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Airbus Customer Services

Ccile DAUDET

Managing Aging Aircraft


A320 Program
Structures seminar 2015

Managing Aging Aircraft

Presentation title
Expertise details
Ccile started at Airbus in the Flight Test Domain where she performed
flight test envelop opening for A318, A340-500/-600 and A380.
Then she moved to Structure Support Engineering in 2008, where she
firstly dealt with A320/A380 fuselage and cockpit windows for all
programs.
Now shes product leader of nose/forward fuselage and cockpit windows
for all programs. Shes been deeply involved on A320 maintenance
planning update since 2013.

Your
photo
here

Presented by

Ccile
DAUDET
Product Leader
ATA 53-10/53-20
and ATA 56
cecile.daudetl@airbus.com

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Structures seminar, 10-13 March 2015, Toulouse

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AIRBUS S.A.S. All rights reserved.

Confidential and proprietary document.

Managing Aging Aircraft

Structures seminar, 10-13 March 2015, Toulouse

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Structures seminar, 10-13 March 2015, Toulouse

Managing Aging Aircraft

Context
2007
Mandatory Fleet survey
resulted in a new fatigue
mission(*) 1FC=2FH

2008
New Full Scale
Fatigue Test

April 2012 ALS(**) PART 2 revision 1


A320 Extended Service Goal
A320 Update due to new fatigue mission

(mission mix 34% 0.75hr +


49% 2hr +17% 4.5hr)

2014
A320 fleet leader
reaches the
Design Service
Goal (DSG)
(*) Initial certification mission 1FC=1.25FH
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(**) Airworthiness Limitation Section

2015
Widespread
Fatigue Damage
(WFD) justification
(FAR 26.21)

Structures seminar, 10-13 March 2015, Toulouse

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Managing Aging Aircraft

Structures seminar, 10-13 March 2015, Toulouse

Managing Aging Aircraft

Maintenance Programme Update Damage Tolerant Certification


The A320 Structure is
certified as Damage Tolerant

Initiation Detectable Critical

Crack can occur


Crack length

Structure can still withstand


significant loads without failure
Demonstrated Maintenance
Programme published in the

ALS(*) Part 2

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(*) Airworthiness Limitation Section

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Critical

Interval
Safe Crack Growth
Period

Detectable

FCdet

FC
Mandated
Threshold

FCcrit

Structures seminar, 10-13 March 2015, Toulouse

Managing Aging Aircraft

Maintenance Programme Update - ALS Part 2 Revision 1 dated April 2012 / ISB
Impact on ALS Part 2 Revision 1 A320-200
Tasks
-

46 New with a Grace Period


98 Revised:
- 16 Reduced threshold
- 82 Increased threshold
71 Deleted
Maintenance A320-200 global status
12% less tasks
13% Higher Mean Threshold
8% Higher Mean Interval
In addition 19 ISBs have been introduced

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ALS Airworthiness Limitation Section ISB: Inspection Service Bulletin

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Structures seminar, 10-13 March 2015, Toulouse

Managing Aging Aircraft

Maintenance Programme Update - Major Inspections findings


One operator had major findings on high Flight Cycle aircraft (~45.000FC) while
performing the applicable inspection tasks:
Frontal windshield frame,
Lateral sliding window frame,
Frame 16 (crossbeam splicing),
Pressure membrane FR35-36,
Centre wing box upper beam.

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Structures seminar, 10-13 March 2015, Toulouse

Managing Aging Aircraft

Maintenance Programme Update Severity assessment


Weight on
severity index

Key Parameters

Threshold

at initiation

with propagation

long

short

low

high

low

high

available

not available

yes

not yet

Re-inspection
interval
Finding rate
Impact on
planning
Repair solution

Spares available

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Severity Index
Threshold x Interval x Finding rate
x Impact planning x Repair
solution x Spares availability

- Low
- Medium
- High

27 ALI/ISB identified
as most critical tasks

Structures seminar, 10-13 March 2015, Toulouse

Managing Aging Aircraft

ALI/ISB Section Nose Fuselage

ALI 531101
Door cut out intercostal fittings
FR16/20
TH 36 500 FC

ALI 531103
Door stop fittings FR20
TH 48 000 FC
ALI 531127
FR11 splicing
TH 42 400 FC

ALI 531110
Cross beam splicing FR16/20
TH 34 700 FC / 69 400 FH

ALI 531129
Frontal windshield frame
TH 30 600FC

ALI 531184
Vertical web fwd pressure
bulkhead
TH 34 000 FC
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ALI 531126
FR 8 splicing
TH 25 500 FC

MRB 531125
Lateral sliding window frame
TH 48 000 FC/ 96 000 FH
ALI 531133 TH 26 700FC
ALI 531105 TH 27 600 FC
ALI 531130 TH 48 000 FC

Structures seminar, 10-13 March 2015, Toulouse

Managing Aging Aircraft

Section Nose Fuselage


ALI 531129 - Frontal windshield frames and Continuity Fittings
ALI 531129
Frontal windshield frame
TH 30 600 FC (100%)
Figures for post-mod 22058

HFEC of Windshield centre


post, lower attachment area

Fasteners remain installed (bolt and nut should not be removed)


Refer to AMM TASK 53-11-00-220-001-A & NTM 53-11-29

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Structures seminar, 10-13 March 2015, Toulouse

Managing Aging Aircraft

Section Nose Fuselage


ALI 531129 - Frontal windshield frames and Continuity Fittings
Finding rate: Low

Finding rate: High

WINDSHIELD
FRAMES

Generic repair instructions available


Repair kits available.
Continuity Fittings:
Repair by replacement (no access for rework)
Structural access required: Front titanium panel
removal
Repair duration 1 week (access, structural
work, close up)
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Windshield Frames:
Major repair by frame replacement
Structural access required: Titanium panel, crown
panel + fittings, lateral panel (partially) removal
Repair duration 3 weeks (access, structural
work, close up)

Structures seminar, 10-13 March 2015, Toulouse

Managing Aging Aircraft

Section Nose Fuselage


ALI 531129 - Frontal windshield frames and Continuity Fittings
ALI 531129
Frontal windshield frame
TH 30 600 FC (100%)
Figures for post-mod 22058

WAY FORWARD

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ISB 53-1245 will be updated to cancel and replace ALI (End 2015)
Inspection will be done through ISB

Design improvement under study for forward fit.

Structures seminar, 10-13 March 2015, Toulouse

Managing Aging Aircraft

Section Nose Fuselage


MRB 531125 - Lateral sliding window frame
MRB 531125
Lateral sliding window frame
TH 48 000 FC/ 96 000 FH (100%)
ALI 531133 TH 26 700 FC
ALI 531105 TH 27 600 FC
ALI 531130 TH 48 000 FC

MRB 531125 DET of Central/Lateral


window frame around fastener

Fasteners remain installed (bolt and nut should not be removed)


Refer to AMM TASK 53-11-00-220-805-A

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Structures seminar, 10-13 March 2015, Toulouse

Managing Ageing Aircraft

Section Nose Fuselage


MRB 531125 - Lateral sliding window frame
Finding rate: Medium
POSSIBLE CRACK

Generic repair instructions available


Repair kits available.
Lateral window frames:
Major repair by frame replacement
Structural access required: Lateral panel, crown panel, upper
panel (partially) removal
Repair duration 2 weeks (access, structural work, close up)

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Structures seminar, 10-13 March 2015, Toulouse

Managing Ageing Aircraft

Section Nose Fuselage


ALI 531125 - Lateral sliding window frame
MRB 531125
Lateral sliding window frame
TH 48 000 FC (100%)
ALI 531133 TH 26 700 FC
ALI 531105 TH 27 600 FC
ALI 531130 TH 48 000 FC

WAY FORWARD

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Inspection will be done through ISBs


ISBs will cancel and replace MRB/ALIs

Design improvement under study for forward fit

Structures seminar, 10-13 March 2015, Toulouse

Managing Ageing Aircraft

Section Nose Fuselage


ALI 531110 - Cross beam splicing FR16/20
ALI 531110
Cross beam splicing FR16/20
TH 34 700 FC/ 69 400 FH

Roto-test of holes at Crossbeam Splicing,


FR16 and FR20.

Additional inspection requirements (2 first upper fastener rows)


LH/RH frames 16 and 20 to be inspected at the same time.

2 upper fasteners rows in addition to the 4 required holes


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Structures seminar, 10-13 March 2015, Toulouse

Managing Aging Aircraft

Section Nose Fuselage


ALI 531110 - Cross beam splicing FR16/20
Finding rate: High

Standard repairs:
Oversized fasteners + cold working
Repair bushes + cold working

Major repair by frame replacement (low probability):


4 cases so far for A/C having more than 40 000FC out of more
than two hundred A/C inspected
Repair duration 2 weeks (access, structural work, close up)

Generic repair instructions available


Repair kits available.

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Structures seminar, 10-13 March 2015, Toulouse

Managing Aging Aircraft

Section Nose Fuselage


ALI 531110 - Cross beam splicing FR16/20
ALI 531110
Cross beam splicing FR16/20
TH 34 700 FC/ 69 400 FH

Crack length
critical
Interval
Safe Crack Growth Period

WAY FORWARD

ISB 53-1286 cancels ALI, provides repair


instruction and introduce economical threshold
MSB 53-1295 cancels ISB requirement
SBs expected Q2 2015
Serial mod (cold working)

detectable

FC
FCdet

Mandated TH
34 700FC
Recommended TH
21 700FC
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FCcrit

Structures seminar, 10-13 March 2015, Toulouse

Managing Aging Aircraft

ALI/ISB Section Forward Fuselage


FR35

FR24

NO CRITICAL TASK IDENTIFIED

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Structures seminar, 10-13 March 2015, Toulouse

Managing Aging Aircraft

ALI/ISB Section Centre fuselage


ALI 533180
Upper surface of pressure deck membranes
TH 48 100 FC
ALI 533181
Longitudinal beams flanges
TH 48 500 FC
ALI 532166
ALI 533186
FR 35 forward face to
pressure bulkhead
TH 43 400 / 40 000 FC
MSB 53-1268 (optional)

ALI 533140
FR 47 splice plate circumferential skin splice
TH 40 300 FC

ISB 53-1269/MSB 53-1270


Frame foot at FR43 RH/LH
TH 40 000 FC
ISB 53-1258/MSB 53-1251
Side box beam flange FR43
TH 24 000 FC

ALI 533185
Pressure membrane FR35-36
TH 48 000 FC
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ISB 53-1259
Ti-angle keel beam side panel FR40-FR42
TH 30 000 FC

Structures seminar, 10-13 March 2015, Toulouse

Managing Aging Aircraft

ALI/ISB Section Aft and Rear fuselage

ALI 534124
Upper corner aft
pax door FR 68
TH 32 700 FC

ISB 53-1260/MSB 53-1271


Splice plate FR47 butt joint P5-P7
(LH/RH)
TH 30 700 FC

ALI 534129
ALI 534130
Door stop fittings FR 66/68
TH 34 100 FC

ISB 53-1257/MSB 53-1261


Tack holes at FR50-FR63 (LH only)
TH 38 200 FC
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Structures seminar, 10-13 March 2015, Toulouse

Managing Aging Aircraft

Section Rear fuselage


ALI 534129 FR66 / ALI 534130 FR68 - door stop fittings holes
ALI 534129 40 200 FC <TH< 48 000 FC
ALI 534130 34 100 FC <TH< 40 900 FC
Door stop fittings FR 66/68

LH SHOWN
RH SYMMETRICAL

Roto-test inspection of door stop fitting holes


in Frames 66 & 68 webs

FR66

FR67
FR68

TYPICAL VIEW

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Structures seminar, 10-13 March 2015, Toulouse

Managing Aging Aircraft

Section Rear fuselage


ALI 534129 FR66 / ALI 534130 FR68 - door stop fittings holes
Finding rate: High

Standard repairs:
Oversized fasteners + cold working
Repair bushes + cold working
SRM repair introduced since Nov 2013

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Structures seminar, 10-13 March 2015, Toulouse

Managing Aging Aircraft

Section Rear fuselage


ALI 534129 FR66 / ALI 534130 FR68 - door stop fittings holes
ALI 534129
ALI 534130
Door stop fittings FR 66/68

Crack length
critical
Interval
Safe Crack Growth Period

WAY FORWARD

ISB 53-1288 cancels ALI, provide repair instruction


MSB 53-1290 cancels ISB requirement
Service Bulletins available

detectable

FC
FCdet

FCcrit

Mandated TH
34 100FC - 48 000FC
Recommended TH
20 700FC
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Structures seminar, 10-13 March 2015, Toulouse

ALI/ISB Section Centre Wing Box

ISB 57-1178
Front spar vertical stringers
and horizontal beams
TH 24 000 FC
Effectivity Limited up to MSN 155
Effectivity extension expected

ISB 57-1175
Lower ribs at FR36
TH 47 800 FC
Effectivity Limited up to MSN 84

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Managing Aging Aircraft

Structures seminar, 10-13 March 2015, Toulouse

Managing Aging Aircraft

ALI/ISB Wing and Pylon location

ALI 572009
Outer wing rear spar
TH 48 000 FC

ALI 545102
Lower arms at rib 1
TH 24 000 FC

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Managing Aging Aircraft

Structures seminar, 10-13 March 2015, Toulouse

Managing Ageing Aircraft

Conclusion
Critical tasks under review and classified by severity

Select an image
Review due to be completed Q2 2015

Most severe ALI replaced by ISB combined with MSB

Structure Support:
Shaping the future together
Methodology for ageing fleet
support in place

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Appropriate material support put in place

Timely and detailed information provided to affected


Airlines using dedicated Webinar Sessions

Airbus S.A.S. All rights reserved. Confidential and proprietary document. This document and all information contained herein is the sole property of AIRBUS. No intellectual property rights are granted by the delivery of this document or the disclosure of
its content. This document shall not be reproduced or disclosed to a third party without the express written consent of AIRBUS S.A.S. This document and its content shall not be used for any purpose other than that for which it is supplied. The statements
made herein do not constitute an offer. They are based on the mentioned assumptions and are expressed in good faith. Where the supporting grounds for these statements are not shown, AIRBUS S.A.S. will be pleased to explain the basis thereof.
AIRBUS, its logo, A300, A310, A318, A319, A320, A321, A330, A340, A350, A380, A400M are registered trademarks.

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Airbus Customer Services


Jean-Jacques FRAYSSIGNES

Solutions for Aging


Fleets
Structures seminar 2015

Solutions for ageing fleets


Expertise details
In WB chief engineer team since 2005

Your
photo
here

Head of SDO system team since 2009


Presented by

Aging Fleet project manager

Jean-Jacques
FRAYSSIGNES
A300 / A310 Program
System director
Jean-jacques.frayssignes@airbus.com

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March 2015

Background
Airbus
Fleet
Age
profile in 10 years
Aging
fleet
will
double
2011

# A/C

700
600

LR

SA

WB

500

700# A/C

536 A/C 20 yrs

600

1178 A/C 15 yrs

500

400

400

300

300

200

2020 projection

SA

WB

980 A/C 20 yrs

2535 A/C 15 yrs

200

100
0

LR

100
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 # Year0

# Year
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39

+ Extended Service Goals options

Heavy maintenance slots close to double


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March 2015

Background
Objectives:

Increase our capacity to support aging fleet

Ensure retention of knowledge base in Airbus

Ensure out of production proprietary parts remain available

In order to:

Minimize unexpected down time during inspections and repairs

Maintain Dispatch reliability and Availability of Ageing A/C

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March 2015

Knowledge base
Out of production program : A300 / A310

Series Design Office (SDO)


A300-A310 Chief
Engineer

UK
Chief Engineer

GE
Chief Engineer

FR
Chief Engineer

Wings

AFT Fuselage
Fin

Fwd Fuselage
Pylons HTP

O
Recorders
Cabin

Engines
Avionics Air
/Bleed F/CTL
- Hyd Utilities

Fuel (incl
MRTT)

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Your contacts in Support


remain unchanged
In addition 50 Engineers
are fully dedicated to
A300 A310
Embedded in Airbus
Service Support
organization
Ensuring Engineering
support

March 2015

Knowledge base
Support ageing fleet = AIRBUS Group Competence priority
Objective

Focus on aircraft availability and on support to Airbus ageing fleet


Increase capability of anticipating unexpected findings and by analyzing the past,
understanding the present to modelize the future.

Road map

Job descriptions update and evaluation 2015


Training learning solutions development 2015 -2016

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March 2015

Out of production spares availability


Dedicated organization set-up for Out of Production proprietary parts
Missions : Ensure a robust supply chain

Secure regularly ordered parts availability

Solutions

Last Time Buy (short term)


Secure manufacturing capability

Engineering change
Purchase raw material
Re-use of used parts
3D printing

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Deploy robust processes to


manage Out of Production
spare requests

March 2015

Out of production spares availability: Spares supply chain restructured


All ordering centralized in Hamburg: Satair
Lean organisation and simplified processes
Consolidated Order Management
Central supplier performance management

Enhanced process
dedicated to Out of
Production parts management
implemented

Backed-up by a strong Spares Engineering


Supporting 24/7 whenever required
Collocated to Design Engineering and
manufacturing in 4 countries

Tools and methods for daily


operations deployed

Supported by a dedicated Out of Production team


High level of expertise
Provide tools for daily operations
Transferring knowledge to operations

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Prepare for the future


Inspections based on fatigue related items
Airbus
forecasts
A/L
inputs

IN-SERVICE REPORTS
FATIGUE
&
DAMAGE TOLERANCE
JUSTIFICATIONS

Fleet Scheduled
Maintenance Forecasts

Implement solution
FATIGUE TEST RESULTS

Risk identification vs
In-service effect
Probability
Complexity of repair
Aircraft affected
Timeframe for inspection
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Define solution
Define repair if needed
Ensure parts availability
Speculated as necessary
Inspect earlier, when appropriate

Approved repair solution


Parts or repair kit secured
Tooling (if required)
Repair support on request

Prepare for the future


Inspections based on fatigue related items
2014

A330
A340

A320F

Q3

Q4

2015
Q1

Q2

Q3

2016
Q4

Q1

Q2

Q3

Q4

Risk identification & solution


identification

A number of risk items identified for which


solutions are being developed

Solution implementation
Risk identification & solution
identification
Solution implementation

A320F inspection review nearing


completion

A330/A340 inspection reviews to be


completed in 2015

A310 A300/600: managed at SDO level to assess most critical inspections and solutions anticipation
following WFD exercise

Solution availability will be scheduled according to aircraft maintenance schedule

Airlines invited to share their maintenance schedules with Airbus


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Analyse the past to prepare for the future


Data analysis

Objective establish prediction model

Define the parameters for research (age, region, etc)

Age vs Findings
Influence of environment (location/destinations of flights)
Influence of missions (Long/Short haul, corrosive cargo)

Typical problem areas (structure/systems)


Unscheduled events/repairs outside SRM
Scheduled maintenance findings vs unscheduled findings

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Prepare for the future: analyse the past


Data analysis roadmap
2015
Q1

A330
A340

Data assessment
Analysis
Prediction model

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Q3

Q4

Q1

Q2

Q3

Q4

Analysis focused on corrosion


and zonal inspections

Similar recommendations /
solutions as for fatigue related
inspections are foreseen

A320F

Methods and tools definition

Q2

2016

Summary
Aging fleets and heavy maintenance
requirements will double in the next decade
Select an image

Airbus increasing its capacity to support


these fleets

Supply of proprietary parts secured


Structure Support:
Shaping the future together

Dedicated engineering embedded in Airbus

Flying together for decades to come

Further analysis on-going to support the

Support

future

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Airbus S.A.S. All rights reserved. Confidential and proprietary document. This document and all information contained herein is the sole property of AIRBUS. No intellectual property rights are granted by the delivery of this document or the disclosure of
its content. This document shall not be reproduced or disclosed to a third party without the express written consent of AIRBUS S.A.S. This document and its content shall not be used for any purpose other than that for which it is supplied. The statements
made herein do not constitute an offer. They are based on the mentioned assumptions and are expressed in good faith. Where the supporting grounds for these statements are not shown, AIRBUS S.A.S. will be pleased to explain the basis thereof.
AIRBUS, its logo, A300, A310, A318, A319, A320, A321, A330, A340, A350, A380, A400M are registered trademarks.

AIRBUS S.A.S. All rights reserved.

Confidential and proprietary document.

AIRBUS S.A.S. All rights reserved.

Confidential and proprietary document.

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