MANAGEMENT OF OBSOLESCENCE

Transcription

1 MANAGEMENT OF OBSOLESCENCE 1

2 Sequence Obsolescence case studies Research trend during Life cycle of the system Causes and role of Electronics Obsolescence Mitigation Forecasting and Cost of obsolescence. Policy guide Manual Solution for Existing Assets Strategy for Future Systems

3 Definitions A loss in the utility of an asset due to the development of improved or superior equipment, but not due to physical deterioration The process or condition of going out of date or being no longer in use the process of becoming obsolete; falling into disuse or becoming out dated

4 On Condition Maintenance (OCM) A path towards an ideal situation where minimum Preventive Actions lead to low Corrective Actions need Extract Relevant Database Predict Health Non Invasive Procedure

5 PAF Inventory Mirage JF C-130 FT K-8 A-5III F F-7P FT-7P F-7PG & FT-7PG

6 Experience on Mirage aircraft Aircraft inducted in 1967 Obsolesces started appearing in 90 s Australian Retired aircraft Spanish Package & Lebanon Stock Libyan Package System Upgrades

7 Avionics Concerns Mirage Avionics Upgrade project designed by SAGEM of France. Three LRUs (HPDU, and MFD) BAE SYSTEMSUD EU, Phenomenal increase in the repair prices (10 times in three years) Demand for 5-year long-term support package. After repeated negotiation 7 years support package concluded. Design authority to provide training for in country repair of PCB s. AGAV Radar (for AM-39 'Exocet) Support package.

8 Go Back 8

9 Achievements Fleet remained operational to meet National Security requirement A reactive approach results in high cost. Difficult to forecast the quantity accurately Took unwanted stock as a package Excess or shortage of stock Customer in a poor negotiation position Need to change to proactive approach in future

10 Chinese aircraft Case Study

11 Case Study FT-5 A/C grounded on advice of Chinese Retired A/C put under storage. Planned for possible extension of life. Australian firm (Aerostructures) contracted for 10 % life extension. Aerostructures quoted $ 3.8 Million. Price negotiated to $2.1 Million on Work Share basis. Program named as LOTEX: Life Of Type Extension.

12 DISASSEMBLY

13 TEARDOWN ACTIVITY

14 USAGE SPECTRUM MONITORING Usage Spectrum Monitoring provide usage band for the actual flights. USM would provide stress information at critical locations. USM Recorders (MAXLIFE) installed on five AIRCRAFT. Usage data periodically downloaded

15 USAGE SPECTRUM MONITORING

16 ENGINEERING SOLUTION Every structure depending upon its material, geometry, loading and environment can tolerate certain amount of damage. Fracture Mechanics provides us the tools to quantify the property of damage tolerance. Damage Tolerance of an aircraft structure at the end of OEM structural life limit can be figured out. The prospects of life extension are realized.

17 ENGINEERING SOLUTION Finite Element Analysis Internal Loads Model. Fine Grid Modeling and Analysis. Classical Stress Analysis Loads Analysis Stress Analysis Deflection Analysis Damage Tolerance Analysis (Fracture Mechanics) Residual Strength Analysis Crack Growth Analysis

18 Lesson Learned Excellent contribution from All Stakeholders. Knowledge Transfer gave a new dimension to in vogue engineering practices. As envisioned, PAF capability in the area of Structural Integrity enhanced. Damage Tolerance Analysis by joint team of engineers. Program Management experience at Aeronautical Research Center LOTEX is a step forward in the direction for achieving selfreliance in A/C Structural Integrity.

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20 LIFE CYCLE PROJECT ( CADMID) Monitor Effectiveness of OM Activity Develop, Implement and Periodically Revalidate Obsolescence Strategy 20

21 OBSOLESCENCE CAUSES Aging Systems Rapid changes in technology Uneconomical production requirements Environmental or safety Constraints (ROHS) Deferred Modernization

22 ELECTRONIC OBSOLESCENCE Electronic industry most dynamic sector. Electronic parts have shorter life cycles. Average cost to redesign a circuit card is $250,000 Study on AS900 by Honeywell International Assume no obsolescence $ 4.24M Design refresh $ 31.12M Aftermarket source buy $51.16M Obsolescence management strategy is needed

23 Obsolescence Mitigation Enhance weapon system through upgrades based on reuse of the existing design, especially the software. Older Hardware replacement for fewer items Specialist engineers to study proposed components Lifetime buy and possible partnering with supplier. Close cooperation required between suppliers, integrators and manufacturers Develop Obsolescence Management Plan (OMP) Collaboration and solution sharing exchanges across Allied Nations and their supply chains.

24 Policy Guide for obsolescence Management Policy guide by Joint Obsolescence Management Working Group given in the Manual Obsolescence Impact Assessment provides understanding of current health and prediction of future problems Low Risk (Reactive Approach) Existing Stock Reclamation Equivalent Alternative Minor Redesign Major Design Last Time Buy. Medium /High Risk (Proactive approach ) Design Considerations Technology Transparency Obsolescence Monitoring Planned System Upgrades Obsolescence Management Plan (OMP)

25 Forecasting And Cost Estimates Factors to be considered Type and complexity, Technology, number of suppliers and laws and regulations. Available commercial tools (Q-star, IHS) Contracting for availability and Risk shared Estimations of the obsolescence cost at bidding stage Commercial tools for life cycle costs (True Planning/SEER) QinetiQ and ARINC assigned to derive cost metrics 25

26 Solutions for Existing Systems Reactive Approach Buy from Stock, Reclamation Repair or Overhaul F3I Reverse Engineering Redesign and Information sharing and supply chain management Conduct market surveys to stay abreast of technology advances. Cost and forecasting Tools

27 Strategy for New Systems Organisation to issue policy for Obsolescence Management (OM). Project Teams responsibilities Carry out Risk assessment to determine the risk to equipment from obsolescence. Decide Reactive or proactive approach or both. Develop and Implement Strategy Measure Performance of OMP

28 Thank You

29 References Maintenance, repair, and operations-wikipedia, the free encyclopedia.mht MAINTENANCE, REPAIR, AND OVERHAUL, MRO, AIRCRAFT MAINTENANCE, AEROSPACE.mht Managing the Aging Aircraft Problem-John W. Lincoln(Aeronautical Systems Center) Aircraft Maintenance Practices, NQF Level 3: BTEC National Guide book issued by DMSMS Avionics Architecture Standards as an Approach to Obsolescence Management. By D.J.Jibb, J.B.Walker