EAMSEmbraer Aircraft Maintenance Services

Value optimization

March - 2016

Embraer

ABOUT US

SUPPORTING

OUR CUSTOMERS

SINCE 2002.

Embraer - EAMS

EMBRAER NASHVILLE

Embraer Aircraft Maintenance Services Inc., a wholly-owned subsidiary of Embraer since 2002, the Nashville facility provides aircraft and component maintenance as well as factory training on the Ejet.

Today we have 480 technicians and support staff who annually produce over 200 aircraft maintenance events and over 11,000 component repairs and overhauls. Annually, our training department performs over 4800 training events for our employee and trains over 100 customer per year on the Ejet.

2002First Embraer MRO for Commercial Aircraft in the United States

2006Hangar 2 is built for the E-Jets (190 – 195)

2012Hangar 3 operations replace the Paint area

Preparation

Streamlining the Value

TAT TAT TAT

Was

te

Was

te

Was

te

Time wasted

EquipmentMethodManpower

MaterialMeasurement EnvironmentManagement

Work condition

Tools

GSE

Racks etc…

Planning WP

Sequence

Knowledge

Availability

Parts available

Delivery system

Roles and responsibilities

Controls

Visibilities Organization

Reaction plan

Production

Control

Set up / Strategy

Understanding the gaps

Vision for Excellence

Workplace / Environment

Safety

High Quality

Cycle

Reduction

(TAT)

Cost control

Support and

Resources

Controls , Visibility

Manpower

effectiveness

Excellence

HANGAR

Process analysis – Using Kaizen/A3

Understanding the As Is.

Process map analysis

Using a process map analysis to

identified process

Using 7 Forms of Waste to find non

value added time:

1. Transportation,

2. Inventory,

3. Motion, Wait,

4. Over process,

5. Over production,

6. Defects

Objective – Reduce non value add time

Inspector

PC Drop Box

IPM 51

Non Routine Printed

Lead Bid Drop Box

Customer Approves Task card

Approved orUnapproved Bin

Lead OrdersMaterial

Task Card Ready toFlow and WOrk

Non Routine Generation Flow – As Is

Old Process had 12 steps and was all hand transfer of

paper from one step to the another

PC Manual InputInto Quantum

Process analysis – Preparation/ Collaboration

Process Map analysis.

5S Collaboration

1. Sort

2. Set in Order

3. Shine

4. Standardize

5. Sustain

Strategy

Project

(Phase 1)

Project

(Phase 2)

Project

(Phase 3)

2014 - Process improvement / Preparation

2015 – Automation / Implementation

2016 / Future –Standardized/Optimize

Hangar 1

Hangar 2

Hangar 3

Improving the current process

• Re-engineered task distribution –

leads, inspection and back shops

• New process Improvements/benefits– Tasks are distributed in accordance with the flow

– Managable groups of tasks

– Distributed from a file cabinet to maintain critical path flow

– Disciplined process to return all tasks to work center

– Sharp reduction in lost/misplaced paperwork

Before After

Minimal Control

Clear Flow

Positive Control

Project

(Phase 1)

Automation/Implementation

EmpowerMx FleetCycle allows us to integrate best practice with

automation

Project

(Phase 2)We were not looking for a software,

we were looking for a platform to change our behaviors

System - EmpowerMx

After:

Visual Management Status page – Real time

Before:

Tasks distributed

manually in accordance

with the workflow

Project

(Phase 2)

System - EmpowerMx

Standardization/ OptimizationProject

(Phase 3)

New process was cut down from 12 steps to 6 steps and they are all electronic.

InspectorNR Directly Entered

Into Empower Lead Bids Job &Orders Materials

Customer Approval Website

Customer Approves Task

Card

Task Card Ready to Flow and Work

Improvement – Non Value Added

“LESS PAPER”

Greatly reducing the time it takes for a task card to go from generation to ready to work.

IPM 51 must be hand written and turned into the Production Controller to be entered into our ERP systme. This had an associated time lag between creation and evaluation.

The system allow for electronic recording of non-routines by the Quality Control personnel.Eliminated handwriting discrepancies, reduced movement, transportation, paper waste, entry time...etc. Decreased lag time between creation and evaluation by nearly 24 hours per task.

BEFORE

AFTER

Improvement – Non Value Added

BEFORE

AFTER

Corrective action was hand written and often found to be illegible. Then transcribed to our ERP system. Paper copy can be lost/misplaced. Also, there were no defined fields for auditing or data mining.

Electronic non-routine with text fields, built in audit requirements, and electronic signatures with audimated formatting. And data mining capabilities

Improvements – Non Value Added

BEFORE

AFTER

The audit and tally record is now electronic and accessible by multiple personnel at one time.

Audits and tally task cards, the inspection team and the customer representative were forced to get the book from one another or wait until the other was finished.

Improvements – Non Value Added

Improvements – Work Flow

Current Day

Remaining Milestones

BEFORE

AFTER

Numerous people interacting with the flow of task cards and no visibility of where those tasks are flowed. Changes go undetected and rely upon the constraint of communication as a control measure.

Electronic milestone assignment within Empower.

Prioritized by Due Date

Shows all Tail Numbers in Dock

BEFORE

AFTER

Greater visibility of the maintenance flow of the aircraft with assignments on one page and ability to sort each task by required by date..

Supporting departments often do not complete the right tasks at the appropriate times.

Improvements – Work Flow

4.11

3.36

3.13 3.15

2.98

2.82

2.25

2.45

2.65

2.85

3.05

3.25

3.45

3.65

3.85

4.05

4.25

Total Actual Hours Applied / Total Task Card Count

Result – Applied hours

EmpowerMX Start

60%

70%

80%

90%

100%

110%

120%

H4

31

7

H4

32

4

H4

34

4

H4

35

0

H4

36

1

H4

37

2

H4

37

9

H4

39

0

H4

39

8

H4

40

5

H4

41

1

H4

42

7

H4

44

8

H4

45

1

H4

47

2

H4

47

6

H4

48

1

H4

49

0

H4

49

9

H4

50

7

H4

51

2

H4

52

0

H4

53

6

H4

54

3

H4

55

4

H4

57

3

H4

58

1

H4

59

1

H4

59

9

H4

60

9

H4

61

8

H4

62

7

H4

63

3

H4

64

1

H4

64

6

H4

64

7

H4

65

7

H4

66

9

H4

67

1

H4

68

6

H4

68

8

H4

70

5

H4

71

4

H4

72

0

H4

74

2

H4

74

5

H4

75

2

H4

76

2

H4

77

5

H4

78

3

H4

78

4

H4

80

0

H4

80

3

Overall Efficiency Last 1.5 Years

Result - Efficiency

BEFORE AFTER

WE STRIVE FOR COMPANY

EXCELLENCE

Aircraft Maintenance Services