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PHM Experience at UTC and Pratt & Whitney PHM Experience at UTC and Pratt & Whitney: Challenges and Opportunities Steve O’Flarity This document is the property of United Technologies Corporation (UTC). You may not possess, use, copy or disclose this document or any information in it, for any purpose, including without limitation to design, manufactureThe PHM or repair Society parts, or obtain FAA or other government approval to do so, without UTC’s express written permission. Neither receipt nor possession of this document alone, from any source, constitutes such permission. Possession, use, copying or disclosure by anyone without UTC’s express written permission is not authorized and may result in criminal and/ or civil liability. 1 October 2009 Pratt & Whitney Proprietary Focus United Technologies PHM Overview Pratt & Whitney PHM Overview Defining Value…It’s Not Easy Lessons Learned (and some we’re all still working on) Click to edit Master subtitle style page 2 1 October 2009 United Technologies Corporation Click to edit Master subtitle style page 3 Public Access Data 1 October 2009 A Tradition Of Innovation Willis Carrier Elisha Graves Otis Igor Sikorsky Fred Rentschler Click to edit Master subtitle style Thomas Hamilton David Sundstrand Charles Chubb Walter Kidde page 4 1 October 2009 Broad UTC PHM Experience Remote Elevator Monitoring Multi-Spectral Fuel Cell Remote Diagnostics EHM, ADEM Diagnostics United Technologies Pratt & Whitney UTC Power Research Center Otis Health Monitoring HUMS Usage-Based Lifing Health Monitoring PW625 P&W Canada HamiltonClick Sundstrand to edit Master subtitleSikorsky Aircraftstyle Sikorsky Aircraft Diagnostic Sensor Fusion Remote Building Monitoring Health Monitoring and Diagnostics Pratt & Whitney Rocketdyne Carrier UTC Fire & Security page 5 1 October 2009 Pratt & Whitney Click to edit Master subtitle style Large Military Engines Small Engines Power Systems Space Commercial Engines page 6 Public Access Data 1 October 2009 Experience and Engineering Excellence New Engine Engines Services Click to edit Master subtitle style Material and Service Repair Services Solutions Over 80 Years of Aircraft Engine Design & Maintenance page 7 1 October 2009 Complete MRO Services Fleet Management Overhaul Repair $/FH Overhauls Click to Healthedit Master Management subtitle styleLine Maintenance Water Wash $/FH Monitoring PW6000 JT9D V2500 CFM56 PW4000 JT8D PW2000 24-Hr Help Center Engine Leasing Customer Training page 8 1 October 2009 Customer Issues are MRO Issues $25.0 Cum Maintenance Cost Availability $20.0 DMC ($M) $15.0 $10.0 $5.0 PURCHASE $0.0 0 5 10 15 20 25 30 35 40 45 50 55 Year Example assumes $2M purchase price and $100 / EFH direct maintenance cost (DMC) at 3,500 EFH / yr Click to edit Master subtitle style Fuel Emissions page 9 1 October 2009 Engine Health Management Integral to managing operations Automatically process data Detect issues before failures Perform troubleshooting Analyze Plan maintenance Turn aircraft Recommend Inspection Click to edit Master subtitle style Maintenance Manage Life cycle costs Forecasting Supply chain page 10 1 October 2009 Engine Management Programs (EMPs) Closed loop alert notification and disposition process Review Document Confirm Customer Maintain Click to edit Master subtitle style Isolate Communicate page 11 1-1 1 October 2009 Key Lessons / Challenges What’s the business case? How do we get data? How do we support small customers, mobile customers (leasing)? How do we solve more of our customers’ problems? Click to edit Master subtitle style page 12 1 October 2009 A Generalized PHM Value Model OBJECTIVE CREATE VALUE RECIPIENT VALUE PROP BUS. PROP Click to edit Master subtitle style OFFERING METRICS page 13 1 October 2009 A Generalized PHM Value Model OBJECTIVE CREATE VALUE RECIPIENT PROVIDER CUSTOMER VALUE VALUE VALUE PROP BUS. PROP Click to edit Master subtitle style OFFERING METRICS page 14 1 October 2009 A Generalized PHM Value Model OBJECTIVE CREATE VALUE RECIPIENT PROVIDER CUSTOMER VALUE VALUE REDUCED REDUCED INCREASED VALUE PROP MAINTENANCE OPERATING AVAILABILITY COSTS COSTS ADDITIONAL BUS. PROP OUTSOURCE GUARANTEES CAPABILITIES Click to edit Master subtitle style OFFERING MAINTENANCE MONITORING BETTER PLANS PLANS FLEET ASSET / MAINTENANCE OPERATING RESIDUAL METRICS COSTS COSTS VALUE RELIABILITY AVAILABILITY page 15 1 October 2009 A Generalized PHM Value Model OBJECTIVE CREATE VALUE RECIPIENT PROVIDER CUSTOMER VALUE VALUE REDUCED REDUCED REDUCE GENERATE INCREASED VALUE PROP MAINTENANCE OPERATING COSTS REVENUE AVAILABILITY COSTS COSTS GUARANTEED BUNDLED / WARRANTY MONITORING IMPROVE ADDITIONAL BUS. PROP MAINTENANCE ADJACENT OUTSOURCE GUARANTEES MITIGATION PROGRAMS RELIABILITY CAPABILITIES COST SERVICES Click to edit Master subtitle style MAINTENANCE USAGE BY VARIOUS VARIOUS BETTER MAINTENANCE MONITORING BETTER OFFERING COST THE HOUR MODELS POSSIBILITIES PRODUCT PLANS PLANS FLEET GUARANTEES REDUCED REDUCED ASSET / ADDITIONAL ADDITIONAL ADDITIONAL MAINTENANCE OPERATING MAINTENANCE WARRANTY RESIDUAL METRICS SALES SALES SALES COSTS COSTS COST COSTS VALUE INCREASED RELIABILITY AVAILABILITY AVAILABILITY page 16 1 October 2009 Define and Quantify the Metrics! OBJECTIVE CREATE VALUE RECIPIENT PROVIDER CUSTOMER VALUE VALUE REDUCED REDUCED REDUCE GENERATE INCREASED VALUE PROP MAINTENANCE OPERATING COSTS REVENUE AVAILABILITY COSTS COSTS GUARANTEED BUNDLED / WARRANTY MONITORING IMPROVE ADDITIONAL BUS. PROP MAINTENANCE ADJACENT OUTSOURCE GUARANTEES MITIGATION PROGRAMS RELIABILITY CAPABILITIES COST SERVICES Click to edit Master subtitle style MAINTENANCE USAGE BY VARIOUS VARIOUS BETTER MAINTENANCE MONITORING BETTER OFFERING COST THE HOUR MODELS POSSIBILITIES PRODUCT PLANS PLANS FLEET GUARANTEES REDUCED REDUCED ASSET / ADDITIONAL ADDITIONAL ADDITIONAL MAINTENANCE OPERATING MAINTENANCE WARRANTY RESIDUAL METRICS SALES SALES SALES COSTS COSTS COST COSTS VALUE INCREASED RELIABILITY AVAILABILITY AVAILABILITY page 17 1 October 2009 Diagnostics and Prognostics Mitigate Risks Reliability typically trades with cost and weight PHM improves reliability, reduces cost Catch small events early before becoming big cost Reporting Turn UERs into pre-planned removals Forecast trends that can be managed on wing Fault Trending Determine overhaul workscope on wing Extend life – usage-based lifing Alerting Our PHM analysis tool is ADEM – Advanced Diagnostics and Engine Management Click to edit Master subtitle style Watch Lists ADEM drives hardware and systems technologies Gas path and subsystem sensor coverage Data Visualization Access to operational performance and usage data Accurate engine simulation models page 18 1 October 2009 Health Management Provides Quantifiable Value Time on wing extension Shop visit cost reduction Fuel consumption reduction Operational cost reduction 35% 30% 25% 20% Click to edit Master subtitle style15% Event Value 10% 5% 0% Bleed HPC HPT 35% 30% EGT Mgmt. 25% 20% Value SummaryInstr. Savings vary by service level, customer, fleet, etc.,15% and do not include significant productivity improvement typically realized TCC 10% 5% Oil Sys. 0% Fan TOW SVC Fuel Operational 1 October 2009 page 19 . Customer Value – HPT Damage Detected PW4000 engine removed prior to additional damage Alerts triggered Trend plots point to HPT Isolation indicates HPT Borescope inspection revealed T1 blade damage Click to edit Master subtitle style Engine removed prior to incurring additional damage EstimatedEstimated Savings:Savings: $700K$700K (UER(UER potentialpotential –– $Million+ $Million+ // Event)Event) page 20 1 October 2009 Industry Health Management Value Stream ACQUIRE DELIVER ANALYZE EXECUTE DATA DATA + REPORT ACTIONS Click to edit Master subtitle style WEAK STRONG page 21 1 October 2009 Improve Data Collection and Delivery Technologies Current technologies are poor: ACARS, Commercial Engine Data Delivery sneaker-net PHM critically needs various field data BROADBAND for… HIGH HIGH SATELLITE 432K-30M bits/sec Warranty / guarantee mitigation PROACTIVE PROGNOSTIC $/FH risk mitigation QAR / LLP usage-based life extension SNEAKER NET Interval and cost estimation forecasting 100100 Kbits Kbits / / sec sec Revenue through health services BANDWIDTHBANDWIDTH REACTIVE Click to edit Master subtitle styleDIAGNOSTIC ACARS Emerging issue detection FLIGHT 2.4-64 Kbits/sec Fuel conservation services and COUPONS 00 Kbits Kbits / / sec sec 30 30 Mbits Mbits / / sec sec LOWLOW consumption guarantees Delayed 1-5 days As it happens Emissions tracking – ETS, U.S. “Cap & POST REAL FLIGHT LATENCY TIME Trade” page 22 1 October 2009 How Do We Address Small / Lease Operators? 57% of world’s operators fly 10 or fewer engines Customers flying >100 engines mostly captive 6% 1% 13% Click to edit Master subtitle style 57% 10 or less engines Profitability? 23% 11 - 30 engines 31- 100 engines Portability? 101-500 engines 500+ engines page 23 1 October 2009 AAlglgoorirtihtmhms s/ / AAnnalaylsyissis Part life Anomaly Manual Isolation Custom detection page 24 algorithms models techniques calculations 1 October 2009 Usage based lifing data Technology advancementsExpanded flight drive value How Can We Address More Problems? optimization Work scope / operations Oil condition, sub-systems / / Condition-based maintenance s s s s a r a r Operational improvements t t Click to edit Master subtitle style o o a a s s Basic trend monitoring D D n n e e Expanded S S instrumentation controls Electronic engine Basic sensors A Holistic Systems Approach Engine Engine and Mounts Engine Build-Up Pylon and Attaching Hardware Aft Pylon Fairing Inlet Primary Exhaust Nozzle Exhaust Plug or Cone BFE (Generators, Hydraulic Pumps, Fire Protection, etc.) Fan Integrated vehicle health and data Cowls Thrust Reverser with management Variable Area Fan Nozzle 100% pylon-on-down (POD) support Click to edit Master subtitle style Environmental Control System Guided Troubleshooting APU page 25 1 October 2009 Questions? Click to edit Master subtitle style page 26 1 October 2009 Click to edit Master subtitle style Thank You! page 27 1 October 2009.
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