RUAG Aviation Supporting operations from nose to tail

Transcription

1 RUAG Aviation Supporting operations from nose to tail Leading supplier, support provider and integrator of systems and components for the civil and military industry. Core competences - maintenance, repair and overhaul, upgrades, manufacturing and integration of subsystems on aircraft and helicopters. Whole of life support Produces Do 228 Next Generation, a robust, flexible glass cockpit turboprop Offers broad spectrum of technical services, product development and testing procedures A reliable and capable partner for customers in the aviation industry. Head Office in Emmen, Switzerland. Total global staff 2,300 Arrival Structure Engine Components Test Flight Departure Reliability Innovation Availability Affordability

2 3 Life Cycle Management Phase-out Remarketing & Disposal Analysis& Evaluation Final assembly Phase-in Upgrade & Integration Operations Upgrade Modification Integration MRO Engineering- Aussie Innovation with Swiss Precision Manufacturing Supply Chain & Logistics

3 Application and Experience Engineering Support Metrology procedures & certification Hydraulic system manufacture, analysis & testing Material treatments Software for control & data analysis Assembly & Test Computational fluid dynamics Structural finite element analysis Mechanical design & manufacture Test Facility design & manufacture Machining techniques & modifications, (tooling design, cutting techniques

4 SUSTAINMENT CHALLENGES Component obsolescence Reliability degradation Environmental degradation Lack of spares OEM support Lifed items Cost of ownership

5 Value Added Benefits of RBE Experienced in sustaining aircraft (in some instances as sole operators or with OEM support). Improved asset availability through system/component reliability improvements. Manufacture of long lead time/unavailable spares (requires MLA with OEM). Reduced life cost through preventative maintenance. Team utilisation of engineering to expand repair limits. Innovative engineering solutions incorporating leading edge technologies.

6 Engineering focus Asset Life Extension Programs: Reliability Improvements Preventative Maintenance programs (refurbishment rather than on condition...) Repair limit expansion Innovative Environmental Degradation (Corrosion) Recovery Technologies - Supersonic Particle Deposition (SPD). ****

7 Reliability Improvements Item Engineering Activity F-111 Horizontal Tail Servo Actuator Reverse engineering, Alternate material, Enhanced processing History HTSA regularly removed for oscillation Extensive history of galling with subsequent loss of aircraft control Average MTBF < 250 hrs Actual 40 to 50 hrs Replacement Costs were indeterminate (no longer available) Current status 159 valves now overhauled and recovered (April 07) 90 achieved full overhaul life of 1,025 hrs operational life! 49 have accrued in excess of 500 hrs operational life 26 were removed for standard USAF modification action 10 have been removed for repair (leakage) after accruing in excess of 500 operational hours 10 removals due to valve failure (seal failure) Remainder are in service or service stock Case Study No. 1 F-111 HTSA

8 Reliability Improvements Item Navy Sea King Helicopter Hydraulic Pump Engineering Activity Redesign, FEA Analysis, Alternate material, Enhanced processing, Assembly and Test, Qualification, Acceptance History Housing Failure due to poor material selection during design and age deterioration Current status Rosebank re-engineered, redesigned and conducted engineering analysis and subsequent validation programs Poor Reliability Overheating during Operation Increased reliability. Overheating eliminated Long lead time and high cost for replacement items Case Study No. 2 Sea King Pump

9 Reliability Improvements Item Engineering Activity F-111C and G Wheel Brake; Multiple Disk Brake Assembly P/n / BUS F-111C Mission Critical F-111G Safety Critical Reverse engineering, to eliminate Binding Brakes History Ageing Aircraft Management Program investigating failures, A.O.G., cannibalisation rates of Multiple Disk Brake. OEM unable to support. Advised of design weakness; needs redesign. Fleet availability affected. Brakes necessarily inducted for R&O. Current status Rosebank conducted Preliminary Design Review, engineering analysis and subsequent validation program for spring holder flange. Established sustainability support service. Baseline MTBF 1 Nov hrs current May ,316 hrs. 395% performance increase. AUD$30k. Development costs. R&O savings for LOT 2012 AUD$500k alone.

10 Case Study 3 C130 Hercules Authorized Honeywell Upgrades C-130 Main Engine Gen Shaft Disconnect upgrade part number is 61B3-21 Kit number is SK-337 Mod carried out in accordance with SB R-551 C-130 New ATS Post Mod part number / C-130 Upgrade Older ATS (Pre Mod) new ATS being phased in part number & PN: C-130 Anti-Ice Valve Part number / is related C130 Starter Control Valve Part number

11 Case Study 3A C130 Hercules Deviations TASK IDENT PRIME EQUIP COMPONENT/ASSEMBLY NAME Date Raised ITEM PART NO ITEM SERIAL NO 001 Braking System C130J Dual Brake Valve PN Various FILE REF 002 Issue 1 Nose Landing Gear NLG Piston Oversized Cross Hole P/N MS32 RER-ENG Issue 2 Nose Landing Gear NLG Piston Oversize Cross Hole P/N MS132, 6J65, RER-ENG Issue 3 Nose Landing Gear NLG Piston Oversize Cross Hole P/N MS132, 6J65, 15PJ13, RER-ENG Issue 4 Nose Landing Gear NLG Piston Oversize Cross Hole 08/08/07 P/N MS132, 6J65, 15PJ13, 16PJ2, RER-ENG Issue 5 Nose Landing Gear NLG Piston Oversize Cross Hole 08/10/07 P/N MS132, 6J65, 15PJ13, 16PJ2, , ENG-AEO-DC- C MLG MLG Piston Thread Blending 18/09/ PT6 ENG-AEO-DC- C MLG MLG Outer Cylinder Rework 18/09/ H0811 ENG-AEO-DC- C130 11

12 Case Study 3B C130 Hercules Deviations TASK IDENT PRIME EQUIP COMPONENT/ASSEMBLY NAME Date Raised ITEM PART NO ITEM SERIAL NO FILE REF 005 MLG Cylinder Piston Reamed bushes 01/12/ , As listed ENG-AEO-DC- C MLG MLG Cylinder Assessment of Reworked Upper Seal Area 07/12/ RX4 RER-ENG-01/1/7 007 Issue 2 Rudder Rudder Booster Assembly Lever Attachment- Alternate Bolt 008 Rudder Rudder Booster Assembly Damper attachment screws 009 Aft Cargo Door Snubber Assembly - Filler Port Leak Check 010 NLG NLG Piston Use of Cad Plating MIL- STD-870 in lieu of IVD Aluminum Plating MIL-PRF /04/ RER-ENG-01 Part 1(15) 12/03/ RER-ENG-01/1/17 13/05/11 5C ,0370, 0395,0415, 0416 ENG (001) 21/5/ B223 ENG

13 Case Study 4 - F/A-18 Hornet Customer Royal Australian Air Force Platform F/A-18 Hornet Problem Multiple Asset Availability Issues, Corrosion Problems, No Authorized Repair Schemes Available Diagnosis Ageing asset, new initiative required Solution Engineer and Manufacture, in excess of 300 Deviations developed and raised under the guidelines of DGTA (AEO). Total of 29 Operational Procedures developed and published for component recovery. Resulting Benefit to Customer Increased Asset & Aircraft Availability 13

14 F-18 TIGER TEAM - ASSET LIFE EXTENSION Problem: F/A-18 Undercarriage is on condition Undercarriage (U/C) is High Strength Steel (< 260 KSI) Original protective coating breaking down US & Spain have recorded U/C failures due to stress corrosion cracking initiated from corrosion pits Retention of assets through approved expanded repair limits (Rosebank Engineering has raised over 100 design changes in the last three years under our DGTA AEO Accreditation) Savings over AUD$4m RAAF alone. Refurbishment versus On Condition

15 Recovery and Repair of Components that otherwise have been classified as Scrap Royal Australian Air Force data collected in a three year period noted that the repair of components by Rosebank resulted in reliability increases of up to 68%. Without Rosebank s initiative and subsequent proposal to the customer, many of these components may have been otherwise disposed of as scrap. Significant life cycle cost savings. 15

16 F/A-18 MLG Shock Absorber Primary Piston Part No: 74A Sulphamate Nickel Repairs 1.Main Outside Diameter 2. Bearing Lugs 16

17 F/A-18 NLG Cylinder Part No: 74A Series 1. Gland Nut Repair 2. Steering Lug Repair 3. Lug repair 17

18 Gland Nut Repair Corroded Thread 18

19 Gland Nut Repair Corrosion Removal New Base Thread Machined 19

20 Gland Nut Repair Fit New Manufactured Gland Nut 20

21 Gland Nut Repair Completed Repair Investigative analysis indicates 95 % of NLG cylinders require repair Customer benefit: Cost of repair 13% that of a replacement part 21

22 F/A-18 Planning Arm Part No: 74A New Manufacture 2. Nickel Lug repairs, Chrome Repair, Oversize Bush Repair 22

23 RAAF DATA on Rosebank Engineering Australia Performance Component Output to May 08 Output to Jul 09 Output to Jul 10 MTBF to May 08 MTBF to Jul 09 MTBF to Jul 10 Reliability Increase last 3 Years Stab % TEF % Aileron % Rudder % LEF % LEF % Component Returns to May 08 Returns to Jul 09 Return AV Returns to Hrs to Jul 10 May 08 Return AV Hrs to Jul 09 Return AV On A/C Av Hrs to Hrs to Jul May On A/C AV Hrs to Jul 09 On A/C AV Hrs to Jul 10 Stab TEF Aileron Rudder LEF LEF

24 A Powerful Combination of Benefits Reliability Our customer orientated culture and commitment to delivering on our promises combined with our high standards, diligence and effective processes to guarantee benchmark reliability. Innovation Our Pursuit of continuous improvement and rigorous adherence to engineering based MRO guarantee innovative solutions to your operational challenges Availability On time delivery and turn around times and industrial solutions aligned with your requirements ensure the superior availability of your fleet. Affordability Reliability, innovation and availability advantages over time will lead naturally to the lowering of life cycle costs.

25 Thank you for your attention!