Aerospace & Defence Newsletter - Aircraft Prognostics and Health Management

1. Jaswin Sood

2. Innovation by Years ……
Annual Revenue :
86,623 $ (Mill)
Employees : 168400
IT Employees : 6231
defense systems and the war fighter through
network-enabled solutions; new, more efficient
members of its commercial airplane family;
integrating military platforms, defense systems and
the war fighter through network-enabled solutions;
creating advanced technology solutions; and
arranging innovative customer-financing options.
Boeing is organized into two business units: Boeing
Commercial Airplanes and Boeing Defense, Space &
Security. Supporting these units are Boeing Capital
Corporation, a global provider of financing
solutions; Shared Services Group, which provides a
broad range of services to Boeing worldwide; and
Boeing Engineering, Operations & Technology, which
helps develop, acquire, apply and protect
innovative technologies and processes.
 Products and services support to customers in 150 countries
Boeing is the world's largest aerospace company
and leading manufacturer of commercial jetliners and
defense, space and security systems. A top U.S.
exporter, the company supports airlines and U.S. and
allied government customers in 150 countries. Boeing
products and tailored services include commercial
and military aircraft, satellites, weapons, electronic
and defense systems, launch systems, advanced
information and communication systems, and
performance-based logistics and training.
Boeing has a long tradition of aerospace leadership
and innovation. The company continues to expand its
product line and services to meet emerging customer
needs. Its broad range of capabilities includes
creating new, more efficient members of its
commercial airplane family; integrating military
platforms,
 Contracts with 21,800 suppliers and partners globally
 Research, design and technology-development centers and programs in multiple countries

3. Boeing Commercial Airplane
• Offering a family of airplanes and a broad portfolio of aviation services for passenger and cargo carriers worldwide.
• Boeing airplanes represent three quarters of the world’s fleet, with nearly 12,000 jetliners in service.
Boeing Defence Space & Security
Revenues
of $53.0 billion
• Designing, building and supporting net-enabled platforms and systems for government and commercial customers
• Formed in 2002 integrating Boeing’s defense, space, intelligence and communications capabilities
Revenues
of $33.2 billion
Boeing Capital Corporation
• Financing subsidiary of The Boeing Company
• Focused on assets that are critical to the core operations of Boeing customers
Portfolio valued
at approximately
Boeing Engineering Operations & Technology $3.9 billion
• Establishing common systems and processes for Engineering, Operations and Supplier Management and Driving environment, health and
safety performance
• Executing safe and efficient test operations
• Providing efficient, effective, secure IT solutions
• Boeing is planning to implement Infrastructure as a Service (IaaS) solutions over the next twelve months. David Nelson is the Chief Strategist
Cloud Computing. (07/07/2014)
• Company is in the midst of mapping an internal cloud-based system. Theodore (Ted) Colbert III, Chief Information Officer, reports that the
adoption will be a slow process, however, is imperative to ensure company competitiveness. (06/02/2014)
• Indicated an increase in spending over the next nine months toward developing Unix and Linux hosting infrastructure. Mark Arvizu is the Chief
of Staff, IT Infrastructure. (05/29/2014)
• Company is currently involved in an initiative to develop innovative cyber security and information sharing solutions between the government
and the aviation industry. Stephen Whitlock is the Chief Strategist, Information Security.(04/16/2014)
• Plan is to evaluate global IT architecture design in support of developing business enhancements over the next twelve months and currently
company leverages Akamai TERRA Enterprise Solutions, CATIA, & Microsoft System Center Configuration Manager (SCCM). Theodore (Ted)
Colbert III, Chief Information Officer, designs, secures, deploys, operates & maintains the computing + network infrastructure. This includes
hosting applications and data, network operations, data center operations, messaging & web services, desktop computing technology, & help
desk. (04/14/2014)
• It is planning to develop a global business intelligence (BI) roadmap solution over the next twelve months. The company is currently leveraging
IBM Cognos Business Intelligence, Information Builders Web FOCUS, and SAP Business Objects. Theodore (Ted)Colbert III, Chief Information
Officer, designs, secures, deploys, operates and maintains the computing and network infrastructure. This includes hosting applications and
data, network operations, data center operations, messaging and web services, desktop computing technology, and help desk. (04/14/2014)
• Company recently migrated configurations and assets from database solutions to the SAP platform. Pratap Gulabrao is the SAP/BI Solutions
Architect. (03/10/2014)
Boeing IT initiatives

4. Aircraft are highly complex
systems composed of various
structural, hydraulic, propulsion,
electronic and avionic elements.
Such complex systems require
extensive maintenance. A major
portion of the maintenance
efforts of aircraft structures is
related to Health And Usage
Monitoring . The other
significant portion of the
maintenance involves repair or
replacement. All of this evolves
from a safety criticality aspects
that have to be set either prior to
design or during in-service as a
result from a changing
operational environment. Health
and usage monitor has been
successfully introduced into
helicopters mainly to monitor
vibrations on gears and
specifically on gears shafts,
where once a crack has emerged
have a relatively short crack
propagation life.
The one is already
applied today by many
OEMs, which is to
monitor load
sequences, which are
then used to estimate
the accumulated fatigue
damage indirectly by
means of analytical
procedures. This is what
is commonly known as
Operational Loads
Monitoring(OLM). The
other way is to
integrate systems onto
or into the structural
component , which
allows direct
determining the
occurrence, size and
possibly even the
location of damage and
which mainly works on
an actuator- sensor
basis.
The monitoring of Airframes And Hydraulic Sub-systems is limited
to on-ground inspection using various NON- Destructive Testing(NDT)
techniques. The current inspection techniques also include Visual
Observation, Eddy Currents and Ultrasonic Techniques. The types of
structural damages include Wear damage, Fastener and Static failures,
Corrosion ,Fatigue Cracks Etc. Damage monitoring is a very crucial
aspect of Aircraft Health monitoring which is done through systems
inherent in an aircraft in two ways .
More than 65 airlines
and 2,000 airplanes
around the globe depend on
Airplane Health Monitoring from
BOEING
On an average 136
Reports per flight are
recorded from Airplane
Monitoring system
A huge amount of data is being sent
off via systems on the airplane,
such as satcom and ACARS which
costs up to a $1,000 a
month per aircraft.

5. The health and usage monitoring techniques
for propulsion systems is highly advanced.
Different in-flight Engine Condition
Monitoring (ECM) systems have been
gradually developed and are still further
improved. The ECM systems have been
approved by the Federal Aviation Authority
(FAA) .
and are used by many aircraft
operators. Various parameters , including
vibrations, temperature, pressure, fuel usage,
revolutions per minute are utilized to monitor
engine condition and detect/locate possible
malfunctions a sufficient time before possible
in-flight failures. Engine monitoring systems
involve using sensors placed in various
locations in an aircraft engine to gather
information about the engine’s performance.
The sensors provide Real-time Information to pilots
on the operation of the engines and also capture data
for analysis of the performance of the engine over
time. The data captured reveals important
information about the health of the engine. For
example, sensors will monitor how much fuel it takes
to make a set amount of power. Increases over time in
the amount of fuel consumed would indicate a
degrading of the efficiency of the engine, which means
the engine is more expensive to operate and it will
need maintenance to restore its efficiency. Sensors
can also detect impending failures and notify both the
crew and ground stations. The data from the
sensors are accumulated and transmitted at regular
intervals to ground stations monitored by the engine
manufacturers. Alert messages indicating anomalies
are instantly transmitted.
ECTM for the OEMs
WebECTM® is P&WC’s
most advanced aircraft
turbine engine condition
trend monitoring
software
Rolls Royce uses
Engine Health
Management (EHM)
to track the health of
thousands of engines
operating worldwide.
GE’s Remote
Monitoring and
Diagnostics (RM&D)
proactively identifies
operation discrepancies,
and monitors overall
engine performance.

6. AHM from
Airplane Health Monitoring is a Boeing product for what the industry
generally calls Integrated Vehicle Health Monitoring. Boeing has 53
customers world wide which uses this product for there aircraft
operating on roughly 1900 airplanes including approximately 75% of all
777s, 50% of all 747s and all 787 customers for entry into service.
Operators are reducing Flight delays, Cancellations , air turn backs and
diversions through the AHM tool. Designed by Boeing AHM collects in
flight airplane information and relays it in real-time to maintenance
personnel on the ground via the Web portal MyBoeingFleet.com. When
the airplane arrives at the gate , maintenance crews can be ready with
the parts and information to quickly make any necessary repairs.
Airbus Real Time Health Monitoring (AiRTHM) is a state-of-the-art
service based on Airbus’ engineering expertise and A380 technology,
allowing real-time remote access to more than 250,000 parameters
(ACARS communication). The A380 certified uplink capability enables
Airbus to further investigate warnings and faults, both in-flight and on-ground,
to deliver real-time advice service. A dedicated Airbus
engineering team has been established to deliver AiRTHM service 24/7
to operators' maintenance control centres, relying on Airbus’
engineering departments and knowledge. This service is offered to all
A380 operators and also will be available from the A350 XWB jetliner’s
service entry.
Benefits
Prognostics
Fault Forwarding
Reduced Downtime
Disruptions
Improved Supply
chain Efficiency
Reduced NFF
(No Fault Found)
Real time
flight
watching
AiRTHM from AIRBUS

7. COMPETITORS IT SOLUTIONS
IVHM IT SOLUTION BY INFOSYS

8. COMPETITORS IT SOLUTIONS
IVHM:
A system that enables automatic
detection, diagnosis, prognosis
and mitigation of adverse events
arising from component failures.
Integrated Vehicle Health
Management System abbreviated
as IVHM brings together the best
of Mech. / Aero Engineering,
sensor tech., communication and
Data analytics. IVHM aims at
reducing both Maintenance +
Operational costs whilst improving
overall Aircraft Safety. Shown
alongside and below are the IVHM
solution of Infosys for A/C Landing
Gear (LG), demonstrating the use
case of LG retraction mechanism.
IVHM IT SOLUTION BY INFOSYS
ON BOARD IVHM
SYSTEM ON AN
AIRCRAFT
ENTERPRISE IVHM
SYSTEM AT GROUND
STATION
ABOUT:
The aim of Health Monitoring System
is to diagnose initiation of any
defect, its analysis thereby trigger
maintenance workflows to avoid
exigency like AOG’s.
IVHM SYSTEM ARCHITECTURE :
1. Collage of Sensors
2. One or more remote data
concentrator– aggregator all
sensor data via interfaces
3. Central computer onboard with
non volatile memory
4. Relational DB on NV RAM
5. Local Data bus to IVHM
6. External Interface (wired,
wireless, serial, etc.) for Data
collection by ground systems
The IVHM ground systems (as
shown alongside below)
comprises of many robust
enterprise modules, viz.:
1. Prognostics and Advice
Generation
2. Trace and Track Landing
Gear and associated LRU’s
(Line Replaceable Units),
Components, Parts
3. Integration with O&M
(Operations +
Maintenance) ERP’s
a) Schedule maintenance
checks + activities
based on condition,
raise tickets, trigger
alerts
b) Supply chain
availability,
integration with order
management system
in order to facilitate
scheduled
maintenance halts.
4. Portal and Interfaces for
Data reports and
presentations to the
Airlines (Aircraft
Operators), MRO’s & OEM’s

9. COMPETITORS IT SOLUTIONS
SHM:
As a citation of one of the
Aerospace Industry challenges is
the Impact on the Structural
integrity of an Aircraft due to
cyclic Compression, Tensile and
Hoop stresses induction during
flight operations.
The complete aircraft structure
is concurrently subjected to cyclic
stresses during each Flight Cycle
(01 Flight Cycle = 01 Takeoff + 01
Landing)
With aging of aircraft structure
in multiple flight cycles and flight
hours the structure is susceptible
and vulnerable to fatigue
cracking, structural damages and
eventual catastrophic failures over
a period of aircraft operating life
in Fleet.
To address the aforementioned
challenge, SHM termed as the
Structural Health Monitoring was
envisaged. SHM is an online
health monitoring system &
enables concurrent triggering of
alerts and corrective maintenance
tips/recommendations as & when
the airplane structure falls into
Damage tolerance limits or
beyond repairable limits.
SHM IT SOLUTION BY INFOSYS
ABOUT:
SHM systems’ key focus is to
monitor aspects related to
damages and loading conditions
having direct influence on
fitness of structure for service
and its damage tolerant life
span.
SHM system Multi-faceted
functionalities include:
• Detection of un-anticipated
structural damage events
• Damage location
identification
• Damage Characterization via
imaging
• Monitoring Damage growth
• Enabling Feedback action /
Alarm – Event-Trigger
mechanism
SHM system utilizes
embedded non-destructive
testing sensors as an integral
structural part and operates
with min. human intervention
Shown alongside is a filament
of a CFRP (Carbon Fiber
Reinforced Plastic) with an
itching layer of sensor
circuitry enabling real time
monitoring of structural
health

10. COMPETITORS IT SOLUTIONS
SHM IT SOLUTION BY INFOSYS
SHM SUBSYSTEMS: Key subsystems of SHM are shown below-
SHM FUTURE IN AIRCRAFT INDUSTRY:
Ideally SHM system for an aircraft encompasses inspection and
integrity of entire aircraft constituents viz. A/C Structure, Power
plant, corresponding sub systems. Since SHM is dependent upon smart
sensors some of the associated unresolved industry challenges are
enumerated below:
I. SENSORS – From the analogy shown left top, unlike Human nervous
system, sensors are hybrid and hence sensor optimization might vary
for the same area under health monitoring depending on global or
local health considerations, Sensing mechanism must facilitate
accurate wireless transmission to central station and also be FAA/
Other Regulatory authorities approved
II. WIRELESS COMMUNICATION – challenges of Energy Efficiencies of
Communication protocols, Data + Time synchronizations, data losses
III. SENSOR DATA PROCESSING – Identification of effective data
normalization & data fusion techniques, Data filters to deal with Bad
or Corrupt Sensor data, Data acquisition being continuous, Large data
storage, retrieval & processing techniques required
Analogy SHM to Human Brain with respect to Pain Areas identification
SHM with Wired Sensor Network for Data Acquisitioning + Processing
DIAGNOSIS PROGNOSIS LIFE
EXTENSION +
PREDICTIVE
MAINTENANCE

11. COMPETITORS IT SOLUTIONS HUMS IT SOLUTION BY GOODRICH’S SENSORS
& INTEGRATED SYSTEMS NOW UTC AEROSPACE SYSTEMS
ABOUT:
With UTC Aerospace Systems HUMS on board, aircraft
readiness is boosted, flight safety is enhanced and maintenance
costs are lowered. Early indication of potential problems means
operators can plan appropriate actions to correct the issue
during the next major maintenance interval or to immediately
make a fix before the situation escalates into a damaged
component. With insight into the total health of the helicopter,
operators greatly reduce the surprise problems that cause flight
delays, cancellations or early terminations.
HUMS on-board system constantly monitors component
health from tip to tail by tapping into hundreds of aircraft
flight-control signals and specialized accelerometers distributed
throughout the aircraft. By synthesizing performance
information including speed, torque, temperature and pressure
data as well as comprehensive vibration and rotor track and
balance data, the system executes real-time diagnostics
without pilot involvement. The system provides “go” or “no-go”
status on the flight deck display or more detailed health
assessments and recommended maintenance actions on the
ground station.
HUMS:
The Health and Usage Monitoring Systems (HUMS) developed by
Goodrich’s Sensors and Integrated Systems (now UTC Aerospace
Systems) business is a series of networked diagnostic sensors that
continuously and comprehensively monitors the mechanical
performance of the entire aircraft.
This powerful system provides real-time data that enhances
predictive maintenance. Integrating the HUMS data with Sikorsky
Aerospace (Part of UTC conglomerate) Services’ OEM installation
expertise and support capabilities enables a breakthrough,
proactive maintenance system that lowers operating costs and
increases fleet availability.
The UTC Aerospace Systems Health and Usage Management
System (HUMS) automatically monitors hundreds of aircraft
signals and through synthesis and analysis of the data, tracks the
usage and health of the aircraft and its major assemblies. SCHEMATICS OF HUMS OPERATIONAL USE

12. COMPETITORS IT SOLUTIONS
iMRO BY SAP AND HCL AXON
INDUSTRY CHALLENGE:
The Aerospace and Defence (A&D) Industry continually
faces new challenges in a highly regulated and complex
business environment. Defence Supplier Organisations are
working under increased pressure to offer more flexible
and higher value-add services and products while coping
with internal transformation to become more efficient.
Aerospace Organisations and Operators have seen
unparalleled global challenges in recent years including
increased environmental regulation and need the ability to
respond effectively and quickly to these challenges in order
to stay in business.
Supplier Contract Management, Integrated Supply Chain,
Use Based Contract Structures, Intelligent Business
Information & IIT Landscape Optimisation are some of the
areas of focus for A&D Companies. Combination of
Technology& Transformation enables a proactive approach
to market changes & ability to respond quickly to new
opportunities.
ABOUT:
iMRO is SAP and HCL AXON's industry solution add-on for Maintenance, Repair
and Overhaul (MRO). It is an SAP complimentary software product which
extends SAP ERP MRO specifically for this industry. iMRO enhances the SAP user
interface to meet industry requirements in the areas of maintenance
engineering, planning and operations for business organizations in the following
market segments:
I. Airlines performing their own or external third party aircraft, engine, line
or component repair
II. Travel and transportation organizations (such as railways or freight
forwarders) managing and maintaining a complex fleet and infrastructure
of transportation equipment
III. Dedicated MRO providers performing third party (revenue bearing)
maintenance services
IV. Aviation and Aerospace original equipment manufacturers who
simultaneously perform after-market delivery maintenance and support
services on their or their competitor's products
V. Defence and other public sector organizations managing and maintaining
fleets or aerospace, transportation or nautical assets

13. HONEYWELL AEROSPACE SELECTS FLATIRONS
FOR TRAINING DEVELOPMENT SERVICES
SITA - INTRODUCE ENHANCED A/C
TRACKING CAPABILITY IN INDIA
SITA, which provides IT and
communications solutions to the
global air transport industry, today
discussed its innovative technology to
track aircraft with leading members
of the Indian airline community.
SITA’s AIRCOM Server Flight Tracker is
being introduced to allow airlines
efficiently and cost effectively track
their aircraft. The solution, which is
currently being evaluated by several
airlines for testing, will utilize
technology that is already installed in
aircraft to provide advanced tracking
capabilities.
The workshop was inaugurated by
Shri. Ashok Lavasa, Secretary,
Ministry of Civil Aviation (MoCA) and
the keynote address was delivered by
Dr. Prabhat Kumar (Director General)
covering more than four million pages
and 40,000 documents annually.
“When seeking a partner for the
development of training content, our
objective was to reduce the overall
costs reusing technical publications
content in the development of
training materials,” said Lewis
Mallory, Director Flight Simulation
Support, Technical Pubs & Customer
Product Training for Honeywell
Aerospace.
In collaboration with Flatirons, 75% of
Honeywell’s illustration content in
training materials is reused directly
from existing technical
documentation. This amounts to a
32% cost savings for the overall
project when compared to the costs
of recreating and duplicating
illustrations for each training project.
Leaders and executives from all
major airlines and airports in
India attended the workshop.
The SITA AIRCOM Server Flight
Tracker solution will enable
interested airlines to track
aircraft movement by merging
SITA’s airline dispatcher Centre
system and airline operations
Centre system (AIRCOM) Server,
with its Future Air Navigation
System (FANS) ground
application, which is available
to Air Navigation Service
Providers (ANSPs). The FANS
system is already installed in
many aircraft, so the solution
does not call for extensive
additional cost or investment
by the airlines.
Flatirons Solutions announced
that Honeywell Aerospace, a
provider of products and services
to commercial, defence, and
space aircraft worldwide, has
selected the Flatirons’ Training
Services group to serve as its
primary developer for training
content. The contract includes
developing new training
materials, updating existing
source materials, and making
modifications to training content
used by Honeywell’s employees
and customers for servicing and
maintaining Honeywell products.
In 2009, Honeywell Aerospace
selected Flatirons as its global
supplier for technical
publications services,

14. BOEING EXPANDS CUSTOMERS' FUEL-EFFICIENCY
CAPABILITIES BY ACQUIRING ETS AVIATION
Boeing (NYSE: BA) today announced an agreement to
acquire ETS Aviation, a provider of fuel-efficiency
management and analytics software. ETS Aviation
solutions lead the market, providing more than 120
airlines and corporate flight departments the tools
necessary to accurately monitor fuel consumption,
identify fuel savings opportunities, and track and report
carbon emissions. ETS Aviation's fuel efficiency solutions
support more than 600 commercial aircraft across nearly
900,000 flights annually.
GARUDA INDONESIA AIRLINES GOES LIVE WITH TCS SWIFT MRO SOLUTION
Tata Consultancy Services a leading IT services, consulting
and business solutions organization, today announced the
go-live of a new Maintenance, Repair and Overhaul (MRO)
application program with PT Garuda Indonesia (Persero)
Tbk. (Garuda Indonesia Airlines), Indonesia’s national
airline, via its aircraft maintenance subsidiary GMF
Aeroasia.
Garuda’s relationship with TCS began in 2012 when the
airline sought a solution to upgrade, consolidate and
enhance its MRO technology infrastructure which was
spread across numerous applications from multiple vendors.
The program to implement the TCS SWIFT MRO
platform moved from blueprint phase to go-live in 13
months, much faster than a typical MRO project that can
take three to five years to complete. With the TCS SWIFT
MRO solution, Garuda replaced over 50 legacy applications,
implemented over 300 business processes, and migrated
over 3 million records of data for 140 aircraft and fitted
parts into a unified solution. The first phase of the project,
now live, comprises the SAP-based end-to-end pre-configured
SWIFT MRO solution for MRO, supply chain
processes, finance and human resources modules.

15. Jaswin Sood