Rotable
Management
Jens Schöneberg
Solution Architect MRO/M&E
2000 SAP AG European A&D Information Forum 2000, March 14./15.2000 / 1 Jens Schoeneberg (E2)
Content
1
Rotable Management in Aerospace
2
SAP Solution
3
SAP Future Focus
2000 SAP AG European A&D Information Forum 2000, March 14./15.2000 / 2 Jens Schoeneberg (E2)
Content
1
Rotable Management in Aerospace
2
SAP Solution
3
SAP Future Focus
2000 SAP AG European A&D Information Forum 2000, March 14./15.2000 / 3 Jens Schoeneberg (E2)
What is a Rotable?






Repairable Part
Serialized
Long Life Cycle
Expensive Components
Big / Complex Components
Life Limit Controlled
2000 SAP AG European A&D Information Forum 2000, March 14./15.2000 / 4 Jens Schoeneberg (E2)
Rotable Management Cycle
Aircraft
Stock
Procurement
Scrapping
Serviceable
Unserviceable
In-house Repair
2000 SAP AG European A&D Information Forum 2000, March 14./15.2000 / 5 Jens Schoeneberg (E2)
Subcontracting
Scenarios with/without Intermediate Storage
Open-loop scenario
Technical
object
Part(s)
Part(s)
Warehouse
Replacement
part(s)
Part(s)
Closed-loop scenario
Technical
object
Part(s)
Repair
process
Part(s)
2000 SAP AG European A&D Information Forum 2000, March 14./15.2000 / 6 Jens Schoeneberg (E2)
Repair
process
Rotable Management Requirements
 Support of maintenance/repair processes

In-house

Subcontracting
 Documentation of all maintenance tasks performed
 Traceability of rotable parts back to birth

Inventory

Configuration (production site)

Repair shop (shop floor) / Subcontractor
 Handling of rotable part status

Tracking of rotable part conditions

Part number change due to modification

Handling of exchange parts from subcontractors

Valuation according to parts condition
2000 SAP AG European A&D Information Forum 2000, March 14./15.2000 / 7 Jens Schoeneberg (E2)
Business
related
Aviation
Authority
related
Content
1
Rotable Management in Aerospace
2
SAP Solution
3
SAP Future Focus
2000 SAP AG European A&D Information Forum 2000, March 14./15.2000 / 8 Jens Schoeneberg (E2)
As-Maintained Configuration
Functional
location
Technical
objects
Equipment/
Serial
number
Assembly
Material
2000 SAP AG European A&D Information Forum 2000, March 14./15.2000 / 9 Jens Schoeneberg (E2)
Serial Number and Equipment
Equipment master record
Material E-2002
Serial data
Serial number 1351
• Stock information
• Serial number history
2000 SAP AG European A&D Information Forum 2000, March 14./15.2000 / 10 Jens Schoeneberg (E2)
Rotable Exchange Process
Removal of part
Shipment of part
Workshop /
Subcontractor
Warehouse
Replacement part
(1) Rotable exchange
process
Return of serviced part
(2) Repair process
2000 SAP AG European A&D Information Forum 2000, March 14./15.2000 / 11 Jens Schoeneberg (E2)
Life Controlled Rotables I
Technical Object
Chracteristics of
Classification System
Counter
Flight Hours
Take-offs/Landings
Counter
Reading
Flight hours 2351
Counter
Reading
Input Sources:
- Manually via R/3
- Intranet/Internet
- PM-PCS Interface
Landings 511
2000 SAP AG European A&D Information Forum 2000, March 14./15.2000 / 12 Jens Schoeneberg (E2)
Life Controlled Rotables II
Aeroplane counter
Landing gear counter for tires
12/02.
20 Take-offs/landings
20/02.
30 Take-offs/landings
12.02.
350 Take-offs/landings
20.02.
360 Take-offs/landings
Difference of 10
take-offs/landings
carried forward
2000 SAP AG European A&D Information Forum 2000, March 14./15.2000 / 13 Jens Schoeneberg (E2)
Rotable Exchange
Update on
Flight Hours
Life
Contolled
Rotable
Rotable
Maintenance
Plan R/3
Pump P111
Aircraft Configuration
P111
1 4 5 3 Hours
Automatic
creation
PM/CS
Order
Discrepancy
found
Manual
creation
PM/CS
Notification
2000 SAP AG European A&D Information Forum 2000, March 14./15.2000 / 14 Jens Schoeneberg (E2)
Trigger/Initiate
Rotable
Exchange
Traceability of Rotable within As-Maintained
Configuration
G-BIKA
Usage list
01.03. - 20.09.98
G-BIKA
2000 SAP AG European A&D Information Forum 2000, March 14./15.2000 / 15 Jens Schoeneberg (E2)
Rotable Traceability witin Inventory
Subcontractor
Purchasing
Ser No.-1
New
Ser No.-1
New
Ser. No. 1
Unserviceable
Shipping
In-house
Ser No. 1
Ser. No. 1
Ser No. 1
Serviceable
2000 SAP AG European A&D Information Forum 2000, March 14./15.2000 / 16 Jens Schoeneberg (E2)
Receipt
Valuation Based on Parts Condition
Material
with valuation type A
(condition-based
valuation)
Valuation type
NEW
$ 3,000.00
Valuation type
SERVICE
$ 2,200.00
Valuation type
UNSERVICE
$ 1,280.00
2000 SAP AG European A&D Information Forum 2000, March 14./15.2000 / 17 Jens Schoeneberg (E2)
In-house Repair Process
Removal of part
Shipment of part
In-house
Workshop
Warehouse
Replacement part
(1) Rotable exchange
process
Return of serviced part
(2) In-house repair
process
2000 SAP AG European A&D Information Forum 2000, March 14./15.2000 / 18 Jens Schoeneberg (E2)
Refurbishment Order
Goods issue
with movement
type 261
Stock
Plant 0001
SLoc 0002
Maintenance order 800175
Order type:
PM04
UNSERVICE
Material
Quantity 3
Serial number
From
To
P-2001 Fuel pump
53, 81, 27
UNSERVICE
Plant:0001
SLoc: 0002
SERVICE
Plant: 0001
SLoc: 0001
Goods receipt
with movement
type 101
SLoc = Storage location
2000 SAP AG European A&D Information Forum 2000, March 14./15.2000 / 19 Jens Schoeneberg (E2)
SERVICE
Stock
Plant 0001
SLoc 0001
EnjoySAP - Refurbishment
Automatic change of valuation type during goods movement
Stock
Material
Serial number
UNSERVICE
P-2001
53
Stock
SERVICE
Plant
1000
Storage location 0002
Batch
UNSERVICE
Material
Serial number
P-2001
53
Plant
1000
Storage location 0001
Batch
SERVICE
Proposal of serial numbers during goods issue
Refurbishment
order
Object list:
- Serial number 1
- Serial number 2
- Serial number 3
2000 SAP AG European A&D Information Forum 2000, March 14./15.2000 / 20 Jens Schoeneberg (E2)
Goods
issue
Object list:
- Serial number 1
- Serial number 2
- Serial number 3
Subcontracting Process
Removal of part
Shipment of part
Subcontractor
Warehouse
Replacement part
(1) Rotable exchange
process
Return of serviced part
(2) Subcontracting
process
New with
IS A&D 4.6
2000 SAP AG European A&D Information Forum 2000, March 14./15.2000 / 21 Jens Schoeneberg (E2)
Purchase Order for Subcontracting
MRO Provider
Subcontractor
+
Purchase Order
10 L
1pc DISC SerNr 47
1pc DISC SerNr 47
2pc BLADE
DISC Serial Number 47
2000 SAP AG European A&D Information Forum 2000, March 14./15.2000 / 22 Jens Schoeneberg (E2)
Part that will be receipt back
Parts that will be provided
to the subcontractor
Picking, Packing, Shipping
xxxxxxxxxxxx
xxxxxxxxxx
xxxxxxxxxx
xxxxxxxxx
xxxxxxxxxxxx
xxxxxxxxxx
xxxxxxxxxxxxx
xxxxxxxxx
Warehouse
Purchase order
Subcontracting
DISC
1pc
BLADE 2pc
SC inventory monitor
DISC
BLADE
(1) Create SD
delivery
(2) Post goods
issue for P/O
SC vendor SUBC1
SC = Subcontracting
2000 SAP AG European A&D Information Forum 2000, March 14./15.2000 / 23 Jens Schoeneberg (E2)
Vendor
stock
Goods Receipt
SC vendor
Comp.: DISC
Goods receipt
of rotable
Purch. Order
history
1) Goods receipt for the
serviced rotable
2) Component consumption
Warehouse
SC = Subcontracting
2000 SAP AG European A&D Information Forum 2000, March 14./15.2000 / 24 Jens Schoeneberg (E2)
Goods Receipt
Consumption of
parts from
SC vendor stock
Goods receipt of
servicable parts
Part number change
Serial Number change
Valuation change
 Three scenarios are supported at the time of the goods receipt:

Rotable with the same material and serial number is received

Material number of rotable changes (due to upgrade), but serial
number remains the same

Subcontractor sends back replacement part, with different serial
number
 The new parts condition might require a valuation change
 For traceability reasons, the history for a specific serial number
must be complete
SC = Subcontracting
2000 SAP AG European A&D Information Forum 2000, March 14./15.2000 / 25 Jens Schoeneberg (E2)
Warranty Assignment
Tail G-BIKA
• Valid from 5.1.1998
Master warranty
• Measuring point:
Flight hours
Cycles
• Description
• Warranty services
• Warranty counter
Assignment
Tail C-678
• Valid from 12.10.1998
• Measuring point:
Flight hours
Cycles
2000 SAP AG European A&D Information Forum 2000, March 14./15.2000 / 26 Jens Schoeneberg (E2)
Content
1
Rotable Management in Aerospace
2
SAP Solution
3
SAP Future Focus
2000 SAP AG European A&D Information Forum 2000, March 14./15.2000 / 27 Jens Schoeneberg (E2)
EnjoySAP - Rotable Exchange Process

Easy-to-use transaction for exchange of
rotable part during line maintenance

Supported functions

Creation of PM/CS notification to
document discrepancies and which is
used as rotable part traveller

IPC access to identify replacement part

Configuration update at time of removal /
installation

Configuration completeness check

Automatic goods movement postings for




Goods receipt/issue
Change of ownership
Change of parts condition
Valuation change
2000 SAP AG European A&D Information Forum 2000, March 14./15.2000 / 28 Jens Schoeneberg (E2)
Removal of part
Warehouse
Replacement part
Initial Provisioning / Follow up Procurement*
Level 1
Level 2
Level 3

No of Aircraft

No of Locations

Budget

No of Parts per Aircraft



Flying hours per Aircraft a
Day
Turn around time per
Location
Costs (have to be
calculated)

Stock transfer time

Mean Time Between
Removal

Turn Around Time

Service Level

....
Repair Float
required
Repair Float
required
per location
2000 SAP AG European A&D Information Forum 2000, March 14./15.2000 / 29 Jens Schoeneberg (E2)
Optimal Stock
per location
* Depends on client funding
Integrated Planning for Rotables Using APO*
Fulfillment System
Planning System
R/3
APO
Maintenance plan
Forecast
DP
Historical data
PM/CS order
Detailed Planning
SNP
Inventory
Refurbishment order
P.O. subcontracting
Fullfillment Planning
PP/DS
P.O. new part
Synchronize
P.O. = Purchase order
2000 SAP AG European A&D Information Forum 2000, March 14./15.2000 / 30 Jens Schoeneberg (E2)
* Depends on client funding
Reliability Monitoring in BW

Development of Extractors for
the following Key Performance
Indicators (KPIs):

Mean Time Between Removal
(MTBR)

Mean Time Between
Unscheduled Removal
(MTBUR)

Mean Time Between Failure
(MTBF)
2000 SAP AG European A&D Information Forum 2000, March 14./15.2000 / 31 Jens Schoeneberg (E2)