AIRCRAFT MAINTENANCE PREDICTIVE ANALYSIS Data Mining 25 Jan 07

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AIRCRAFT MAINTENANCE PREDICTIVE ANALYSIS(Data
Mining) 25 Jan 07
OKLAHOMA CITY AIR LOGISTICS CENTER
TEAM TINKER
Mr. Bob Wright OC-ALC/ENFO Robert.wright_at_tinker.af
.mil
I n t e g r i t y - S e r v i c e - E x c e l
l e n c e
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Problem

• Many USAF airframes average age are at or beyond
  design limits and experiencing growing
  unpredicted component failures
• Current damage analyses for structural components
  do not consider extensive maintenance activity
  accomplished on these airframes
• Much relevant maintenance data (description of
  defects found, or repair accomplished) is either
  captured on paper only, or not captured at all
  and not related to a specific a/c

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Mil-Std-1530 Requirement
MIL-STD-1530C (Aircraft Structural Integrity
Program)
5.4.3.1 Structural maintenance database
development. The structural maintenance database
shall be developed to capture adequate, detailed
information on the aging processes (fatigue,
corrosion, delaminations, etc.) which occur in
the aircraft and thus support the ongoing
evaluation of structural integrity during
sustainment. The database shall be developed to
record all significant damage findings such as
cracks, corrosion, and/or delaminations
discovered during program depot maintenance,
analytical condition inspections, time compliance
technical order (TCTO) structural inspections,
teardown inspections, and normal operational
maintenance. The database shall also be able to
record a description of the damage types, damage
sizes, damage locations, inspection techniques
(including POD information), aircraft
configuration, pertinent aircraft usage history
including basing information, and corrosion
preventive methods (e.g., wash cycles, coatings,
etc.). The database shall also be able to record
all significant repairs and/or modifications so
as to maintain configuration control. These
records shall include a description of the
repair/modification and when it was incorporated.
Additional considerations for data to be recorded
shall facilitate the analysis update described in
5.5.6.
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What is Needed

• Provide quantitative information for decisions
  related to individual aircraft and fleet system
  health.
• Acquire, consolidate, and evaluate maintenance
  data to provide a continual update of the health
  of operational aircraft.
• Significant damage findings during PDM
• Analytical Condition Inspections/results
• TCTO structural Inspections/results
• Field -3 repairs
• Identify/use existing Air Force systems when
  possible
• Depot and Field level (i.e. CAMS, PDMSS, G081,
  etc.)
• Provide alternative solutions for data short
  falls.
• Damage size, type, and location.
• Pictures/Diagrams
• Basing information,
• Modification and repair actions.

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Functional Requirements forMaintenance Data
Analysis

• 327th ASW ASIP managers need trending analysis
  relating actual defects found to aircraft usage
• 76 MXW needs to anticipate incoming non predicted
  defects based on aircraft usage and PDM history
  ASIMIS / G050
• ASC and Fleet Viability Board need to view
  current fleet status and future repair
  requirements to determine best course of action
  for airframes

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Using usage data and mx information to anticipate
Structural Failures
Proposed Vision
New Mil-Std 1530C Task V (sustainment) goal
ASIMIS
Usage Monitoring
G050
Structural Models
Assessment
Reporting
Actual Fleet Condition
Inspection Fidelity
Damage Findings
76 MXW
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ASIMIS Aircraft Usage Reporting

• Usage data available via web-based tool called
  DART
• Flight loads recorder data can be accessed via
  web system called ADADS

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Maintenance Data Collection

• Consolidates the following data
• NDI Log
• AFMC 202s (Technical Assistance Requests)
• T.O. 00-25-107 (Tech Manual for Requesting
  Maintenance Assistance)
• AFTO 349
• AFTO 95 Corrosion Data
• AFTO 427 Integral Fuel Cell Repairs
• Structural Audit Findings
• Graphical User Interface (GUI)
• Data retrieval Analysis
• Eventually data input

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76 AMXG/QIQ Proposed Projects

• Automated Process Guide Automates inspection
  processes utilizing mobile data collection
  devices
• Ensures standardization and complete inspections
• More accurate tie to WUC and HMC technical data
  codes
• Labor Analysis Provides visibility into work
  flow including back shops and support processes
• Flags labor problem areas for individual analysis
• Low Percent Analysis Anticipates incoming non
  predicted defects based on aircraft usage and PDM
  history (not a reliability study!!)
• Quality Data Analysis Analyzes aircraft defects
  to provide root cause and trend analysis

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Support Requirements forMaintenance Data Analysis

• ASIMIS collects usage history per tail number
• Flight hours, landings, fuel offloads, time _at_
  mach/alt
• 76 MXW will collect defect/repair information per
  tail number
• We still need tools to query defect information
  captured during maintenance and display against
  usage data to enable trending analysis

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Point of Contacts

• Randel Bowman, 76 AMXG/QIQ
• E-mail randel.bowman_at_tinker.af.mil
• Bob Wright, OC-ALC/ENFO
• E-mail robert.wright_at_tinker.af.mil
• Ken Simmons, OC-ALC/ENET
• E-mail kenneth.simmons_at_tinker.af.mil