Intelligent Incorporation Of Advanced Technology Into Legacy ...

Four Steps For Intelligent Incorporation Of Technology1. Identify Stakeholders, Common Goals AndCritical Metrics– Example: USAF, P&W, Maintainers, Etc.Integrating The “Puzzle”OperationalLimitsStabilityMargin2. Review And Understand Engine Data– Performance, Safety, Affordability &Reliability3. Select Proven Technologies Ready ForInsertion Into A Legacy Engine4. Balance Technology Selections WithCustomer RequirementsGoal ManagementCustomizedControlActuatorManagementAutomaticControlDirectedMaintenance“Pieces of the Puzzle”3

Step 1: Identify Stakeholders & GoalsExample: USAF F100-PW-229• USAF Goals– Centralized Intermediate Repair– Reduced Maintenance Man-Hours– Increase Safety & Time On Wing;Reduce Maintenance Cost• P&W Goal– Improve The F100-PW-229 PositionFor The Future• USAF/P&W Common Goals– Focus On Safety & ReliabilityThrough 2035+4

Step 2: Review And Understand Engine DataExample: F100-PW-229Understand Fleet5

Step 3: Select Proven Technologies Ready For InsertionExample: P&W Technology Development & Engineering Standard WorkElementsP&W Engineering Standard WorkRigorous, Comprehensive and Continuously ImprovingTechnology Review StepsEstablished Processes Used To Assess And Advance Technology MaturityAnd Facilitate Transition To P&W Engineering Standard Work6

Example: P&W Technology Pull Process• Technologies Are Selected Based On Proven Track Records– Commercial Engines Technologies» Output Of Development Engine Certification Process–5 th Generation Fighter Technologies» F119/F135 Development And Field Exposed Technologies• Technologies Must Meet Goals Of All Stakeholders To Be CostEffective7

P&W Example Of Technologies Evaluated For Incorporation• Turbine Airfoils– Advanced Cooling Configurations– Thermal Barrier Coatings– TMF / Oxidation Lifing Systems• Disks– Life Extension– Residual Stress Effects• Fan / Compressor Airfoils– Foreign Object Damage– Surface Treatments– Probabilistic Assessments– Erosion– Repair (IBR’s)– Mistuning (Field Effects)– HCF, Damping, etc.• Bearings– Monitoring / Trending– Hybrid Bearings• System– Usage-Based FleetManagement– Integrated Prognostics & HealthMonitoringTechnologies Selected Based On Best Fit With Desired Outcome8

Pull Process Guides Technology DevelopmentUSAFComponent Improvement ProgramActivitiesRobust Fixes For forCurrent IssuesEngine EnhancementPackageInterval ExtensionFocused Low RiskTechnology InsertionUsage Based Lifing& Health Monitoring2012Turbine Technologies• Improved Coatings• Advanced Cooling SchemesFOD Tolerance TechnologyLogistics TechnologyAnomaly DetectionFault IsolationTodayAdvanced Life AnalysisFocused Wear TasksLLP Design Enhancements9

Example: F100-PW-229 EEP Prognostic Health MonitoringF100-PW-229 EEP Achieves Propulsion Safety, Affordability &Readiness Goals• Historical F100 IFSD CausesFrom Last 5 Years Evaluated• Early Identification Of AnomalyCan Avoid IFSD And CostlySecondary Damage• Directed Maintenance ActivitySignificantly Decreases Cost AndMistakes Leading To UnwantedConsequences10

Example: F100-PW-229 EEP Advanced LifingLeverages Science & Technology Investment In Advanced Lifing AndPrognosis• Advanced Rotor LifeTools Developed &Implemented For F100Usage Algorithm FeasibilityDemonstrated For F100Components Using ActualContinuous PW-229 Mission Data• Usage-Based LifingPotential Demonstrated& To Be Implemented InF10011

Step 4: Balancing Technology With Customer RequirementsFuture State OfEngineMaintenanceCustomer NeedsAlignmentW/GoalsEngine NeedsIFSDUER DriversAlignmentW/GoalsNewly DevelopedTechnologiesAlignmentW/GoalsImplementationAlign WithPlannedVisitsTiming of NextShop VisitAlignmentW/GoalsEngine CostPull Only Selected Technologies From Developed GroupingThat Best Meets Customer, Engine, Cost And ScheduleEffective AndAffordableSolutions12

Example: Effect Of F100-PW-229 EEP Technology InsertionIncorporated Technologies Reduce Maintenance Cost By 20%• 975 Engine Removals Can Be Avoided• Maintenance Cost Savings From Reduced UER And SER Removals$1,000CumulativeSavings ETOC(Millions Savings(Millions, FY07$)FY07$)$900$800$700$600$500$400$300EEP & Usage Based Life (UBL)$810$508EEP –ExtendedIntervalNetPresentValue(3.2%)$40$248$395$200$100$02005 2015 2025 2035$77EEP –CurrentIntervalEEP-CurrentIntervalEEP-ExtenedIntervalEEP-EMLI (UBL)13

Summary: F100-PW-229 EEP Technology InsertionF100-PW-229 Legacy Engine Safety, Affordability & ReadinessImprovedPW-229 Engine EnhancementPackage Objectives• Reduce IFSD Rate By 25%• Double Mean Time BetweenRemoval (MTBR)• Reduce UER Rate By Half• No Change In Depot Cost PerEngine• Incorporate In Depot BuildStandard By 2012Safety: Goal: 75% ReductionIn Propulsion RelatedClass A MishapsAffordability: Goal: 10% ReductionIn Propulsion RelatedMaterial / AcquisitionCostsReadiness: Goal: ATOWIncreased 2X14

SummaryP&W Is Committed To Product Performance, Safety, Affordability& ReliabilityTechnology Pull Process Provides Cost Effective DevelopmentP&W Performs Extensive Testing To Mature Technologies &Selects Only Those With A Proven Track RecordF100-PW-229 EEP Provides Example Of Technology MaturationAnd Insertion To Meet Stakeholder Goals15