Aircraft Technical Records From Burden to Benefit Technical Records From Burden to Benefit ... Cathay Pacific Airways Limited 0 50 100 150 200 250 Without FLYdocs Retrieval FLYdocs

Aircraft Technical Records

From Burden to Benefit

IATA – Atlanta Nov 2015

Rob SaundersHead of Engineering Business Improvement

& LEAN

Paper in Commercial Aviation

A highly optimised, hugely inefficient industry of

people, pens and paper held together by

silos of automation

A Challenging Problem

Barriers to Introducing Paperless Maintenance

Buy in from Regulatory Agencies

Many regulations are law - Many countries

Lessors and Finance companies driving the need for Paper

Driven by the regulators……. Driven by the Airlines

Availability of structured data from OEMs and repairers

Few Data Standards

Maturity of systems and technology to support changes to the processes

Ability to meet of Mechanics and Engineers mindset

Cost of introducing technology and process changes across industry

Lack of understanding or vision for ‘back office, not so trendy’ functions

Tendency for airlines to accept incremental improvement of Siloed

processes that should be redundant

Lease Return Vicious Circle• CX Component Acceptance Data Standard – 7335 out of 14152

acceptance requirements are Lease return driven

Lessorrequested

more from ex-operator

Ex-operatorpenalized by not fulfilling

requirements

Ex-operators

asked for more next time lease

A/C in

Lease Contract

(Authority req’t + Airline specific req’t)

Next Operator asked for

more

Operators asked for moreLessors ask for more

Alignment required to come up with ONE standard

Paperless Objectives – IATA paperless EWG

• Eliminate process inefficiencies

• Improve cost avoidance (Lease Returns. Inventory, paper Management)

• Reduce in service disruption

Enable Airlines to reduce Cost / ATK

and increase revenue

• Influence the Industry to introduce standards (birth record requirements, lease returns requirements)

• Drive priorities for OEMs to deliver paperless

• Drive to set up centralised repair/part history data for all Operators/MROs

• Create awareness in the industry

Introduce Industry

Standards

• Exploit new generation aircraft capabilities

• Leverage on Technology and tightly manage systems and organisational integration – ie avoid the siloed covert developments

• Account for technological growth opportunities – ie data volumes, band width, improved world wide access, mobile devices etc.

Ensure Sustainability & Usability

Mission: To influence Airlines, MROs and Suppliers and Regulators (the Industry) to introduce

business changes that enables the removal of paper records in aircraft maintenance.

Technical Records - scope

M&E Records:

• ‘Time Since’ data

•The Flying configuration

• LSAP / FLS

•The accomplishment history of all

‘airline aware’ maintenance.

Controls:

•Allowable config.

•Task frequency

• Flight Schedule

Paper / Electronic Records:

• Work Cards

• Component Certs.

• Workshop reports

• Repairs

All the Paper

Maintenance

Information System

Document

Information System

Planned Maintenance

Tech / Cabin Log

Records

History

Paper to Data Strategy – 3 project streams

Cathay Pacific Airways Limited

Documents’ Copy Retrieval ProcessRetrieval Cycle

Request from

parties

Email to

HKG TRD

Manage requests

by HKG TRD

Email to

XMN TRD

Retrieve boxes

Retrieve documents

from boxes

Scan documents &

Put documents

back to boxes

Email back to

HKG TRD

XMN

HKG

Before

- Resources:

* 3 persons involved.

(1 in HKG, 2 in XMN)

- Availability:

* Working hours only.

- Process:

* Multi-user access is

not possible;

* Inefficient in fleetwise

documents retrieval;

* Waste created in

duplicated / repeated

requests;

* Documents retrieval

can only be based on

W/C ref. number.


Documents’ Copy Retrieval ProcessRetrieval Cycle

Request from

parties

Email to

HKG TRD

Manage requests

by HKG TRD

Retrieve boxes

Retrieve documents

from boxes

Scan documents &

Put documents

back to boxes

Email back to

HKG TRD

XMN

HKG

Email to

XMN TRD

Retrieve documents from FLYdocs

(Self-service)

After

- Resources:

* Self-service via Web.

- Availability:

* 24 hours x 7 days.

- Process:

* Multi-user access

is available;

* Can do fleetwise

documents retrieval in

one-go;

* Eliminate requests

management;


can be based on

any printed texts in

documents (inc. W/C

ref. number)


0

5

10

15

20

25

WithoutFLYdocsRetrieval

FLYdocsRetrieval

Man-hours

Total Man-hours

Man-hours of Document Retrieval (Comparing)Case Study: Document Retrieval Requests in AUG 2015

23

6

Documents:

60 documents requests (different A/C) from sections;

Last A check of whole A330 fleets from TS.

After

- Resources:

* Self-service via Web.

- Availability:

* 24 hours x 7 days.

- Process:

* Multi-user access

is available;

* Can do fleetwise

documents retrieval in

one-go;

* Eliminate requests

management;


can be based on

any printed texts in

documents (inc. W/C

ref. number)

Before

- Resources:

* 3 persons involved.

(1 in HKG, 2 in XMN)

- Availability:

* Working hours only.

- Process:

* Multi-user access is

not possible;

* Inefficient in fleetwise

documents retrieval;

* Waste created in

duplicated / repeated

requests;


can only be based on

W/C ref. number.


0

5

10

15

20

25

30

35

40

45

50


FLYdocsRetrieval

0

5

10

15

20

25

30

Maintenance Log(Last 3 months)

AD Workcards(9 items)

SB & AMSWorkcards(45 items)

FleetwiseWorkcards(186 items)

A & 2A ChecksDFP

(Latest)

Hardcopy Retrieval

FLYdocs Retrieval

Man hour

Individual Task’s Man-hours Consumption

Man-hours

Total Man-hours

Man-hours of Document Retrieval (Comparing)Case Study: Aircraft B-HUL - E&A Incident on 29th July, 2015

47

8

= Document retrieval according to individual W/O

= Except last 100 pages which remain on aircraft due to operation


0

50

100

150

200

250


FLYdocsRetrieval

Aircraft Lease Return & Sale Projects Case Study: Cathay Pacific B747-400F (B-HUK) Sale Project in JUL 2015

B-HUK

• FLYdocs is used in whole project;

• Total 4,100 items required in records building

(including AD / SB / Repair / LLP etc.)

• Average 60 pages in a single item (record).

Man-days

Total Man-days

(Documents retrieval only)

213

106


Aircraft Lease Return & Sale Projects On-time aircraft lease return & sale projects achieved

2013 2014 2015

B-HWJ

B-HWK

B-HWF

B-HWI

B-HWH

B-HUH B-HUK

B-HXK

B-HXI

• Achieved 100% on-time aircraft lease return & sale projects since Year 2013.

• B-HWJ is the first aircraft achieved on-time lease return in CX/KA history.

Airbus A330-300 Airbus A330-300 Airbus A340-300

Boeing B747-400FBoeing B747-400F

full lease return & sale projects

shown only .

Business Benefits – Records Management System

• No physical storage required for maintenance records

• Savings in Aircraft Lease Fees on redelivery processes

• Fast access to information

• Efficiency improvements in Tech Records section

• Improve security with the electronic information

• Rapid access for investigations

• Improve the Maintenance Program based on Data Analysis

Planned Maintenance

Tech / Cabin Log

Records

History


Current Technical & Cabin Log Process

PRINTING PAGES DISTRIBUTE

OPERATE

TECH/CABIN LOG

ENTRIES

UM DATA ENTRY TRANSPORT AIR MAIL

DATA SCAN

STORAGE

e-RECORDS

1.3M pages / year 1 FTE

1M entries / year

HKG: 17 FTE

3000 sq. ft

~ 50M records

4 Dashboards

UM Data Correction

1.5 FTE

2.5 FTE

COLLECT

1.3M Log Pages

•Data Correction

•Storage

•30 Employees involved

8 FTE

E-log Process – Phase 1: Paperless

PRINTING PAGES DISTRIBUTE

OPERATE

TECH/CABIN LOG

ENTRIES

UM DATA ENTRY TRANSPORT AIR MAIL

DATA SCAN

STORAGE

e-RECORDS

1.3M pages / year 1 FTE

1M entries / year

HKG: 17 FTE

3000 sq. ft

~ 50M records

4 Dashboards

UM Data Correction

1.5 FTE

2.5 FTE

COLLECT

8 FTE

1.3M Log Pages

•Data Correction

•Storage

•30 Employees involved

• Real Time Data Entry

• Accurate / Granular Info

• Enhanced Defect Management

• Improved Contract and Warranty

Management


So....... Job Done

All Happy

Its now fun to be in Tech Records

Well ........ Not Quite!

Planned Maintenance

Tech / Cabin Log

Records

History


The MRO(s)

Hangar Plan

Maintenance Requirements

(inc. AMS)

High Level hangar plan is generated

by applying Task Requirements to Fleet

and Facility constraints. This is based on

projected fleet utilisation (BOP)

Check Execution

Manage production plan

•Track critical path

•Track task ‘clock stops’

•Track shortages

•Track budget NRCs

•Electronic sign off of tasks

Actual man hour bookings

Material Usage

Task Accomplishment

Earned Value Management

•Reliability

•Check Escalations

•Float Calculations

•Technical Records

•Part Change

•Compliance

Hangar Execution

Maintenance Planning and Execution – 20/20 Vision

But There is No Standard

E2P - P2E

Electronic …..to…. Paper…. To…. Electronic

Maintenance Requirements

Technical Records

Tech Docs Management

System

Records Management

System

Check

Execution

Hangar

Execution

E-signature avoids paper and the

need to produce and scan a

document.

E through E

Line Services Mobility

• Mobility Apps for Line Services Frontline

• Available on iOS and Android

• Target company devices + staff BYOD devices

• Improve productivity and services

• Facilitate access to information• Flight Schedules, Meet & Greet Update

• Job Allocation, Workload plan

• Aircraft Defect Alert, Spare status

• Deferral Reference

• Facilitate reporting of tasks• Work Status Update

• Ultimately, all information required are on mobile device, no travelling

required between aircraft and base

22

Scope & Objectives

Improve Productivity

Faster aircraft turn around

Better service

23

Light Maint Mobility

Process Change a key project ingredient Light

Maint

Mobility

Identified paper based processes which can be eliminated

Must acommodate all customer processes / documents

24

• Streamlining Pre-input Planning

• Reduce paperwork & visual vetting

• Additional Dash Boards improves task scheduling and

manpower utilization

• Potential for future Business Intelligence

• Allow constant review of standard hours of particular tasks

• Allow future Business Intelligence for long term planning

• Safety & Quality improvement

• Allow engineers and mechanics to focus on the actual tasks

with information at proximity

• Avoid unnecessary bottleneck

• Visibility of Progress

• Visibility of Parts and Tooling required


…… and other intangible benefitsLight

Maint

Mobility

25

• Each Input on average of printing 700~ 1000 page. i.e.

hundreds of thousands pieces of paper and the

subsequent storage could be avoided


Environmental Benefit in addition…… Light

Maint

Mobility


So....... Will we be Happy?

Well ........ Not Quite!

The OEMs must recognise the issueAn airframe manufacturer’s records at a/c delivery:

• Not all Component locations are not provided.

• ARL / AIR does not include all config. control components

especially Reliability components.

• Required component information such as mfg date for a

calendar date control component is not provided.

• Data quality issue such as duplicate serial number, SN

mismatch with physical component.

• Your Regulators

• Your Airline – but not individually

• Your MROs – but not without standards

• The major manufacturers

IATA & ATA have been the catalyst

Who Can Make a Difference