Jens Schöneberg Solution Architect MRO/M&E

2000 SAP AG European A&D Information Forum 2000, March 14./15.2000 / 1 Jens Schoeneberg (E2)

Jens SchönebergSolution Architect MRO/M&E

RotableManagement



SAP Solution2

Rotable Management in Aerospace1

SAP Future Focus3

Content



SAP Solution2


SAP Future Focus3

Content



Repairable Part Serialized Long Life Cycle Expensive Components Big / Complex Components Life Limit Controlled

What is a Rotable?



Rotable Management Cycle

Stock

Serviceable Unserviceable

ProcurementScrapping

In-house Repair

Aircraft

Subcontracting


Scenarios with/without Intermediate Storage

WarehousePart(s)

Replacementpart(s)

Part(s)

Part(s)

Technicalobject

Repairprocess

Part(s)

Part(s)

Technicalobject

Repairprocess

Open-loop scenario

Closed-loop scenario


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

Businessrelated

AviationAuthority

related


SAP Solution2


SAP Future Focus3

Content



Func-tionallocation

Equip-ment/Serialnumber

Technicalobjects

As-Maintained Configuration

Assem-bly

Material


Serial Number and Equipment

Equipment master record

Serial data

Material E-2002

Serial number 1351

• Stock information

• Serial number history


Rotable Exchange Process

(1) Rotable exchange process

Return of serviced partReplacement part

Removal of part Shipment of part

(2) Repair process

Warehouse Workshop /Subcontractor


Life Controlled Rotables I

Flight Hours

Take-offs/Landings

Chracteristics ofClassification System

CounterReading

Flight hours 2351CounterReading

Landings 511

Input Sources:- Manually via R/3- Intranet/Internet- PM-PCS Interface

Technical Object

Counter


Aeroplane counter12.02. 350 Take-offs/landings

20.02. 360 Take-offs/landings

Landing gear counter for tires12/02. 20 Take-offs/landings

20/02. 30 Take-offs/landings

Difference of 10 take-offs/landings carried forward

Life Controlled Rotables II


Automaticcreation

Update onFlight Hours

RotableMaintenancePlan R/3

Pump P111

PM/CSPM/CSOrderOrder

Rotable Exchange

1 4 5 3

P111

Hours

Aircraft Configuration

Manualcreation

Discrepancy found

LifeContolledRotable

PM/CSPM/CSNotificationNotification

Trigger/InitiateRotable

Exchange


Usage list

G-BIKA

Installation 01.03.98Removal 20.09.98

01.03. - 20.09.98 G-BIKA

Traceability of Rotable within As-Maintained Configuration


PurchasingPurchasing

Ser. No. 1

Ser No.-1New

New

Ser. No. 1Unservice-

able

Ser No. 1Service-

able

Sub-contractor

In-house

Ser No. 1

Ser No.-1

ShippingShipping

ReceiptReceipt

Rotable Traceability witin Inventory


Materialwith valuation type A

(condition-basedvaluation)

Valuation typeNEW

$ 3,000.00

Valuation typeSERVICE

$ 2,200.00

Valuation typeUNSERVICE $ 1,280.00

Valuation Based on Parts Condition


In-house Repair Process




(2) In-house repair process

Warehouse In-houseWorkshop


Refurbishment Order

Maintenance order 800175Order type: PM04

Material P-2001 Fuel pumpQuantity 3Serial number 53, 81, 27

From UNSERVICEPlant:0001 SLoc: 0002

To SERVICEPlant: 0001 SLoc: 0001

StockStockPlantPlant 00010001SLocSLoc 00020002

UNSERVICE

Goods issuewith movement

type 261

StockStockPlantPlant 00010001SLocSLoc 00010001

SERVICE

Goods receiptwith movement

type 101SLoc = Storage location


Material P-2001Serial number 53

Plant 1000Storage location0001BatchSERVICE

Material P-2001Serial number 53

Plant 1000Storage location0002BatchUNSERVICE

EnjoySAP - Refurbishment

StockStock

UNSERVICE

StockStock

SERVICE

Refurbishmentorder

Object list:- Serial number 1- Serial number 2- Serial number 3

Object list:- Serial number 1- Serial number 2- Serial number 3

Goods issue

Automatic change of valuation type during goods movement

Proposal of serial numbers during goods issue


Subcontracting Process




(2) Subcontracting process

New withIS A&D 4.6

Warehouse Subcontractor


Purchase Order for Subcontracting

SubcontractorMRO Provider

10 L 1pc DISC SerNr 471pc DISC SerNr 472pc BLADE

DISC Serial Number 47

Purchase OrderPart that will be receipt back

Parts that will be providedto the subcontractor

+


Warehouse

xxxxxxxxxxxxxxxxxxxxxx

xxxxxxxxxxxxxxxxxxxxxx

xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx

Purchase orderSubcontracting

DISC 1pcBLADE 2pc

SC vendor SUBC1

SC inventory monitor

DISC BLADE

(1) Create SDdelivery

(2) Post goodsissue for P/O

Picking, Packing, Shipping

Vendorstock

SC = Subcontracting


SC vendorSC vendor

1)1) Goods receipt for theGoods receipt for theserviced rotableserviced rotable

2)2) Component consumptionComponent consumption

Purch. Orderhistory

Comp.: DISC

Goods receiptof rotable

Goods Receipt

Warehouse

SC = Subcontracting


Goods receipt of servicable parts

Part number change Serial Number change

Valuation change

Consumption of parts from

SC vendor stock

Goods Receipt

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

SC = Subcontracting


Warranty Assignment

Master warranty• Description

• Warranty services

• Warranty counter

Tail G-BIKA• Valid from 5.1.1998

• Measuring point:Flight hoursCycles

Tail C-678• Valid from 12.10.1998

• Measuring point:Flight hoursCycles

Assignment


SAP Solution2


SAP Future Focus3

Content



EnjoySAP - Rotable Exchange Process

Replacement part

Removal of part

Warehouse

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


Initial Provisioning / Follow up Procurement*

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)

Optimal Stockper location

Repair Float required

per location

Repair Float required

Level 1 Level 2 Level 3

* Depends on client funding


Integrated Planning for Rotables Using APO*

Fulfillment SystemR/3

Historical data

Maintenance plan

PM/CS order

Inventory

Refurbishment order

P.O. new part

P.O. subcontracting

SynchronizeP.O. = Purchase order

Planning SystemAPO

Detailed PlanningSNP

Fullfillment PlanningPP/DS

ForecastDP

* Depends on client funding


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)

Jens Schöneberg Solution Architect MRO/M&E

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