Complex Maintenance, Repair, and Overhaul Overview Objectives After completing this module, you should be able to do the following: Discuss the key functionality available in Oracle cMRO Maintenance, Repair and Overhaul (MRO) At-a-Glance Planned & Unplanned Maintenance Tear-Down & Inspect Repair / Replace Re-Install • Major Overhauls, Unscheduled Repairs and Inspections, Condition Monitoring • Configuration Management • Regulatory Compliance Improved Aircraft Reliability Business Pressures Cost Containment • Where are my highest Aircraft on Ground • How do I minimize the inventory and capital expenses? effects of unscheduled repairs? • How can I improve • How do I decrease asset maintenance productivity? turn around time? Tear-Down & Inspect Regulatory Compliance • How do I ensure compliance to FAA / JAA regulations? • How do I ensure audit trail visibility and availability? Repair / Replace Re-Install Multi-Site Planning & Scheduling • How do I aggregate/assign inventory and resources? • How do improve fleet-level planning? Planning Single, linear planning cycle that ignores cost / skills requirements Maintenance Requirements Spares Management Cost / Skills Analysis Schedule Operational Challenges • Isolated Planning and Execution • Reactive Maintenance Execution • Manual Maintain multiple master configuration versions for similar units Tail #1 Serial # Serial # Serial # AoG* Serial # Serial # Serial # Serial # Serial # Processes • Isolated View of Inventory Tail #1 Serial # Serial # AoG* Maintenance Requirements Serial # Repair / Replacement Document Updates Serial # Serial # Serial # Serial # Serial # Configuration Updates *Aircraft on Ground How Delivers Foundation: Unified Information Architecture • Common data model Develop Contracts Projects HR enables a single source of truth Market Sell Order Customers, Suppliers, Finance Plan Products, … Maintain Procure • Comprehensive suite of applications designed to work together • Robust set of integration services based on open standards • Modular deployment by business flow Service Make Fulfill • Single global instance implementations Oracle Complex MRO Solution Configuration Management Maintenance Planning Create Visit Planned Maintenance Plan / Receive Tear Down Visit Work Package Update Config Unplanned Maintenance Inspect Return to Service Repair / Replace Rebuild Reinstall Maintenance Execution Supply Chain Management Engineering Data Human Resources Contracts Finance / Costing Oracle cMRO Application Integration Oracle Cost Management Oracle WIP Oracle Inventory Oracle Purchasing Oracle Project Manufacturing Oracle cMRO Oracle Order Management Oracle Quality Oracle WMS Oracle eAM Oracle ASCP/ Oracle DP Oracle BOM/ENG Oracle Complex MRO Enables you to… Maintain Complex Configurations Effectively Plan Enterprise-Wide Operations Optimize Maintenance Execution Centrally Manage All Engineering Data …for Line Maintenance, Base Maintenance, and Engine / Component Overhaul Maintain Configuration Control Manage Configuration Changes and History Master Configuration “Allowable Configuration” Unit Configuration “As Installed” / “As Maintained” References Allowable Config. System Tail # Serial # Component Primary • • • • Alternate Serial # Component Primary Serial # Serial # Serial # Serial # Serial # Serial # Serial # Serial # Alternate Allowable Assembly Template Manage Constraints and Rules Link to Maintenance Requirements Support Sub-Master Configurations • Trace Installation / Removal History • Track Unit Specific Information • Update Applicable Configurations with Single Entry Maintain Fleet Configuration Automatically Link Unique Characteristics Corrosion Inhibitor Fleet Sand Filter Ocean Site 1 Site 2 • List All Units in Fleet • Provide Logical Desert Grouping or Hierarchy Site 3 • Manage at the 737-800 757-300 737-700 777-400 737-800 Tail # Tail # Tail # Tail # Tail # Unit Level • Link Directly to Tail # Fleet Maintenance Program Component Tracking Trace Rotables Throughout Their Life OEM Active Unit Shop Airframe TPM (Jan ’88) (Oct ’88) (Feb ’92) (Dec ’96) (May ’01) A-1FP1 A105 Repair A125 Retrofit A-1FP2 B225 Replace A145 Calibrate B-1CP1 B255 Modify B225 Modify D-1FP4 C135 B255 D-1FP5 C195 C185 • Provide visibility to work history of tracked components • Allow purchasing to control capital expenditures • Improve predictive maintenance for engineering changes Support Regulatory Compliance Provide Tracking and Traceability of All Asset Data • Complete Configuration History • Maintenance Data Tail # - Repair / Check History Serial # Serial # - Problem / Failure Reports - Reliability Data - Quality Information Serial # Serial # Serial # Serial # • Airworthiness Directives / Service Bulletins Serial # Serial # Serial # • Engineering Change Orders / Modification Orders Provide Complete FAA Compliance for Every Configuration Oracle Complex MRO Enables you to… Maintain Complex Configurations Effectively Plan Enterprise-Wide Operations Optimize Maintenance Execution Centrally Manage All Engineering Data Plan at all Horizons Automatically Flow Requirements to All Plans Fleet & Locations Fleet Maintenance Program Define frequency and content of maintenance checks for all aircraft Scope / Coverage Long Term Plan Forecast resource requirements; analyze and assign capacity Unit Maintenance Plan Assign due dates to maintenance requirements for each aircraft Base Overhaul Visit Work Package Aircraft Establish tasks to be performed during next aircraft visit Days Planning Time Frame Years Fleet Maintenance Program Define Frequency and Content of Maintenance Checks Line Base Overhaul • Identify maintenance requirements based on OEM specifications for each asset type • Define intervals, thresholds and effectivity for all requirements • Link requirements to associated documents and routes • Track dependent relationships and flag affected components • Capture changes from Airworthiness Directives (ADs) or Service Bulletins (SBs) Create Single, Tailorable Plan for Entire Fleet; Ensure Compliance Long Term Planning Forecast Needs Across Entire Organization Long Term Plan Resources • • • • • Line Base Overhaul Identify tools / equipment Forecast spares / material requirements Incorporate needs into inventory planning Establish manpower needs based on skills Estimate total man-hours • Analyze capacity to maximize utilization • Analyze scenarios to determine optimal • Visit 1 • Visit 2 • Visit… Capacity / Location schedules • Create reservations at assigned locations • Identify excess capacity Base Overhaul Unit Maintenance Plans Integrate Fleet and Unique Needs for Each Unit Tail #001 Aircraft Environment Tail #002 Condition Monitoring Checks Tail #003 FMP Requirements One-Time Modifications Tail #004 Aircraft Usage Out-of-Phase Inspections Log Book Items Deferred Items • List All Open Maintenance Requirements for Each Aircraft • Calculate Due Dates Based on Time Remaining and Unit Maintenance Plan Forecasted Usage • Automatically Flow Deferrals Back to Unit Maintenance Plan Material Planning Footprint Effectively Manage Spares Planning and Allocation Flight patterns Fleet additions Complex MRO UMP Planned Visits Line Base Overhaul Historical planned requirements Historical unplanned requirements Demand Planning Future requirements Future requirements from visit Exceptions Global Order Promising Demand Fulfillment Recommendations • Transfer • Procure • Service Advanced Supply Chain Planning Customer service level Time-phased echelon stocking recommendations • By location • By item Inventory Optimization Budget Inventory holding min / max Oracle Complex MRO Enables you to… Maintain Complex Configurations Effectively Plan Enterprise-Wide Operations Optimize Maintenance Execution Centrally Manage All Engineering Data Line Maintenance Flow Flight Schedule Create Unit Schedule (AC availability for Maintenance) Create Transit Check Visits through open API New Visit or changed Schedule Identify Maintenance Opportunities Update Transit Check Visits through open API Release Visit to Production & Create Work Orders Select non routine for deferral Check for MEL/ CDL Eligibility Execute Workorders Defer non routine according to MEL instructions Close Visits M & O Procedures are automatically added to the visit Reschedule deferred non routine to another visit Base Maintenance Flow Aircraft Utilization Forecasts Maintenance Requirements Unit Configuration Actual Aircraft Utilization Schedule Visit - Assign Hangar Space - Run Material Demand - Level Resources - Simulation Plans Calculate Due dates for Maintenance Requirements Associate Maintenance Requirements to Visits Production - Issue/Return Material - Defer WorkOrders Identify Non Routine Close Visit Customer Service Requests Release Visit to Production Production Planning - Identify Addl. Resource Reqs. - Identify Addl. Material Reqs. - Assign Resources Engine Overhaul Flow Engine Reliability Calculate Due Dates for Maintenance Requirements Engine Performance Monitoring Associate Maintenance Requirements to Visits Engine Line Production Planning Production Conrol Module Line Module Disposition In House Vendor Material Planning Create Non Routine Work Orders 3rd Part Repair Station Material Demand Planning Supply Chain Fullfillment Engine Build and Test Production Execution Inventory Marshalling (Serial Number Reservation) Module Build and Test Line Maintenance Execution - Transit Technician selects or creates Line Maintenance Visit - Views work Orders in context of Line Maintenance Visit - Creates Non Routine Work Orders - Requests Deferrals where needed - Can log in / log out to create resource transactions or data clerk - Records time after the work is performed - Technician can close visit after completing and recording work Base Maintenance Execution - User logs into “My Work Orders” UI - Sees only work orders assigned to self or qualified to work on - User is guided through process by “smart defaulting” buttons. (parts change icon is only active if a parts change is required. QA Icon is only enabled if QA Plan needs to be recorded) -User performs: -Parts Change -Records Quality Data / Sign Off -Logs Non Routine - Accesses Relevant Documents -Adds additional Material Requirements Overhaul Maintenance Execution - Mechanic chooses primary and secondary disposition for removed Part based on the condition and further actions - A non routine work order will be generated for components Which require inspection, repair, or scrap -The off/on log is automatically updated based on the removal and Installation details Oracle Complex MRO Enables you to… Maintain Complex Configurations Effectively Plan Enterprise-Wide Operations Optimize Maintenance Execution Centrally Manage All Engineering Data Complete Document Repository Provide Easy Access, Traceability for Compliance • Register all technical documents • Centralize revision control Schematics • Provide subscription and distribution information Voice / Video Online Access • Reference maintenance objects • Link to legacy electronic Text / Scanned publication systems Route Management Leverage Common Work Steps to Increase Efficiency Create Work / Task Cards • Type & Title • Number / Revision Control • Workflow-Driven Approvals • Quality Plans Define Work Instructions • Templates / Established Work Steps • Engine & Component Overhaul Disposition Actions Establish Resource Needs • Labor Skills • Tools and Equipment • Spare Parts • Associated Documents Standardize Best Practices and Streamline Workflow Capture and Analyze Data at All Levels Ensure Quality at the Source Partners Component Suppliers Your Company OEMs Operator Role-Based Access • Collect / aggregate data • Analyze information • Distribute results Closed loop Corrective action Integrated Enterprise Repository 3rd Party Maintenance Providers Reusable Templates - Routes Leverage Template Data to Improve Productivity Task: Air Filter Change Operation 2.3.5 Task: Wheel Inspection Xxx Xxx Xxx Xxx Xxx Xxx Operation Xxx Xxx Xxx Task: Xxx1.5.5 XxxAPU Overhaul Xxx Xxx Xxx Xxx Xxx Xxx Operation Xxx Xxx Xxx Xxx4.23 Xxx Operation 2.3.6 Xxx Xxx Xxx Xxx Xxx Xxx Xxx Xxx Xxx Xxx Xxx Xxx Xxx Xxx Xxx Xxx Xxx Operation 1.5.6 Xxx Xxx Xxx Xxx Xxx Xxx Xxx Xxx Operation 4.24 Xxx Xxx Xxx Xxx Xxx Xxx Xxx Xxx Xxx Xxx • Create template for single operation or series of operations • Automatically create templates from operations in new process • Leverage templates for unrelated processes with the same operation Eliminate Need to Re-Enter Information or Perform System Queries Oracle Complex MRO Integrated configuration and component lifecycle tracking Comprehensive fleet and unit-based maintenance planning and scheduling Complete execution management for all scheduled, unscheduled, and overhaul activities Total route management with reusable templates and an integrated document index Maintain Complex Configurations Effectively Plan Enterprise-Wide Operations Optimize Maintenance Execution Centrally Manage All Engineering Data Oracle Complex MRO Total Control of Complex Configurations Effective Enterprise-Wide Planning Optimized Maintenance Execution Centralized Engineering Data Management Summary You should now be able to do the following: Discuss key functionality in Oracle cMRO