6 prerequisites for implementing proactive maintenance in production

Proactive maintenance is essential in the aerospace industry and is more than just prevention. Unlike traditional manufacturing sectors, where a breakdown might cause a minor hiccup, the ripple effects of a single failure can be catastrophic in the aerospace industry.

Proactive maintenance is the disciplined approach of using data, expertise, and planning to prevent these failures before they occur. To use an analogy, it’s not about firefighting – it’s about fire prevention.

The aerospace manufacturing environment is one where tolerances are miniscule and the margin for error is virtually zero. In this high-stakes arena, proactive maintenance is an absolute necessity. It’s the difference between a successful, on-time launch and a costly, reputation-damaging failure.

This article is a practical guide aimed at aerospace professionals who understand the gravity of their work. We’ll delve into the six essential prerequisites for implementing a robust proactive maintenance strategy in aerospace manufacturing.

Importance of proactive maintenance in aerospace manufacturing
Aerospace manufacturing is a field rife with complexities absent in other industries. You’re dealing with materials that must withstand extreme conditions, systems that must operate flawlessly for extended periods, and regulations as complex as the machinery you’re building.

Proactive maintenance is the linchpin that holds these moving parts together. It enables manufacturers to anticipate issues and solve them before they escalate into major problems, ensuring that the aircraft you produce are as reliable as they are advanced.

If you’re still relying on reactive maintenance – fixing things when they break – you’re not just behind the curve; you’re playing a dangerous game. In aerospace manufacturing, reactive maintenance doesn’t just lead to downtime. It can result in catastrophic failures that put lives at risk and can cost millions in liability and lost contracts.

The reputational damage can also be irreversible. In an industry where trust and reliability are paramount, falling into a reactive maintenance cycle is a pitfall that no organization can afford.

However, these six prerequisites will enable you to implement a robust and effective proactive maintenance strategy.

1: Equipment reliability data
Equipment reliability data encompasses a complex array of variables, such as temperature tolerances, material fatigue, and vibration levels. These variables directly affect the performance and lifespan of critical components such as jet engines and avionics systems.

Ignoring this data or relegating it to a secondary role is akin to navigating through a storm without instruments. This data informs you about when a part is likely to fail, the conditions that could trigger the failure, and the preventive measures that can avert it.

Turbine blade lifespan prediction
Consider the turbine blades in a jet engine, which operate under extreme temperatures and pressure. Manufacturers craft these blades from superalloys designed to withstand such conditions, but even these materials have limitations.

Collecting and analyzing reliability data from thermal stress tests, metal fatigue analyses, and real-world operational data allows you to create predictive models for blade failure, and the advantages of this approach are numerous.

Scheduling blade replacements during regular maintenance windows eliminates the need for emergency replacements, which are both risky and expensive. Enhanced safety is another benefit, as it significantly reduces the likelihood of catastrophic failure during a flight. Armed with this data, you also gain leverage in negotiations with suppliers, allowing you to demand higher quality and reliability.

2: Maintenance software
In aerospace manufacturing, generic maintenance software simply won’t cut it. The software you choose must be capable of real-time monitoring of aerospace-specific components, from intricate avionics systems to high-performance jet engines. It should also offer predictive analytics features that can integrate with your existing data streams and provide a holistic view of your equipment’s health.

Real-time telemetry data integration
Imagine being the maintenance supervisor of a fleet of commercial jets. These jets come with advanced avionic systems that generate real-time telemetry data during flights.

You should opt for maintenance or EAM software that can integrate this real-time telemetry data. This integration allows the software to predict when key avionics components might fail, based on actual operational data.

The benefits of such software are: reduced downtime, increased safety, and substantial cost savings. By preemptively identifying potential failures, you can schedule maintenance during off-peak hours, minimizing disruption and maximizing operational efficiency.

3: Skilled maintenance personnel
The skill set required for maintenance in aerospace goes beyond general mechanical aptitude. Maintenance personnel must hold certifications specific to aerospace, such as FAA certifications for aircraft mechanics. These certifications ensure your team has the specialized knowledge required to maintain complex aerospace systems.

Hydraulic landing gear training
Hydraulic landing gear systems are complex and require specialized knowledge for proper maintenance. Invest in training programs that focus on aerospace systems such as hydraulic landing gear. Ensure that your team is not just familiar with but proficient in maintaining these systems.

A well-trained team reduces the risk of human error, enhances safety, and ensures compliance with stringent aerospace regulations. Specialized training can lead to quicker diagnosis and resolution of issues, reducing downtime.

4: SOPs for each equipment type
The equipment in aerospace requires specialized standard operating procedures (SOPs). Whether it’s a jet engine or an avionics system, each piece of equipment should have its own detailed SOP, outlining every step of the inspection and maintenance process.

Carbon-fiber-reinforced polymer maintenance
The high strength-to-weight ratio of carbon-fiber-reinforced polymers (CFRPs) has increased their use in aircraft wings. Develop an SOP that outlines the steps for inspecting and maintaining CFRPs in aircraft wings. This should include tests for material fatigue, stress fractures, and other potential issues.

A well-defined SOP reduces the risk of oversight or error in maintenance. It’s also helpful for compliance with aerospace regulations and can serve as a training tool for new personnel.

5: Adequate budget and resources
The high costs associated with aerospace components make budgeting for their maintenance a critical task. Aside from just allocating funds for repairs, this also concerns planning for regular testing, inspections, and eventual replacement of high-cost items such as titanium fasteners or avionics systems.

Budgeting for titanium fasteners
Titanium fasteners are commonly used in aerospace applications because of their strength and corrosion resistance. However, they come with a hefty price tag.

Implement budget allocation strategies that account for the regular testing and replacement of these high-cost components. Proper budgeting avoids last-minute scrambles for funds when a critical component fails. It also allows for bulk purchasing at negotiated rates, leading to cost savings in the long run.

6: Continuous improvement
In aerospace manufacturing, the concept of continuous improvement is an operational imperative. Using Six Sigma or Total Quality Management methodologies, you can analyze flight data, maintenance records, and other operational metrics to refine your maintenance processes.

Cockpit instrumentation maintenance
Cockpit instrumentation is a critical system that requires regular maintenance to ensure flight safety. Use flight data to identify patterns or anomalies in cockpit instrumentation performance. Based on this data, refine your maintenance schedules and SOPs.

Continuous improvement in maintenance practices leads to enhanced reliability and safety. It also results in cost savings by optimizing maintenance schedules and reducing the frequency of unplanned outages.

Conclusion
With a razor-thin margin for error, the stakes are high in aerospace manufacturing. A robust proactive maintenance strategy is therefore a critical necessity. The six prerequisites we’ve explored are not isolated elements. They are interconnected pillars that form the foundation of an effective maintenance strategy in this demanding industry.

If you’re serious about elevating your maintenance practices, start with a comprehensive audit of your current systems and procedures. Identify the gaps and misalignments with the prerequisites. Next, prioritize your actions. If your team lacks the proper certifications, that’s an immediate area for action; if your software can’t integrate real-time telemetry data, it’s time for an upgrade.

The benefits of proactive maintenance extend beyond the obvious cost savings and enhanced safety. You’ll find that a well-implemented proactive maintenance strategy can improve your organization’s reputation for reliability and quality, which can open doors to new opportunities and contracts.

A disciplined, data-driven approach to proactive maintenance doesn’t just keep operations running – it elevates the entire industry’s standards. And in an industry where excellence is the minimum requirement, that’s an achievement worth striving for.

About the author: Eric Whitley serves as the director of smart manufacturing at L2L.