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Jens Schöneberg Solution Architect MRO/M&E

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. Rotable Management in Aerospace. 1. SAP Solution. 2. SAP Future Focus. 3.

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Jens Schöneberg Solution Architect MRO/M&E

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  1. 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)

  2. Content Rotable Management in Aerospace 1 SAP Solution 2 SAP Future Focus 3 • 2000 SAP AG European A&D Information Forum 2000, March 14./15.2000 / 2 Jens Schoeneberg (E2)

  3. Content Rotable Management in Aerospace 1 SAP Solution 2 SAP Future Focus 3 • 2000 SAP AG European A&D Information Forum 2000, March 14./15.2000 / 3 Jens Schoeneberg (E2)

  4. 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)

  5. Rotable Management Cycle Aircraft Stock Procurement Scrapping Serviceable Unserviceable In-house Repair Subcontracting

  6. Scenarios with/without Intermediate Storage Open-loop scenario Part(s) Part(s) Technical Repair Warehouse object process Replacement Part(s) part(s) Closed-loop scenario Part(s) Technical Repair object process Part(s)

  7. 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 Business related Aviation Authority related

  8. Content Rotable Management in Aerospace 1 SAP Solution 2 SAP Future Focus 3 • 2000 SAP AG European A&D Information Forum 2000, March 14./15.2000 / 8 Jens Schoeneberg (E2)

  9. Assem-bly Material As-Maintained Configuration Func- tional location Technicalobjects Equip-ment/ Serial number

  10. Serial Number and Equipment Equipment master record Material E-2002 Serial data Serial number 1351 • Stock information • Serial number history

  11. Rotable Exchange Process Removal of part Shipment of part Workshop /Subcontractor Warehouse Return of serviced part Replacement part (2) Repair process (1) Rotable exchange process

  12. CounterReading CounterReading Flight hours 2351 Landings 511 Life Controlled Rotables I Technical Object Chracteristics ofClassification System Counter Flight Hours Take-offs/Landings Input Sources: - Manually via R/3- Intranet/Internet- PM-PCS Interface

  13. Life Controlled Rotables II Aeroplane counter 12.02. 350 Take-offs/landings 20.02. 360 Take-offs/landings Difference of 10 take-offs/landings carried forward Landing gear counter for tires 12/02. 20 Take-offs/landings 20/02. 30 Take-offs/landings

  14. Rotable Maintenance Plan R/3 Pump P111 P111 Hours 1 4 5 3 Rotable Exchange Update on Flight Hours Aircraft Configuration Life Contolled Rotable Automatic creation PM/CSOrder Trigger/Initiate Rotable Exchange Discrepancy found PM/CSNotification Manual creation

  15. G-BIKA Traceability of Rotable within As-Maintained Configuration Removal 20.09.98 Installation 01.03.98 Usage list 01.03. - 20.09.98 G-BIKA

  16. Rotable Traceability witin Inventory Sub-contractor Shipping Ser No.-1 New Purchasing Ser. No. 1 Unservice-able In-house Ser No.-1 New Ser No. 1 Ser. No. 1 Ser No. 1 Service-able Receipt

  17. 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

  18. In-house Repair Process Removal of part Shipment of part In-houseWorkshop Warehouse Return of serviced part Replacement part (2) In-house repair process (1) Rotable exchange process

  19. UNSERVICE SERVICE Refurbishment Order Stock Plant 0001 SLoc 0002 Goods issue with movementtype 261 Maintenance order 800175 Order type: PM04 Material P-2001 Fuel pump Quantity 3 Serial number 53, 81, 27 From UNSERVICE Plant:0001 SLoc: 0002 To SERVICE Plant: 0001 SLoc: 0001 Stock Plant 0001 SLoc 0001 Goods receipt with movement type 101 SLoc = Storage location

  20. Stock UNSERVICE Stock SERVICE EnjoySAP - Refurbishment Automatic change of valuation type during goods movement Material P-2001 Serial number 53 Plant 1000 Storage location 0002 Batch UNSERVICE Material P-2001 Serial number 53 Plant 1000 Storage location 0001 Batch SERVICE Proposal of serial numbers during goods issue Refurbishmentorder Goods issue Object list: - Serial number 1 - Serial number 2 - Serial number 3 Object list: - Serial number 1 - Serial number 2 - Serial number 3

  21. Subcontracting Process Removal of part Shipment of part Subcontractor Warehouse Return of serviced part Replacement part (2) Subcontracting process (1) Rotable exchange process New with IS A&D 4.6

  22. Purchase Order for Subcontracting MRO Provider Subcontractor + Purchase Order 10 L 1pc DISC SerNr 47 1pc DISC SerNr 47 2pc BLADE Part that will be receipt back Parts that will be providedto the subcontractor DISC Serial Number 47

  23. xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx Purchase order Subcontracting DISC 1pc BLADE 2pc Picking, Packing, Shipping Warehouse SC inventory monitor DISC BLADE (1) Create SD delivery (2) Post goods issue for P/O SC vendor SUBC1 Vendor stock SC = Subcontracting

  24. Warehouse Goods Receipt SC vendor Comp.: DISC Purch. Orderhistory Goods receipt of rotable 1) Goods receipt for the serviced rotable 2) Component consumption SC = Subcontracting

  25. Goods Receipt Consumption of parts fromSC vendor stock Goods receipt of servicable parts • 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 Part number change Serial Number change Valuation change SC = Subcontracting

  26. Warranty Assignment • Tail G-BIKA • Valid from 5.1.1998 • Measuring point: Flight hours Cycles • Master warranty • Description • Warranty services • Warranty counter Assignment • Tail C-678 • Valid from 12.10.1998 • Measuring point: Flight hours Cycles

  27. Content Rotable Management in Aerospace 1 SAP Solution 2 SAP Future Focus 3 • 2000 SAP AG European A&D Information Forum 2000, March 14./15.2000 / 27 Jens Schoeneberg (E2)

  28. EnjoySAP - Rotable Exchange Process Removal of part • 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 Warehouse Replacement part

  29. Initial Provisioning / Follow up Procurement* Level 1 Level 2 Level 3 • No of Aircraft • No of Parts per Aircraft • Flying hours per Aircraft a Day • Mean Time Between Removal • Turn Around Time • Service Level • .... • No of Locations • Turn around time per Location • Stock transfer time • Budget • Costs (have to be calculated) Repair Float required Repair Float required per location Optimal Stock per location * Depends on client funding

  30. Fulfillment System R/3 Planning SystemAPO Forecast DP Maintenance plan Historical data PM/CS order Detailed Planning SNP Inventory Refurbishment order P.O. subcontracting Fullfillment Planning PP/DS P.O. new part Integrated Planning for Rotables Using APO* Synchronize P.O. = Purchase order * Depends on client funding

  31. 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)

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