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5 Steps to Heaven – A Rolls-Royce Perspective

5 Steps to Heaven – A Rolls-Royce Perspective

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5 Steps to Heaven – A Rolls-Royce Perspective

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  1. 5 Steps to Heaven – A Rolls-Royce Perspective Dr Ian K Jennions EHM Global Capability Owner IBM Almaden Institute, San Jose7th May 2008 ©2008 Rolls-Royce plcThe information in this document is the property of Rolls-Royce plc and may not be copied or communicated to a third party, or used for any purpose other than that for which it is supplied without the express written consent of Rolls-Royce plc. This information is given in good faith based upon the latest information available to Rolls-Royce plc, no warranty or representation is given concerning such information, which must not be taken as establishing any contractual or other commitment binding upon Rolls-Royce plc or any of its subsidiary or associated companies.

  2. 5 Steps to Heaven – A Rolls-Royce Perspective Business Landscape 5 Steps to Heaven Simulation of Total Care Value in Data Introduction Our Service Business Asset Management Technology Successes Marine EHM (Equipment Health Management) AE3007 HP Vane QUICK Future Current Issues Summary © 2008 Rolls-Royce plc

  3. Rolls-Royce’s four markets © 2008 Rolls-Royce plc

  4. Rolls-Royce Group plc - 2007 © 2008 Rolls-Royce plc

  5. Video: ‘New Thinking, Joined Up Thinking' © 2008 Rolls-Royce plc

  6. 5 Steps to Heaven – A Rolls-Royce Perspective Business Landscape 5 Steps to Heaven Simulation of Total Care Value in Data Introduction Our Service Business Asset Management Technology Successes Marine EHM (Equipment Health Management) AE3007 HP Vane QUICK Future Current Issues Summary © 2008 Rolls-Royce plc

  7. Changing Customer Requirements Traditional Support • Spare parts • Repair & overhaul Extended Support • Partnered capability to cover complete weapon systems • Turn-key services • Non-propulsion related support solutions Total Support • Complete, availability- based service. Can cover all off-aircraft, and some on-aircraft activity • Configuration management & reliability enhancements covered Reactive Aligned Integrated Customer Value Advanced Support • Comprehensive package integrating elements of basic and enhanced support • Spares inclusive R&O contracts Enhanced Support • Data & forecasting services • Technical & logistics support • Customer training Increased Scope © 2008 Rolls-Royce plc

  8. Extended Support Total Management Total Support Engine Availability Customer Risk Service Provider Risk Advanced Support Asset Management Enhanced Support Forecasting Basic Support Traditional Stage 5 • Future EHM • Unknown at this time, but could include Powerplant and/or platform health monitoring Stage 4 Increasing Scope of Service Provision • Extended EHM • Piece part diagnostics • Prognostic capability • Networking of systems (BROADEN) Stage 3 • Total Care EHM • Data fusion – oil/performance/vibration • Integration with LCC & WSG tools • Advanced diagnostic • Dynamic performance model (COMPASS) Stage 2 • Advanced EHM • Lifing • Performance trending • Oil trending • Vibration trending • Improved life counting • Basic diagnostics Stage 1 • Basic EHM • Lifing – cyclic counts • Digital borescope Customer Exploits Info. to Reduce Cost RR Exploits Info. to Increase Cost Effectiveness of Product Commodity Service The EHM Transformation Staircase - Defence © 2008 Rolls-Royce plc

  9. Total Care Simulation - Example • Product Operation • aircraft, engine, airport, operations control • Product Behaviour • engine, module, part, virtual characteristic • Asset Management • parts, modules, dedicated & lease pool spare engines, operator interaction • Manufacturing & Supply • aircraft, engines, modules, parts • Transportation & Logistics • engines, modules, parts • Engine Repair, Overhaul & Test • capacity, capability, resourcing, availability • Component & Module Repair © 2008 Rolls-Royce plc

  10. Total Care Simulation- video © 2008 Rolls-Royce plc

  11. Customer Service Data LCC Modelling Toolkit (WP3) Designer Knowledge Desktop (WP1) Product Designer Customer Integrated Products and Services (IPAS) New (IPAS) New (IPAS) Key: New (IPAS) New (IPAS) Existing Existing Knowledge flow Service Engineers/Overhaul trained and Service Engineers/Overhaul trained and motivated to share knowledge with design. motivated to share knowledge with design. Service Engineer/ Service Engineer/ Tools, methods and processes available to Tools, methods and processes available to Overhaul Shop Overhaul Shop support data and knowledge capture support data and knowledge capture Service Data Service Data LCC Modelling Toolkit (WP3) Designer Knowledge Desktop Designer Knowledge Desktop (WP1) Product Designer Product Designer Service Provider Service Provider LCC Modelling Toolkit Customer Customer Customer Customer Designer able to search easily for Designer able to search easily for knowledge via intuitive interface, knowledge via intuitive interface, ontology models and social ontology models and social Social Issues and Solutions solutions. Able to do LCC trade solutions. Able to do LCC trade - - Social Issues and Solutions (WP1) offs, understands service needs offs, understands service needs Product designed to support the service offering Product designed to support the service offering – – existing service knowledge base fully used, existing service knowledge base fully used, continuous improvement via optimized IPAS continuous improvement via optimized IPAS Processes Processes Optimised IPAS Processes – – – – – – – – © 2008 Rolls-Royce plc

  12. ETC New Doc Legacy Data Source 2 Legacy Doc New Data Source 4 The IPAS System Architecture Knowledge Desktop Knowledge K-Search Ontologies Parts Features SAP SDM RCP Reports Other Information Mechanisms Materials Data Types K-Forms K-Forms Data Web Services © 2008 Rolls-Royce plc

  13. IPAS Results – the ability to search legacy data • Legacy data is largely unstructured and is captured and stored in a variety of ways. • Development of ontologies for hardware description, failure mechanism etc. allow us to make sense of unstructured legacy data. • K-Search provides a means of interrogating legacy data and presenting structured search results back to the user • K-Search is a learning system that builds an understanding of document content such that after the ‘learning process’ >95% rate of correct automated document content classification can be achieved. Automatically extracting knowledge from legacy unstructured data © 2008 Rolls-Royce plc

  14. 5 Steps to Heaven – A Rolls-Royce Perspective Business Landscape 5 Steps to Heaven Simulation of Total Care Value in Data Introduction Our Service Business Asset Management Technology Successes Marine EHM (Equipment Health Management) AE3007 HP Vane QUICK Future Current Issues Summary © 2008 Rolls-Royce plc

  15. Marine Off-shore Supply and Service Vessel Propulsion units monitored: • 4 Bergen 6 cylinder C engines. • 2 Azipull thrusters. • 2 Tunnel thrusters. • 1 swing up thruster. © 2008 Rolls-Royce plc

  16. Vessel 49 EHM Network Installation. RRM Service Centre RRM Ship network EHM Central unit Propulsion EHM unit Engines EHM unit Engines Data Coll. unit Thrusters EHM unit Ethernet © 2008 Rolls-Royce plc

  17. AE3007 HPT Vane Distress • Leading edge burns away over time • Causes: cooling blockage, oxidation • Condition that typically occurs on high time engines (primarily on-condition engines) • Causes increased stress on the 1st stage blade leading to high cycle fatigue (secondary damage) • Turbine blade fracture leads to in flight shut down and a 2x shop visit cost © 2008 Rolls-Royce plc

  18. AE3007 HPT Vane Distress Vane distress showed up as performance changes. • Data fusion allows clear signature to be set • Fuel flow, turbine temp, pressure & speed • 50 hour window after detection with 96% confidence of preventing HPT blade failures • Allows time to schedule removal • Thresholds set to balance false positives and false negatives • Relatively small number of false alerts and false negatives © 2008 Rolls-Royce plc

  19. AE3007 HPT Vane Distress - Savings • The alternative of not having EHM for this issue • Allow HPT-1 blade failures • Pull engines in mod campaign • Implement a 50 hr boroscope inspection interval • 8 yr EHM Savings estimated at over $60M • Based on mod campaign or inspections both ($$$$) • Savings continue as engines age and experience vane distress © 2008 Rolls-Royce plc

  20. So What’s the Problem ? • With high-integrity systems such as jet engines, conventional fault detection methods have limited capability: • The most important examples (i.e. the abnormalities) are very rare • Some of the fault conditions may not have been seen before • Subtle pre-cursor events often exist prior to failure but these are rarely detected by employing conventional techniques. • Advances being made at RR via advanced computational and signal processing methods, specifically: • QUICK, learn a description of normality and test against it (OBS) • Crack detection and propagation (Cranfield University) • Knowledge Based Diagnostics (Sheffield University) • DAME (Universities of York, Leeds, Sheffield and Oxford) © 2008 Rolls-Royce plc

  21. Quantitative User friendly Intelligent Collection of Knowledge (QUICK) • QUICK is a system used for real time acquisition and intelligent analysis of vibration and performance data from gas turbine engines. • QUICK has been developed over a number of years between Oxford University, Oxford BioSignals and Rolls-Royce The innovation in the product lies in: • The use of Computational Intelligence to quantify features • Building models of normality • Fusion of data from disparate sources for engine diagnostics. • The system is exploitable in other fields (e.g. medical) © 2008 Rolls-Royce plc

  22. QUICK video: Innovation Award © 2008 Rolls-Royce plc

  23. Novelty Thresholds – Bayesian EVT 23 © 2008 Rolls-Royce plc

  24. Example results – 826 tests 24 © 2008 Rolls-Royce plc

  25. 5 Steps to Heaven – A Rolls-Royce Perspective Business Landscape 5 Steps to Heaven Simulation of Total Care Value in Data Introduction Our Service Business Asset Management Technology Successes Marine EHM (Equipment Health Management) AE3007 HP Vane QUICK Future Current Issues Summary © 2008 Rolls-Royce plc

  26. Different perspectives – system boundaries © 2008 Rolls-Royce plc

  27. LOCAL PLATFORM Often has to operate deployed and autonomously, and often has an ability to self maintain. If the platform is mobile, data communications may be limited EHM Intelligence Dichotomy • Fleet centred view - the realisation of full value by having an accurate, real time fleet view of the state of all assets • Platform centric view - Devolving EHM intelligence to the local platform to compensate for: • limitations in communicating with a central information hub (a lack of infrastructure and capacity) • Requirements for assets to operate and be maintained autonomously • Concerns for data privacy and IPR Communications Some organizations bandwidth may be do not want to export CENTRAL HUB LOCAL PLATFORM limited and may be their data beyond LOCAL PLATFORM expensive their firewalls Processes EHM data Often has to operate centrally and issues Often has to operate deployed and autonomously, alerts. Maintains an deployed and autonomously, Data Communications infrastructure and often has an ability to overview of the condition and often has an ability to self maintain. If the platform of the full fleet. Is able to self maintain ‘on mission’. If is mobile, data Real time monitoring offers advantages of mitigate the operational the platform is mobile, data communications may be better resolution, earlier detection and a consequences of communications channels limited wider scope of failure mode detection - at failure may change and be limited the price of having to process much higher data volumes THE RESULT IS PRESSURE TO PUSH EHM INTELLIGENCE TOWARD THE PLATFORM © 2008 Rolls-Royce plc

  28. Service Data Manager CoreControl CoreAlert Aero Exec Integrator SAP Gold (T45 Programme) Vision: HUMS Information Fused with Operations for Optimised Fleet Management © 2008 Rolls-Royce plc

  29. Vision: The Operations Room of the Future? Oil uplift and utilization data transferred from Squadron and pilot reports Repair and Overhaul EHUMS data download from A/C using data retrieval unit (DRU) routed via Ground Support System (GSS) to Operations Centre AI fault recognition and diagnosis All Operations linked through global GRID system Customers can view status on DefenceManager Operations Room - processes information Agent-based aftermarket modelling and decision support Customers alerted by pager, e-mail or cell phone Service team monitors output and liases with customer © 2008 Rolls-Royce plc

  30. 5 Steps to Heaven - Summary • In the OEM to Service business transformation data is key • Operating on the data to create information and knowledge has been demonstrated, including value, in a number of areas. • With risk shift from Customer to OEM in a Service model EHM is risk mitigation, informing the Aftermarket business and helping to minimise unplanned events • Basic EHM has been yielding good results for a number of years, the next steps are much more complicated © 2008 Rolls-Royce plc

  31. Cranfield Integrated Vehicle Health Management Centre of Excellence • Vision • A world-class research and demonstration Centre of Excellence, seeking to establish industry standards and yielding competitive advantages in Integrated Vehicle Health Management (IVHM) for its industry members. • Strategic Aims • Attract Investment – supplement launch funding by attracting additional investment from new core partners/members and research funding bodies • World Recognition – working with industry and academic leaders • Technology Transfer – implementation of concepts and technologies within the industry and develop the associated skills base • Self Sustaining – after 5 years • Delivery of Competitive Advantage – to the key stakeholders Generic Architecture CoE Concept Funding/ Governance • http://www.cranfield.ac.uk/cua © 2008 Rolls-Royce plc