EAMSEmbraer Aircraft Maintenance Services
Value optimization
March - 2016
Embraer
ABOUT US
SUPPORTING
OUR CUSTOMERS
SINCE 2002.
Embraer - EAMS
EMBRAER NASHVILLE
Embraer Aircraft Maintenance Services Inc., a wholly-owned subsidiary of Embraer since 2002, the Nashville facility provides aircraft and component maintenance as well as factory training on the Ejet.
Today we have 480 technicians and support staff who annually produce over 200 aircraft maintenance events and over 11,000 component repairs and overhauls. Annually, our training department performs over 4800 training events for our employee and trains over 100 customer per year on the Ejet.
2002First Embraer MRO for Commercial Aircraft in the United States
2006Hangar 2 is built for the E-Jets (190 – 195)
2012Hangar 3 operations replace the Paint area
Preparation
Streamlining the Value
TAT TAT TAT
Was
te
Was
te
Was
te
Time wasted
EquipmentMethodManpower
MaterialMeasurement EnvironmentManagement
Work condition
Tools
GSE
Racks etc…
Planning WP
Sequence
Knowledge
Availability
Parts available
Delivery system
Roles and responsibilities
Controls
Visibilities Organization
Reaction plan
Production
Control
Set up / Strategy
Understanding the gaps
Vision for Excellence
Workplace / Environment
Safety
High Quality
Cycle
Reduction
(TAT)
Cost control
Support and
Resources
Controls , Visibility
Manpower
effectiveness
Excellence
HANGAR
Process analysis – Using Kaizen/A3
Understanding the As Is.
Process map analysis
Using a process map analysis to
identified process
Using 7 Forms of Waste to find non
value added time:
1. Transportation,
2. Inventory,
3. Motion, Wait,
4. Over process,
5. Over production,
6. Defects
Objective – Reduce non value add time
Inspector
PC Drop Box
IPM 51
Non Routine Printed
Lead Bid Drop Box
Customer Approves Task card
Approved orUnapproved Bin
Lead OrdersMaterial
Task Card Ready toFlow and WOrk
Non Routine Generation Flow – As Is
Old Process had 12 steps and was all hand transfer of
paper from one step to the another
PC Manual InputInto Quantum
Process analysis – Preparation/ Collaboration
Process Map analysis.
5S Collaboration
1. Sort
2. Set in Order
3. Shine
4. Standardize
5. Sustain
Strategy
Project
(Phase 1)
Project
(Phase 2)
Project
(Phase 3)
2014 - Process improvement / Preparation
2015 – Automation / Implementation
2016 / Future –Standardized/Optimize
Hangar 1
Hangar 2
Hangar 3
Improving the current process
• Re-engineered task distribution –
leads, inspection and back shops
• New process Improvements/benefits– Tasks are distributed in accordance with the flow
– Managable groups of tasks
– Distributed from a file cabinet to maintain critical path flow
– Disciplined process to return all tasks to work center
– Sharp reduction in lost/misplaced paperwork
Before After
Minimal Control
Clear Flow
Positive Control
Project
(Phase 1)
Automation/Implementation
EmpowerMx FleetCycle allows us to integrate best practice with
automation
Project
(Phase 2)We were not looking for a software,
we were looking for a platform to change our behaviors
System - EmpowerMx
After:
Visual Management Status page – Real time
Before:
Tasks distributed
manually in accordance
with the workflow
Project
(Phase 2)
System - EmpowerMx
Standardization/ OptimizationProject
(Phase 3)
New process was cut down from 12 steps to 6 steps and they are all electronic.
InspectorNR Directly Entered
Into Empower Lead Bids Job &Orders Materials
Customer Approval Website
Customer Approves Task
Card
Task Card Ready to Flow and Work
Improvement – Non Value Added
“LESS PAPER”
Greatly reducing the time it takes for a task card to go from generation to ready to work.
IPM 51 must be hand written and turned into the Production Controller to be entered into our ERP systme. This had an associated time lag between creation and evaluation.
The system allow for electronic recording of non-routines by the Quality Control personnel.Eliminated handwriting discrepancies, reduced movement, transportation, paper waste, entry time...etc. Decreased lag time between creation and evaluation by nearly 24 hours per task.
BEFORE
AFTER
Improvement – Non Value Added
BEFORE
AFTER
Corrective action was hand written and often found to be illegible. Then transcribed to our ERP system. Paper copy can be lost/misplaced. Also, there were no defined fields for auditing or data mining.
Electronic non-routine with text fields, built in audit requirements, and electronic signatures with audimated formatting. And data mining capabilities
Improvements – Non Value Added
BEFORE
AFTER
The audit and tally record is now electronic and accessible by multiple personnel at one time.
Audits and tally task cards, the inspection team and the customer representative were forced to get the book from one another or wait until the other was finished.
Improvements – Non Value Added
Improvements – Work Flow
Current Day
Remaining Milestones
BEFORE
AFTER
Numerous people interacting with the flow of task cards and no visibility of where those tasks are flowed. Changes go undetected and rely upon the constraint of communication as a control measure.
Electronic milestone assignment within Empower.
Prioritized by Due Date
Shows all Tail Numbers in Dock
BEFORE
AFTER
Greater visibility of the maintenance flow of the aircraft with assignments on one page and ability to sort each task by required by date..
Supporting departments often do not complete the right tasks at the appropriate times.
Improvements – Work Flow
4.11
3.36
3.13 3.15
2.98
2.82
2.25
2.45
2.65
2.85
3.05
3.25
3.45
3.65
3.85
4.05
4.25
Total Actual Hours Applied / Total Task Card Count
Result – Applied hours
EmpowerMX Start
60%
70%
80%
90%
100%
110%
120%
H4
31
7
H4
32
4
H4
34
4
H4
35
0
H4
36
1
H4
37
2
H4
37
9
H4
39
0
H4
39
8
H4
40
5
H4
41
1
H4
42
7
H4
44
8
H4
45
1
H4
47
2
H4
47
6
H4
48
1
H4
49
0
H4
49
9
H4
50
7
H4
51
2
H4
52
0
H4
53
6
H4
54
3
H4
55
4
H4
57
3
H4
58
1
H4
59
1
H4
59
9
H4
60
9
H4
61
8
H4
62
7
H4
63
3
H4
64
1
H4
64
6
H4
64
7
H4
65
7
H4
66
9
H4
67
1
H4
68
6
H4
68
8
H4
70
5
H4
71
4
H4
72
0
H4
74
2
H4
74
5
H4
75
2
H4
76
2
H4
77
5
H4
78
3
H4
78
4
H4
80
0
H4
80
3
Overall Efficiency Last 1.5 Years
Result - Efficiency
BEFORE AFTER
WE STRIVE FOR COMPANY
EXCELLENCE
Aircraft Maintenance Services
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