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Pratt & Whitney Proprietary

PHM Experience at UTC and Pratt & Whitney:

Challenges and Opportunities

Steve O’Flarity

The PHM Society

1 October 2009

1 October 2009page 2

Click to edit Master subtitle style

Focus

United Technologies PHM Overview

Pratt & Whitney PHM Overview

Defining Value…It’s Not Easy

Lessons Learned (and some we’re all still working on)



Public Access Data

United Technologies Corporation



A Tradition Of Innovation

Willis CarrierWillis Carrier

Thomas HamiltonThomas Hamilton

Elisha Graves OtisElisha Graves Otis

David SundstrandDavid Sundstrand

Igor SikorskyIgor Sikorsky

Charles ChubbCharles Chubb

Fred RentschlerFred Rentschler

Walter KiddeWalter Kidde



Broad UTC PHM Experience

United Technologies Research Center

Multi-Spectral Diagnostics

UTC Power

Fuel Cell Remote Diagnostics

Sikorsky Aircraft

Usage-Based Lifing

Sikorsky Aircraft

HUMS

Pratt & Whitney

EHM, ADEM

PW625PW625

UTC Fire & SecurityCarrier

Otis

Pratt & Whitney Rocketdyne

Remote Building Monitoring and Diagnostics

Remote Elevator Monitoring

Hamilton Sundstrand

Health Monitoring

P&W Canada

Health Monitoring

Diagnostic Sensor FusionHealth Monitoring



Pratt & Whitney

Public Access Data

Military EnginesLarge Commercial

Engines

Small Engines SpacePower Systems


Click to edit Master subtitle styleMaterial and

Repair ServicesService

Solutions

EngineServices

New Engines

Experience and Engineering Excellence

Over 80 Years of Aircraft Engine Design & Maintenance



Complete MRO Services

Engine Leasing

PW4000

JT9D

CFM56

PW2000

JT8D

V2500

PW6000

Repair

Customer Training

Overhaul

Water WashHealth Management

$/FH MonitoringLine Maintenance

Fleet Management$/FH Overhauls

24-Hr Help Center



Customer Issues are MRO Issues

Example assumes $2M purchase price and $100 / EFH direct maintenance cost (DMC) at 3,500 EFH / yr

Fuel

Emissions

Availability

$0.0

$5.0

$10.0

$15.0

$20.0

$25.0

0 5 10 15 20 25 30 35 40 45 50 55Year

DM

C ($M

)

Cum Maintenance Cost

PURCHASE



Automatically process dataDetect issues before failuresPerform troubleshooting

AnalyzePlan maintenanceTurn aircraft

RecommendInspectionMaintenance

ManageLife cycle costsForecastingSupply chain

Engine Health ManagementIntegral to managing operations



Confirm

Isolate

Communicate

Maintain

1-1

Document

Customer

Engine Management Programs (EMPs)Closed loop alert notification and disposition process

Review



Key Lessons / Challenges

What’s the business case?

How do we get data?

How do we support small customers, mobile customers (leasing)?

How do we solve more of our customers’ problems?



A Generalized PHM Value ModelCREATEVALUE

OBJECTIVE

RECIPIENT

VALUE PROP

BUS. PROP

OFFERING

METRICS




PROVIDERVALUE

CUSTOMERVALUE

OBJECTIVE

RECIPIENT

VALUE PROP

BUS. PROP

OFFERING

METRICS




PROVIDERVALUE

CUSTOMERVALUE

REDUCEDMAINTENANCE

COSTS

REDUCEDOPERATING

COSTS

INCREASEDAVAILABILITY

OBJECTIVE

RECIPIENT

VALUE PROP

BUS. PROP

OFFERING

METRICS

RELIABILITY

OUTSOURCE ADDITIONALCAPABILITIES GUARANTEES

AVAILABILITY

OPERATINGCOSTS

ASSET /RESIDUAL

VALUE

MAINTENANCEPLANS

MONITORINGPLANS

BETTERFLEET

MAINTENANCECOSTS




GENERATEREVENUE

REDUCECOSTS

GUARANTEEDMAINTENANCE

COST

IMPROVERELIABILITY

PROVIDERVALUE

CUSTOMERVALUE

WARRANTYMITIGATION

MONITORINGPROGRAMS

USAGE BYTHE HOUR

MAINTENANCECOST

GUARANTEES

BUNDLED /ADJACENTSERVICES

REDUCEDMAINTENANCE

COST

ADDITIONALSALES

REDUCEDMAINTENANCE

COSTS

REDUCEDOPERATING

COSTS


REDUCEDWARRANTY

COSTS

OBJECTIVE

RECIPIENT

VALUE PROP

BUS. PROP

OFFERING

METRICS

BETTERPRODUCT

ADDITIONALSALES

ADDITIONALSALES

VARIOUSMODELS

VARIOUSPOSSIBILITIES

RELIABILITYINCREASEDAVAILABILITY


AVAILABILITY

OPERATINGCOSTS

ASSET /RESIDUAL

VALUE

MAINTENANCEPLANS

MONITORINGPLANS

BETTERFLEET

MAINTENANCECOSTS



Define and Quantify the Metrics!CREATEVALUE

GENERATEREVENUE

REDUCECOSTS

GUARANTEEDMAINTENANCE

COST

IMPROVERELIABILITY

PROVIDERVALUE

CUSTOMERVALUE

WARRANTYMITIGATION

MONITORINGPROGRAMS

USAGE BYTHE HOUR

MAINTENANCECOST

GUARANTEES

BUNDLED /ADJACENTSERVICES

REDUCEDMAINTENANCE

COST

ADDITIONALSALES

REDUCEDMAINTENANCE

COSTS

REDUCEDOPERATING

COSTS


REDUCEDWARRANTY

COSTS

OBJECTIVE

RECIPIENT

VALUE PROP

BUS. PROP

OFFERING

METRICS

BETTERPRODUCT

ADDITIONALSALES

ADDITIONALSALES

VARIOUSMODELS

VARIOUSPOSSIBILITIES

RELIABILITYINCREASEDAVAILABILITY


AVAILABILITY

OPERATINGCOSTS

ASSET /RESIDUAL

VALUE

MAINTENANCEPLANS

MONITORINGPLANS

BETTERFLEET

MAINTENANCECOSTS



Diagnostics and Prognostics Mitigate RisksReliability typically trades with cost and weight

PHM improves reliability, reduces costCatch small events early before becoming big cost

Turn UERs into pre-planned removals

Forecast trends that can be managed on wing

Determine overhaul workscope on wing

Extend life – usage-based lifing

Our PHM analysis tool is ADEM – Advanced Diagnostics and Engine Management

ADEM drives hardware and systems technologiesGas path and subsystem sensor coverage

Access to operational performance and usage data

Accurate engine simulation models

Reporting

Fault Trending

Alerting

Watch Lists

Data Visualization



Health Management Provides Quantifiable Value

Savings vary by service level, customer, fleet, etc., and do not include significant productivity improvement typically realized.

Time on wing extension

Shop visit cost reduction

Fuel consumption reduction

Operational cost reduction

0%5%

10%15%20%25%30%35%

TOW SVC Fuel Operational

0%

5%

10%

15%

20%

25%

30%

35%

Bleed

HPCHPT

EGT Mgmt.

Instr.

TCC

Oil Sys. Fan

Value Summary

Event Value



Trend plots point to HPT

Isolation indicates HPT Borescope inspectionrevealed T1 blade damage

Engine removed prior toincurring additional damage

PW4000 engine removed prior to additional damage

Customer Value – HPT Damage Detected

Estimated Savings: $700K (UER potential – $Million+ / Event)Estimated Savings: $700K (UER potential – $Million+ / Event)

Alerts triggered



Industry Health Management Value Stream

ACQUIREDATA

DELIVERDATA

ANALYZE+ REPORT

EXECUTEACTIONS

STRONGWEAK



Improve Data Collection and Delivery Technologies

Current technologies are poor: ACARS, sneaker-net

PHM critically needs various field data for…Warranty / guarantee mitigation

$/FH risk mitigation

LLP usage-based life extension

Interval and cost estimation forecasting

Revenue through health services

Emerging issue detection

Fuel conservation services and consumption guarantees

Emissions tracking – ETS, U.S. “Cap & Trade”

BA

ND

WID

TH

LATENCYPOST

FLIGHTREALTIME

HIG

HLO

W

REACTIVEDIAGNOSTIC

PROACTIVEPROGNOSTIC

2.4-64 Kbits/sec

432K-30M bits/sec

100

Kbits

/ sec

As it happensDelayed 1-5 days

0 Kb

its/ s

ec30

Mbi

ts/ s

ec

ACARS

FLIGHTCOUPONS

QAR /SNEAKER NET

BROADBANDSATELLITE

BA

ND

WID

TH

LATENCYPOST

FLIGHTREALTIME

HIG

HLO

W

REACTIVEDIAGNOSTIC

PROACTIVEPROGNOSTIC

2.4-64 Kbits/sec

432K-30M bits/sec

100

Kbits

/ sec

As it happensDelayed 1-5 days

0 Kb

its/ s

ec30

Mbi

ts/ s

ec

ACARS

FLIGHTCOUPONS

QAR /SNEAKER NET

BROADBANDSATELLITE

Commercial Engine Data Delivery



57%

23%

13%

6% 1%

How Do We Address Small / Lease Operators?

57% of world’s operators fly 10 or fewer engines

10 or less engines

11 - 30 engines

31- 100 engines

101-500 engines

500+ engines

Customers flying >100 engines mostly captive

Profitability?Portability?



Algorithms /

Analysis

Algorithms /

Analysis

Basicsensors Basic trend monitoring Manual

calculations

Expandedinstrumentation

Oil condition, sub-systems

Custommodels

Isolation techniques

Work scope / operationsoptimization

Electronic enginecontrols

Anomaly detection

Condition-based maintenance

Operational improvements

How Can We Address More Problems?Sen

sors

/ DataSen

sors

/ Data

Technology advancements drive value

Part lifealgorithms

Expanded flight data

Usagebasedlifing



A Holistic Systems Approach

Integrated vehicle health and data management

100% pylon-on-down (POD) supportThrust Reverser with

Variable Area Fan Nozzle

Fan Cowls

Primary Exhaust Nozzle

Exhaust Plug or Cone

Engine Mounts

Pylon and Attaching Hardware

Aft Pylon FairingInlet

Engine and Engine Build-Up

BFE (Generators, Hydraulic Pumps, Fire

Protection, etc.)

Environmental Control System

APUGuided Troubleshooting



Questions?



Thank You!

phm experience at utc and pratt & whitney: challenges and ... · pw4000 engine removed prior to...

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