22 nd January 16 TAP M&E Presentation- TOC- CCPM -Airplane Availability 1 Airplane Availability Theory of Constrains - Critical Chain Project Management Pedro Miguel Rodrigues da Costa General Manager - Continuous Improvement & Processes Lima ,22 nd January , 2016
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22nd January 16 TAP M&E Presentation- TOC- CCPM -Airplane Availability 1
Airplane Availability
Theory of Constrains - Critical Chain Project Management
Pedro Miguel Rodrigues da Costa
General Manager - Continuous Improvement & Processes
Lima ,22 nd January , 2016
22nd January 16 TAP M&E Presentation- TOC- CCPM -Airplane Availability 2
Welcome to TAP M&E Continuous Improvement at M&E
Pilot Project–May 2014,CS-TNS
CCPM-Implementation–Sep-Dec 2014
Conclusions
22nd January 16 TAP M&E Presentation- TOC- CCPM -Airplane Availability 3
Welcome to TAP M&E Continuous Improvement at M&E
Pilot Project–May 2014, CS-TNS
CCPM-Implementation–Sep-Dec 2014
Conclusions
22nd January 16 TAP M&E Presentation- TOC- CCPM -Airplane Availability 4
Organization TAP Group
(*) Controlled by an external independent entity in accordance with the Competion Authority directives.
22nd January 16 TAP M&E Presentation- TOC- CCPM -Airplane Availability 5
Lisbon TAP M&E offers a vast span of services ranging from line maintenance to heavy maintenance checks, engine overhaul, components maintenance, engineering and planning services, material support and integrated maintenance packages, for the Airbus A300-600, A310, A330, A340, A320 family; for the engine models CFM56-3,-5A, -5B,-5C,-7B and CF6-80C2/A/B. Hangars: 3 Hangar Capacity: 3 WB, 5 NB Hangar Area: 26,380 m² Total Building Area: 71,200m²
Porto Alegre
TAP M&E makes available to its Customers airframe maintenance for Boeing B727, B737 CL, B737 NG, BBJ, B767; for Airbus A320 family; for Embraer EMB 120, ERJ 135/145, E-JET 170/175/190/195 and Legacy; complete overhaul for Landing Gears, APU and PWC engines PW118/A/B, PW120/A, PW121, PW125B, PW127 and PT6; plus avionics and accessories maintenance for over 17,000 part numbers. Hangars: 5 Hangar Capacity: 1 WB, 5 NB Hangar Area: 12,500 m² Total Building Area: 55,000m²
Rio de Janeiro TAP M&E provides aircraft maintenance services (A, B, C, IL and D checks, aircraft painting, engineering and planning support) for the Boeing B727, B737 CL/NG (incl. BBJ), B747-200/300, B757, B767, B777, DC10, MD11; for the Airbus A300-B4, A300-600, A310, A330, A340. Hangar: 1 Hangar Capacity: 4 WB Hangar Area: 14,500 m² Total Building Area: 180,000m²
Aircraft Maintenance
Components Maintenance
Engines Maintenance
Warehouses Offices and Labs.
Security control to airport airside
Security control to TAP premises
Hangar 6
Hangar 5 Hangar 4
Organization TAP Group
22nd January 16 TAP M&E Presentation- TOC- CCPM -Airplane Availability 6
Continuous Improvement Team History
Timeline
July 2009
Jan 2010
Feb 2010
Apr 2010
May 2010
Starting point
Decision to create an internal team to capture the opportunities
Internal recruiting process
Team setup
Team start
First pilots developed at
Engine Maintenance
First pilots at Aircraft
Maintenance
TOC CCPM
May 2014
Diagnostic on possible
opportunities to capture at
TAP M&E Aircraft
Maintenance
June 2015
TOC VSS
ComponentsMaintenance
22nd January 16 TAP M&E Presentation- TOC- CCPM -Airplane Availability 7
Maintenance and Engineering EVP
Aircraft Maintenance
Engine Maintenance
Components Maintenance Logistics
Marketing & Sales Organisation and Development
Quality and Safety Engineering
Sponsor Continuous Iimprovement Project
• Sales Portugal • Sales Engines • Communication & Brand •Customer Service
•Continuous Improvement & Processes •HR Development •Information Technologies •Finance and Accounting •Equipment and Facilities
•Fleet and Projects •Technical Publications •DOA projects
• Quality Engineering • Laboratories
•Engineering and Quality •Planning and Control •Logistics •Base Maintenance •Operational Maintenance
•Engineering and Quality •Planning and Control •Logistics •Engine Shop •Support Shops
•Engineering and Quality •Planning and Control •Logistics •Avionics Shop •MHP Shops
In-house repair capability for over 80% of the engine parts
Flame Spray and HVOF
12%
88%
Engine Type
CF6
CFM56
SCM
SCM
SCM
SCM
SCM
SCM
SCM
SCM
SCM
22nd January 16 TAP M&E Presentation- TOC- CCPM -Airplane Availability 9
Welcome to TAP M&E Continuous Improvement at M&E
Pilot Project–May 2014, CS-TNS
CCPM-Implementation–Sep-Dec 2014
Conclusions
22nd January 16 TAP M&E Presentation- TOC- CCPM -Airplane Availability 10
Continuous Improvement Project TAT C-Checks
22nd January 16 TAP M&E Presentation- TOC- CCPM -Airplane Availability 11
Theory of Constraints Is a methodology for identifying the most important limiting factor (i.e. constraint) that stands in the way of
achieving a goal and then systematically improving that constraint until it is no longer the limiting factor.
Theory of Constraints
22nd January 16 TAP M&E Presentation- TOC- CCPM -Airplane Availability 12 22nd January 16 TAP M&E Presentation- TOC- CCPM -Airplane Availability 12 12
Critical Chain theory and high-level application to C-checks
1ª Priorities
2ª Priorities
3ª Priorities
ASSY INSP REPAIR
1º WIP / Staggered
3º Priorities/ “Buffer Management”
2º “Full-Kitting”
22nd January 16 TAP M&E Presentation- TOC- CCPM -Airplane Availability 13 22nd January 16 TAP M&E Presentation- TOC- CCPM -Airplane Availability 13
“Little Law’s”
TAT x THROUGHPUT = WIP
Setting Goals
Demand
WIP
TAT
Aircraft System
Throughput (TP)
Critical Chain theory and high-level application to C-checks
22nd January 16 TAP M&E Presentation- TOC- CCPM -Airplane Availability 14
B D F
A C E Time to delivery
Late Project
Start
B D F
C E A Delivery dates “Full-Kit”- Delivery dates
Late
Time to delivery On Time!
Start
Critical Chain theory and high-level application to C-checks
22nd January 16 TAP M&E Presentation- TOC- CCPM -Airplane Availability 15
Project 1
Project 2
Project Completion = 50%
Buffer Consumption = 40%
Priority Index = 0.4/0.5 = 80%
Project Completion = 33%
Buffer Consumption = 50%
Priority Index = 0.5/0.33 = 150%
1 2
5 5 5 5 5 5 15
5 5 5 5 5 5 15
Critical Chain theory and high-level application to C-checks
22nd January 16 TAP M&E Presentation- TOC- CCPM -Airplane Availability 16
Rollout
• Workshop on Critical Chain theory and high-level application to C-checks
• Common understanding of the Critical Chain methodology
• Identify potential implementation obstacles/concerns of the team
• Detailing solution for CS-TNS: • Planning for fast execution • Goals: Identify how work will be
man-loaded, staggered, and grouped to dramatically reduce multitasking
• Detailing solution for CS-TNS: • Scheduling, preparation, and
execution • Goals: Finalize critical chain
project, define full-kitting and execution processes
• ……
SOLUTION WORKSHOP
• Training Supervisors/team leads for CS-TNS (planning and maintenance) covering both shifts What: Introduction to Critical Chain theory and hands-on Concerto training Concerto walk-through What: Review Concerto task priorities for 1st week of execution Goals: Get team accustomed to new task groupings and reports ; Make adjustments for task clarity/accuracy • ……
FINAL SETUP AND TRAINING
• Individual Interviews (30-45 mins) with each member of the core team
• Interview with the Hangar Manager
• Meeting with 2 leaders (responsible for task preparations like material/technical instructions, responsible for work scheduling)
• Meeting with two team leaders within the Hangar Group
• I’d also like to witness a few execution meetings (priorities, issue resolution) for an active aircraft
• ……….
INVESTIGATION AND FULL-KITTING
25th May 14
• Daily meeting with Supervisors/team leaders/Planning/Full Kit/ for CS-TNS covering both shifts
• Up-date information at concerto • Buffering : Create aggressive
plans (don't manage by local dates & local efficiencies )
• Buffer management : align everyone to a single priority system based on buffer consumation
• Focus on priority and Synchronization
• ……
CS-TNS Inspection
26th June 14 11st June 14
Pilot Project – CS-TNS- C3+6Y+EO57+PTU
Rollout
SOLUTION WORKSHOP
FINAL SETUP AND TRAINING
INVESTIGATION AND FULL-KITTING
CS-TNS Inspection
22nd January 16 TAP M&E Presentation- TOC- CCPM -Airplane Availability 17
22nd January 16 TAP M&E Presentation- TOC- CCPM -Airplane Availability 24
Pipeline Before CCPM After CCPM
1
2 3 4
5 6
7
9 10 8
1 2 3
4 5 6
7
9 10 8
$$$$$
11
22nd January 16 TAP M&E Presentation- TOC- CCPM -Airplane Availability 25
22nd January 16 TAP M&E Presentation- TOC- CCPM -Airplane Availability 25
Critical Chain Project Management
Operation
Priority Order
for OO_SFZ
27
22nd January 16 TAP M&E Presentation- TOC- CCPM -Airplane Availability 26
22nd January 16 TAP M&E Presentation- TOC- CCPM -Airplane Availability 26
Critical Chain Project Management
Operation
Priority Order
for
3 Aircrafts
28
22nd January 16 TAP M&E Presentation- TOC- CCPM -Airplane Availability 27
22nd January 16 TAP M&E Presentation- TOC- CCPM -Airplane Availability 27
Pipeline/WIP
Synchronized Priorities
Material Coordenation
Focus and Finished
Buffer Management
Holding Period
Steering Committe :The Steering Committee will resolve policy-type obstacles, ensure organizational commitment, and communicate changes/results throughout the organization and externally where needed.
AM M&E Áreas
Rules &
Responsabilities
……….
Tactical
Maintenance
Director Deputy Director
Head Base
Maintenance
Head of Planning Control Prod.
Control. Manag.
Head of Logistic
Implementer
CIP
TOC- CCPM Steering
Committe
29
22nd January 16 TAP M&E Presentation- TOC- CCPM -Airplane Availability 28
22nd January 16 TAP M&E Presentation- TOC- CCPM -Airplane Availability 28
22nd January 16 TAP M&E Presentation- TOC- CCPM -Airplane Availability 29
22nd January 16 TAP M&E Presentation- TOC- CCPM -Airplane Availability 29
21
24
17
16
16
35
80
19
33
40
0 20 40 60 80
CS-TNT
CS-TTQ
CS-TTN
CS-TNU
CS-TNV
CS-TOI
CS-TGV
OO-SFU
OO-SFY
OO-SFN
-33%
-17%
-6%
-13%
-25%
-20%
-55%
0%
-30%
-20%
-33%
-21%
-6%
-38%
-38%
-6%
-14%
5%
39%
20%
-60% -40% -20% 0% 20% 40% 60%
Before CCPM After CCPM Achieved
# Days-Out-of-Service 129
# Days-Out-of-Service 104
# Days-Out-of-Service 102 (27) ( - 21%) TAP
Fleet
# Days-Out-of-Service 301
# Days-Out-of-Service 241
# Days-Out-of-Service 285 (16) ( - 5%) System
(10 A/C)
As a result of the implementation, we were able to improve fleet availability, by reducing turnaround time by 21%, corresponding to 26 days for the narrow-body and 1 day wide-body aircraft
We also were able to avoid the expense of subcontracting one narrow-body C Check We provide another TAP narrow-body to support the operation in the period between 29 October and 5 December ……….
CCPM-Implementation–Set-Dec 2014
22nd January 16 TAP M&E Presentation- TOC- CCPM -Airplane Availability 30
Welcome to TAP M&E Continuous Improvement at M&E
Pilot Project–May 2014,CS-TNS
CCPM-Implementation–Sep-Dec 2014
Conclusions
22nd January 16 TAP M&E Presentation- TOC- CCPM -Airplane Availability 31
22nd January 16 TAP M&E Presentation- TOC- CCPM -Airplane Availability 31
Conclusions
“LEAN/TOC-CCPM is a bottom up movement, but it's got to have top‐down endorsement“
“LEAN/TOC-CCPM seems to be as much a mindset as a strategy”
“Continuous Improvement as Enabler of Innovation and Operational Excellence”
22nd January 16 TAP M&E Presentation- TOC- CCPM -Airplane Availability 32