United Technologies / Altair Avionics Corp. Proprietary Information
AHS International Helicopter Safety Symposium
Peter WatsonAltair Avionics Corp.
United Technologies Corp.Montreal, Quebec, Canada
September 26-29, 2005
““Better Product Better Product Life Cycle SafetyLife Cycle Safety
Using Diagnostics”Using Diagnostics”
United Technologies / Altair Avionics Corp. Proprietary Information
Generic Aircraft Product LifecycleGeneric Aircraft Product LifecycleTime (in years)
ProductionDiscovery
DefinitionDesign
Development
Testing
Retire
Initial ProductFielding
20-30 years
FieldUsage
ResidualLife
Requirements,Architecture,
Plan documents.
Reviews & acceleratedlife tested
Maj
or
Act
iviti
es
Scope document
ProductTesting &
Certification
Design Documents.
Continuous Innovation and Development
Life
cycl
ePr
oces
s
Continuous Refinement
Con
tinuo
us
Act
iviti
es
Product Configuration Management
Requirements & Scope Change Management
Reviews
Project Management Cycle
Support Processes (Change Management, Training, Daily Flight Ops…
United Technologies / Altair Avionics Corp. Proprietary Information
How do we maximize the component on-wing time?
When should we remove the components?
How do we better plan
the next shop visit?I need more information so we can make the best
business decision?
How do we proactively detect and mitigate emerging global fleet trends
and failure modes?
Whe
n sh
ould
we
dow
n th
e ai
rcra
ft?
What was that?I didn’t hear anything!
OK, tell me what happened?
You did what tomy aircraft?
This will help our This will help our maintenance planningmaintenance planning
decision processdecision process
Why You Need Diagnostics!Why You Need Diagnostics!
The reg’s require it!Improved
Dispatch Reliability
Safety of flight begins with a properly maintained aircraft. Safety of flight begins with a properly maintained aircraft.
United Technologies / Altair Avionics Corp. Proprietary Information
Health Management Value Stream- It depends on what phase of the product’s life cycle you’re currently in- There are different HMVS customers during the different Life Cycle phases.
Maintenance PlanningDecision Support
Operational Usage Data
DATAACQUISITION
DATAMANAGEMENT INVESTIGATE / ANALYSIS DECISION
MAKING
Requirements & Design: Optimized Product Design
Test & Certification: Pre-Service Validation
Entry into Service: Confidence / Peace of mind
Production: Maintenance Planning & Timely Decision Support Tools / FOQA…
Removal from Service: Residual Component Life Reuse
Diagnostics = Predictability: no matter what phase of the products life cycle
Product Life Phase :Product Life Phase : Desired OutcomeDesired Outcome
Maintenance Planning Decision SupportMaintenance Planning Decision Support
United Technologies / Altair Avionics Corp. Proprietary Information
Cell Tower
Internet
WLAN AccessPoint
WirelessHandheld
CellularProviders
Altair Avionics Aircraft Usage Monitoring TechnologyData Management
Integrated WebECTM(R)
Reporting
Fleet Usage ReportsExceedance ReportsE-mail/Pager Alerts
Acquire Data Transmit & Distribute Actionable Information
MLPLaptop
CableHook-up
ISPProviders
XX-XXXXX-XXX
TurbineTracker(TM)
Servers
Certified & Flying Today!
United Technologies / Altair Avionics Corp. Proprietary Information
• opening the door to continuous health monitoringcontinuous health monitoring• allowing for more accurate preventative servicing
and remote troubleshooting • optimizing engine/component on-wing time• offering new level of service to our customers• warranty & reliability enhancements• competitive advantage provided by using
DPHM technology• improved safety factors• improving R&M• driving costs
A Step-Change in Service
United Technologies / Altair Avionics Corp. Proprietary Information
Value Example: Full vs Partial Cycle CountingValue Example: Full vs Partial Cycle CountingAccurate Component Usage Adds Immediate Value Accurate Component Usage Adds Immediate Value
Full CycleFull CycleFull Cycle
Partial CyclePartial CyclePartial Cycle
55--toto--10% additional component10% additional componentusage life identified when usage life identified when
tracked electronicallytracked electronically
Mea
sure
dPa
ram
eter
sM
easu
red
Para
met
ers
TO
Idle
TimeTime
United Technologies / Altair Avionics Corp. Proprietary Information
OPTIMIZING REMOVALS AND WORKSCOPE$$
$’s
OV
ER
HA
UL
CO
STS
(% R
educ
tion)
OVERHAULOVERHAULTODAYTODAY
EXTENDED TIME ON WING
WITH DIAGNOSTICSWITH DIAGNOSTICS% SAVINGS% SAVINGS
EarlyRemoval
LateRemoval
OPTIMIZEDOPTIMIZEDUSAGE POINTUSAGE POINT
We need to shift from time-based to condition-based maintenance where appropriateREDUCED O/H COST
TIME ON WING (% Increase)
Monitor Health -- Reduced Unscheduled Maintenance / RemovalsProactively Manage Product Configuration – Extend Time On WingPlan Removals -- Minimize Service DisruptionsOptimized Work Scopes – Minimize Turn Around TimeContinuous Usage Monitoring – Component Deterioration predictability
United Technologies / Altair Avionics Corp. Proprietary Information
Example: Where Can Diagnostics Help HEMS Operators?Example: Where Can Diagnostics Help HEMS Operators?
SCENE
HOSP XFER SEE EXAMPLE 3A
DAY OR NIGHT
OP?
DAY
WX ABV MINS & STABLE
PREBRIEFED
NO INFO
WX AT MINS OR UNSTABLE
DETERMINE IF ANY OF
THE FOLLOWING
EXIST
FLIGHT REQUEST
PROCEED WITH
CAUTION
PROCEED WITH EXTRA
CAUTION
Yes
NIGHT
WX ABV MINS & STABLE
WX AT MINS OR UNSTABLE
No
Green = NORMAL OPS
Yellow = EXTRA CAUTION ZONERed = CRITICAL
SAFETY DECISION
PREBRIEFED
NO INFOPROCEED WITH
FLIGHT
CRITICAL SAFETY DECISION REQUIRED
EDGE OF ENVELOPE
PWR/PERF/FUEL/ RANGE
VISIBILITY RESTRICTIONS
FOG/RAIN/SNOW/ ICE
WX NEAR/AT MINSTEMP/DEW PT < 3O
DUTY TIME LIMIT/DIST FROM HOME
MINIMUM EQUIP. LIST ITEMS
LANDING ZONE CONCERNS
FLIGHTCREW OPERATIONAL
CONCERNS
MEDICAL CREW CONCERN
From FAA Notice 8000.301 dated 8/1/05APPENDIX 2. EXAMPLES OF TRAINING-WEIGHTED RISK ASSESSMENT AND MANAGEMENT PROCESSES
REQUIRED
United Technologies / Altair Avionics Corp. Proprietary Information
•• ToTo
Ex
am
ple
: A
lert
No
tifi
ca
tio
nE
xa
mp
le:
Ale
rt N
oti
fic
ati
on
United Technologies / Altair Avionics Corp. Proprietary Information
Blade Rub
SegmentRub
Correlation of Measured FieldEvents and then Performing
Focused MaintenanceCan Save Many Thousands of $$$’s
While Improving A/C Reliability Enabling Info
Data Management Maintenance Planning and
Decision SupportMaintenance Execution
Diagnostics can help drive the
cost of ownership down!
United Technologies / Altair Avionics Corp. Proprietary Information
This single flight with both an over-temp & over-torque engine
event cost the operator $100K+
As Measured On AircraftAs Measured On AircraftExceedence detected at [06/16/2003 08:45:19]:
Duration = 2680 (=67 secs)Engine 2 - ITT: Max = 00812.2749, Ave = 00808.4173
Exceedence detected at [06/16/2003 08:54:55]:Duration = 1680 (=42 secs)Engine 2 - Torque: Max = 03990.4150, Ave = 03975.8030
Exceedence detected at [06/16/2003 09:41:12]:Duration = 12880 (=322 secs)Processor 2 - Airspeed: Max = 00257.1400, Ave = 00251.8467
Results of an Eventful FlightResults of an Eventful Flight
Opportunity for inOpportunity for in--flight flight notification tonotification to
help prevent this help prevent this now availablenow available
United Technologies / Altair Avionics Corp. Proprietary Information
ITT
N1
Rotor Speed
Airspeed
Feb 17, 2004 Total Duration= 27 seconds
<97% (3 sec) Min = 96.9%
Max = 106.39 ktsMin = 102.48 ktsAvg. = 104.4 kts
>101.8% (9 sec) Max = 102.58%
Max = 852ºC>810ºC (22 sec)
Actual B412 N1 OverspeedXXX
We need to help the operators maximize usage while We need to help the operators maximize usage while not exceeding the aircraft capabilitiesnot exceeding the aircraft capabilities
United Technologies / Altair Avionics Corp. Proprietary Information
Customer Value Customer Value –– IFSD / UER avoidanceIFSD / UER avoidancePT6A-67D engine removed prior to additional damage occurring
TurbineTracker™ event alert and DAC notification
Event Name Detection Time Event Duration Valid Report Time History
Left Eng ITT > 800 20-May-05 18:52:42. 00:00:20
Engine 1 - Ng Max = 63.2129 % Avg = 40.4976 % Engine 1 - ITT Max = 883.2482 C Avg = 856.8231 C Left Eng ITT > 870 20-May-05 18:52:32. 00:00:05
Engine 1 - ITT Max = 883.2482 C Avg = 880.065 C Engine 1 - Ng Max = 38.5788 % Avg = 35.5131 % Left Eng ITT > 850 ON START 20-May-05 18:52:30. 00:00:09
Engine 1 - Ng Max = 28.2315 % Avg = 34.717 % Engine 1 - ITT Max = 883.2482 C Avg = 869.9468 C
- Engine removed for event and ECTM ® trend shift / performance degradation- Investigation revealed CT blade and segment rub- DAC service provided customer with maintenance recommendations based on engine performance indications
P&WC FMP - Regional Air Lines Description Engine S/N Late Data Status Last Review Date Last Upload Date Notes CN-RLA PS0106 RED 10-Jun-05 16-Jun-05 very hot start ATR-42-1 120689 GREEN 16-May-05 No Data New Installation
XXXXXXX XXXXXXXXXXXXX XXXXXX
XXXXXX
XXXXX
Automated trend data capture expedited removal / repair process
Estimated Savings:Estimated Savings: This had the potential cost of ~$250K to repair
United Technologies / Altair Avionics Corp. Proprietary Information
DATACAPTURE
DATADATACAPTURECAPTURE
ASSETMANAGEMENT
DATAMANAGEMENT
DATADATAMANAGEMENTMANAGEMENT
PREVENTATIVEACTION
PREVENTATIVEPREVENTATIVEACTIONACTION
Predictive AnalysisAircraft Availability
Component Reliability Cost of Ownership
Reliably Captured Accurate DataConfiguration FlexibilityReduced Pilot Workload
Secured Data Centrally LocatedIntegrated Multi-User Solution
Subject Matter Expertise
Aircraft Health ManagementTurning concepts into $ saving reliability improvements
United Technologies / Altair Avionics Corp. Proprietary Information
Conclusions:Conclusions:-- Data recording is an extremely Data recording is an extremely valuable toolvaluable tool-- The implementation cost can be small relative to the The implementation cost can be small relative to the ROIROI-- Helps improve Helps improve communicationcommunication between Operations and Maintenancebetween Operations and Maintenance-- Use the dataUse the data as an element of your overas an element of your over--all Safety Management Systemall Safety Management System-- If you do not use the data then you will not derive the If you do not use the data then you will not derive the full benefitfull benefit of the systemof the system
Remember:Remember:Mission First - Safety Always!
Any Questions?