P&WC Safety Management System539,470,000 total flight hours 24,000,000 flight hours per year 68,716 engines delivered ... Cessna Citation XLS Dassault F7X ATR 72 AgustaWestland AW139

P&WC Safety Management System

For International Helicopter Safety Symposium

30 September 2009 / Montreal

P&WC PROPRIETARY INFORMATION 2

OUTLINE

P&WC Overview

P&WC SMS Implementation

Approach and Philosophy

Governance / Management Structure

Key SMS Components & Elements

Implementation Status

Lessons-learned


P&WC GLOBAL PRESENCE45,000 engines, 9,300 operators and 195 countries

Production

Headquarters

P&WC Service Centers

Research and development

Longueuil

West Virginia

Rzeszow

Other Service Centers


P&WC GLOBAL CUSTOMER BASEOver 35 major aircraft OEM’s

EmbraerEmbraer

Air Tractor

Boeing

Cessna

Eclipse

Epic

Gulfstream

Hawker Beechcraft

Learjet

MD Helicopters

Piper

Quest Aircraft

Thrust Aicraft

Sikorsky

Air Tractor

Boeing

Cessna

Eclipse

Epic

Gulfstream

Hawker Beechcraft

Learjet

MD Helicopters

Piper

Quest Aircraft

Thrust Aicraft

Sikorsky

Bell Helicopter Textron

Bombardier Aerospace

Viking Air

Bell Helicopter Textron

Bombardier Aerospace

Viking Air

Pacific AeroPacific Aero

PilatusPilatus

Agusta

Dassault

EADSAirbusATRCASAPZL-OkecieSocataEurocopter

Piaggio

Sikorsky PLZ-Mielec

Agusta

Dassault

EADSAirbusATRCASAPZL-OkecieSocataEurocopter

Piaggio

Sikorsky PLZ-Mielec

HarbinChenghe

XianNAL

Ilyushin

KazanMIL

Ilyushin

KazanMIL

TashkentTashkent


P&WC IN SERVICE (As of Sept 09)

539,470,000 total flight hours

24,000,000 flight hours per year

68,716 engines delivered

45,010 flying engines

31,566 flying aircraft

9,660 operators

199 countries

163 engine models


6 KEY BUSINESS SEGMENTSCorporate

Military

Regional Civil helicopters

Aftermarket

General aviation

Cessna Citation XLS Dassault F7X

ATR 72 AgustaWestland AW139 Bell 427

King Air C90GT

Bombardier Q400

Embraer Super Tucano

Pilatus PC-12

CASA C295 Repair & OverhaulCustomer First Centre


P&WC HELICOPTER PRESENCE

Bell 412PT6T-3B/D EIS 1981

AgustaWestland AW139PT6C-67C EIS 2004

AgustaWestland KoalaPT6B-37A EIS 2001

Bell Agusta BA609PT6C-67A EIS 2011

UH-1N EIS 1970Eurocopter EC135PW206B EIS 1996

MD900PW206A EIS 1994

AgustaWestland PowerPW206C EIS 1997

Kazan AnsatPW207K EIS 2003

Sikorsky S76DPW210 EIS 2010

Bell 427PW207D EIS 2000

Bell 429PW207D1 EIS 2009

AgustaWestland GrandPW207C EIS 2005

PT6C1,600 – 2,100 shp

PT6T/B1,800 – 2,250 shp

PW210950 – 1,200 shp

PW200600 – 750 shp

EC175PT6C-67E EIS 2011

Sikorsky S76BPT6B-36A EIS 1985

InDevelopment

> 11,000 engines, 42 million hours, 600 operators


OUTLINE

P&WC Overview


Approach and Philosophy

Governance / Management Structure

Key SMS Components & Elements

Implementation Status

Lessons-learned


P&WC SMS IMPLEMENTATIONApproach & Philosophy

P&WC:

embraces the concept of SMS and has been actively working onimplementation since 2004

is deploying a company-wide SMS that covers all functions andTransport Canada approval/certificates

has incorporated proactive risk management processes consistentwith SMS and UTC policies

is leveraging many existing systems as foundation elements for theSMS


TCCA SMS Implementation Dates

Updated: June 10, 2009

November 2011Forecast -November 2011

Forecast -September 2011

AircraftCertification

February 2010Forecast -February 2010

Forecast -December 2009

ApprovedMaintenanceOrganization*(AMO) (573)

December 2010Forecast –October 2010

Forecast - June2010

ApprovedManufacturers(561)

P&WC is prepared for SMS initialcertification phase I by Transport Canadaof CAR 573 Approved MaintenanceOrganizations (AMOs) in February 2010


TCCA Certificates Issued TO P&WC

Design Approval Organization (DAO)AWM 505

CAR 511

Private Operator Certificate (POC)

CAR 604 (CBAA)

Approved Manufacturing Organization

CAR 561

Approved Distribution Organization

AWM 563

Approved Training Organization

CAR 403

Approved Maintenance Organizations (2)CAR 573

Certificate Holder

P&WC Corp.

Corporate Aircraft and Flight Test Bed

Corporate Aircraft

Engines

Engine / APU Type Certificates (Multiple)

Approved Maintenance OrganizationCAR 573


Transport CanadaSMS Requirements

6 Components17 Elements

1. Safety Management Plan1.1 Safety Policy1.2 Non-punitive SMS disciplinary policy1.3 Roles, Responsibilities & Employee Involvement1.4 Communication1.5 Safety Planning, Objectives & Goals1.6 Performance Measurement1.7 Management Review

2. Document Management2.1 Identification & Maintenance of ApplicableRegulations2.2 SMS Documentation2.3 Records Management

6. Emergency Preparedness

5. Quality Assurance

4. Training

3. Safety Oversight3.1 Reactive Processes3.2 Proactive Processes3.3 Investigation and Analysis3.4 Risk Management

CAR 106 – Accountable ExecCAR 107 – SMS Reqirements


P&WC SMS Governance Approach

ManufacturingProduce to

approved design

MaintenanceMaintain to

approved design

Approved Engine DesignEstablishes safe limits

Core SMS elements(Manual & Procedures)ACE operating system

Safety objectives & measurementRisk based safety decisions

Accountable ExecutiveSMS board

SMS steering group


P&WC SMS Governance Structure

SMS Accountable Executive

SMS Board

SMS Steering Group

SMS Steering Group Chair

Chief EngineerCustomer Service

Chief EngineerProduct Integrity

ManagerQuality Systems

Chief EngineerAW & Certification

ManagerC/S Ops QA & Eng

SMS Implementation Team

AMOSt. Hubert, Lethbridge

Flight Ops

DesignDAO

EngineeringType CertificatesPost Certification

ProductionEngine Centres, IMO

Manufacturing

Training Private OperatorSt. Hubert, Mirabel

Implementation Team Leaders

SMS Board meets 4x yrSMS SG meets every month


P&WC SMS BOARD - Composition

PWC PositionTCCA Reqm’tCertificate

PWC PositionSMS Board RoleSMS Role

SMS Board Core Executive

VP Customer ServiceCAR 573 / AWM 403AMO / Training

VP Operations Customer ServiceCAR 573AMO

VP OperationsCAR 561

AWM 563

Manufacturing Distribution

VP EngineeringCAR 511, AWM 505 CAR 604,CAR 573

DAO / Design

Flight Ops POC AMO

SMS Board Members – Responsible Executives

VP QualityAlternate SMS Board ChairExec Responsible

SMS Impl’n

Senior VP

Service Centres & Operations

Alternate SMS Board ChairAccountable ExecutiveDelegate

PresidentSMS Board ChairAccountable Executive


P&WC SMS BOARD Composition cont’d….

Chief Engineer,

Customer ServiceSMS Folder ManagementStatus

SMS Folder Management

Chief Engineer

Product Integrity

PWC PositionSMS Board RoleSMS Role

Chief Engineer, AW & Certification

J. Diamant BousteadSMS Board AdministratorSMS ImplementationTeam Lead

Manager, Quality Systems & Processes

Linda Jankov

PWC PositionSMS Board Role

SMS Board Members / Other

VP Human Resources

VP Finance

VP Counsel

VPs Marketing

SMS

Board Member

SMS Board Members / Other Executives


SMS Policy signed byAccountable Executiveprovided to TCCA01 January 2009

P&WC Safety Policy(SMS Element 1.1)


P&WC Non-Punitive Reporting Policy

UTC Code of Ethics

(SMS Element 1.2 )


P&WC Non-PunitiveEmployee Reporting Systems

DIALOG

UTC OMBUDSMAN

(SMS Element 1.2 )








4. Training




P&WCCertificate Holder

Safety ManagementCAR 107

Quality and Safety Management System ManualCertified by Accountable Executive

DAPMCertified by

VP Engineering

DESIGNAWM 505

QPMCertified by

VP Operations

MANUFACTURINGCAR 561

TPMCertified by

VP CustomerService

TRAININGAWM 403

MPMCertified by

VP CustomerService Ops

MAINTENANCECAR 573

P&WC SMS Documentation Structure

UTC Policy 45Quality

UTC Policy 53Safety

(SMS Component 2)








4. Training




P&WC SMS ImplementationSafety Oversight Process

Required Elements are basedon existing P&WC systems &processes

– Multiple data collection andmanagement systems

– ACE

– Investigations / Analysis

– Multiple Risk Analysis tools

– Management reviews

– Corrective Action

Continued integration requiredto optimize to fully meet PhaseIV intent

Quality EscapesDesign Escapes

Engineering

Action

Engine

InvestigationRoot Cause

Implement

Corrective Action

Reliability Meetings

Event Review

Best

Practices

Future

Designs

In - Service

Engine Event

Screening

(SMS Component 3)


P&WC Data Collection System and Sharing

DEVELOPMENT/DESIGN

•Enovia (Discrepancysystem)

MANUFACTURING

•SAP (QualityNotifications)•Enovia (Audit, CAR)

AFTERMARKET / FIELD

•Enovia (Audit, CAR, fieldreports)

•CMS (Event)

•TRAC (Events &Reliability)

•SAP-EIs (RepairDeviations)

•RFEs (RepairDeviations)

•WSDR (ServiceDifficulty Reports)


Tracking Reliability Aircraft Census (TRAC)P&WC’s Field Experience Data Warehouse

Configuration /Campaign Management

ReliabilityIFSD / BUR

Census

Reporting

Reliability theor y is the foundati on of rel iability engineering. For engineering purposes, reli ability i s defined as:

the probabilit yt hat a device will perform it s intended function during a specified period of time under stated cond itions.

Root Cause


Tracking Reliability Aircraft Census (TRAC)

Reliability AnalystsTRAC / SAS

Statistical System Engineering ReportLab. ReportService Center ReportShop ReportTear Down ReportUR NotificationWarranty claimCMS ReportContact ReportsOEM ReportsOperator Reports

Documentstorage

Automated data feed

TRACdatabase

Reporting

Shops, OEMs, FMP

manual data feed

Census, reliability, configuration

Data extraction for analysis & decision making

Reporting of issues, trends, reliability rates, etc.

to Aviation Authorities, OEMs, & Operators.

DATA ACTIVITY

72,800,000 Data points

690,600 Engine records

146,678 Aircraft records

185 Unique fields


MANAGING FLEET SAFETY

Screening Criteria and Procedures Standardized

Multiple Filtering of In-Service and Overhaul findings

Statistically Based Assessments

Utilize Industry-Accepted Practices (FAA / TCCA approved)

Evaluate Unmitigated Risk and Corrective Action impacts

Mitigate Risk through Fleet Campaign Plans

Safety Review Prior to Release External to P&WC

Engine Safety Criteria Appropriate to Type of Flight Operations

Offshore / CAT A

General Aviation

Single Engine

Regional / Civil Transport


Control System Benefits

Full-Authority Digital Electronic Control system (FADEC)

Reduced pilot workload

Enhanced dispatch reliability

Pilot training mode – OEI (twin engines application)

Automated starting with over temperature protection

Variable Nr governing

Automatic limitingPower sharing

State-Of-Art Diagnostics / Prognostics

Engine run time

Fractional cycle counting

Creep count

Engine Fault Code, Exceedance and Event monitoring

Engine Performance

HUMS capability

Preventative Maintenance

Flexible State of Art Diagnostics & Prognostics for HUMS

OperatorOEMPWC

HUMSFADEC

AC Systems

HUMS

Dedicated Website

ECTM Files

Fault Codes

Transient Data

GBS OutputP&WC

OEM

Local Cell Phone Network

Smart Software

Internet

Transient Data

GBS Output

Local Cell Phone Network

Smart Software

DTU

AC Systems

P&WC Product InitiativesCONTROLS / DIAGNOSTICS & PROGNOSTICS








4. Training





CommunicationGeneral SMS awareness via PWC website and publications

Teams involved in two day SMS Gap analysis workshops

SMS Communication Plan under further development as part of SMSImplementation plan

Training (SMS Component 4)

SMS Module now part of 3 day Airworthiness and CertificationTraining

Human Factors Training part of CAR / STD 573 Requirement for AMO

SMS Training requirements by certificate to be further developed &delivered per SMS Implementation plan

(SMS Element 1.4)


Consolidate & Develop Procedures

2010 2011 20122008 2009

SMS Manual

AE

Com

mi t

St a

tem

ent

Saf e

tyP

ol ic

yR

ev i

sed

Implement Plan (All phases for all certificates)

Gap Analysis

SMS Board & Steering Group Oversight

Reg in forceFeb 2010

AMOPhase I

Feb 2011AMO

Phase II

Feb 2012AMO

Phase III

Feb 2013AMO

Phase IV

Dec 2010Reg in force

ManufacturingPhase I

Nov 2011Reg in forceCertification

Phase I

Develop Plan

TCCA SMS Implementation dates

Regular meetings with TCCA

to update SMS progress


Gap Analysis & Implementation Plan

All required SMS elements reviewed

Specific cross certificate teams to be formed to addressidentified gaps

Management review and acceptance


P&WC SMS ImplementationLessons Learned and Benefits

Specific measurement of cost and benefits of SMS implementation notcurrently available, although similar initiatives have showed tangiblebenefits in quality and safety related metrics (CoPQ’s, Escapes)

Certificates issued under CAR 561 and CAR 573, and AS9100certification, addresses component 5 “Quality Assurance”, and part ofcomponent 4 “Training” requirements

Several existing systems (e.g., EH&S, Quality, ACE tools and processes)require integration within the enterprise-wide SMS framework

Culture and communication are keys to success

Benchmarking with similar companies provides knowledge transferopportunity and best practice sharing

Active participation in rulemaking and industry working groups hasadvanced understanding of SMS requirements


SUMMARY

Extensive and diversified product line of small gasturbine engines and customers

Continuous investment in technologies & products

Global manufacturing and aftermarket presence

Founded on the highest ethical standards

Committed to product and service safety throughimplementation of a fully integrated SMS