e Dete

ction

Tactic

al Exp

loitat

ion

Operat

ional

Enviro

nmen

t

External

Commun

icatio

n

Technical Function

Dow

ntim

e

0

100

200

300

400

500

600

700

Crit

ical

ity

Number of FailuresCriticality


From SALINO we got the number of failures, downtime and criticality.

Discarding short downtime failures, we had evaluate Causes and Duration as a way to evaluate their impact on reliability and operational availability

Criticality: how much a system contributes to mission..

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Availability matrix let us discover the “Gateways”, it means were we have given room to failures, without duly coming with solutions to mitigate the downtime.

(1) Causes of the Failure

Env

ironm

ent

Qua

lity

of D

esig

n

Man

ufac

turin

g D

efec

t

Deg

rada

tion

Bad

Spe

c. o

f Mat

eria

ls

Mai

nten

ance

Indu

ced

Bad

Ope

ratio

n

Tota

l

%

(2) C

ause

of t

he d

elay

Needs Manufacturer Support 6 32 20 9 1 0 0 68 40,48

Long Lead Items 17 4 0 9 6 0 1 37 22,02

Needs DesignEvolution 8 8 3 0 3 6 0 28 16,67

Lack of Tools & Facilities 1 1 0 1 0 2 1 6 3,57

Problem of Access 10 0 0 2 0 0 0 12 7,14

Lack of Budget 5 3 0 5 0 0 0 13 7,74

Obsolescence 1 0 0 3 0 0 0 4 2,38

Total 48 48 23 29 10 8 2 168 100

% 28,57 28,57 13,69 17,26 5,95 4,76 1,19 100

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1. Introduction






improvement

6. Conclusions

AGENDA

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We could know what to do, but how to do it if needs are greater than budgetand if we know that we are not going to got any special budget?

Prioritizing improvement opportunities

Where to start?

ParetoFactor

0

500000

1000000

1500000

2000000

2500000

3000000

3500000

BH OO DB DY UA BB BC RC EN FG RH RD FH GV HX BT DA

ParetoFactor

We will focus on the 20% of the failures with more availability impact, taking into consideration their criticality, their frecuency and their downtime.

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How to prioritize budgetary effort?

We have to built a ranking taking into consideration:

• Availability Impact

• Budgetary effort

• Confident

If we have USD 1M.How can I be more cost-effective?

All the money in one, two ore more problems? On which solutions?

ParetoFactor

0

500000

1000000

1500000

2000000

2500000

3000000

3500000

BH OO DB DY UA BB BC RC EN FG RH RD FH GV HX BT DA

ParetoFactor

Are we really sure on that?

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Following this method, the next is the ranking that should been follow in order to come with cost-effective solutions.

Installation Installation Description Cause/DowntimeAvailability

Impact Number Effort Confidence Focus

KO Combat Mgt. System Quality/Manufacturer 2 3 2 12

BM Diesel Cooling System Quality/LLI 1,8 2 3 11

BD Diesel Engines Degradation/Manufacturer 1,6 3 2 9,4

DP Steering Console Quality/Manufacturer 0,9 3 3 8,3

ME Electric Propulsion Motor Degradation/LLI 0,8 3 3 7,4

GS Attack Periscope Degradation/Manufacturer 0,7 3 3 6,2

BH Air Induction Environment/Evolution 3 2 1 6,1

AvailabilityImpact

BudgetaryImpact

Confident

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1. Introduction






improvement

6. Conclusions

AGENDA

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Methods which may drive submarines’ proposed improvement

1. 40% of the failures that needsmanufacturer support….

What should be done to reduce ……?

• Technology transfer:

- SAGEM: Level 4 maintenance- Thales: SUBTICS- DCNS : Setting to Work, External connectors

• Development of Special Tools to support Logistic Process:

- Information Portals- Logistic Perfornance Indicators- Needs’ satisfaction indicators

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1. 40% of the failures that needsmanufacturer support….


• Technology transfer:

- SAGEM: Level 4 maintenance- Thales: SUBTICS- DCNS : Setting to Work, External connectors

• Development of Special Tools to support Logistic Process:

- Information Portals- Logistic Perfornance Indicators- Needs’ satisfaction indicators

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2. 22% of failures affected by long leaditems…….


• Benchmarking:

- Joint purchasing process- Common Stock- Maintenance plans revision- COTS management policies

• Improvement of inventory management methods:

- Replacement of the zero stock policy (since 1988) by a new one basedon criticality stock levels.

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2. 22% of failures affected by long leaditems…….


• Benchmarking:

- Joint purchasing process- Common Stock- Maintenance plans revision- COTS management policies

• Improvement of inventory management methods:

- Replacement of the zero stock policy (since 1988) by a new one basedon criticality stock levels.

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3. 40% of failures affected by design ofmanufacure…….


• Multidisciplinary Teamwork including the most skilled people in order to propose ballanced solutions:

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3. 17% of failures caused by degradation ofcritical components..….


• Long Term Agreements:

- Availability based contracts for specific sistems.

• Review of the design and the maintenance plans.

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1. Introduction






improvement

6. Conclusions

AGENDA

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Conclusions:

1. Scorpène submarines have evidenced lower reliability and operationalavailability than the one defined in the Contract.

2. This situation comes from open “Gateways” caused by failures on ILS….Logistic products haven't been purchased at the due time.

3. Failures which more impact into reliability and operational availability arethose which needs the support of the manufacturer, those affected bylong lead items and also those derived from design and manufactureaffected by the effect of the exposition to extreme pressure (operationdepth).

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4. We have already implemented solutions, by duly integrating pragmaticcriteria in order to come with cost-effective mitigating solutions, based onthe effect on performances.

5. There are also long term solutions which might be implemented throughusers clubs, as inventory management improvements, joint purchaseprocess in order to benefit of volume, common stocks, etc.

6. The good, transparent and consensuated priority definition…….

Conclusions

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Thank you.

Questions?

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Documents

A Guideline to Improve Reliability and Operational ...academy.amccentre.nl/thesis/presentatie/Presentation_C_Blamey.pdf · A Guideline to Improve Reliability and Operational Availability