pw4000-94/-100 conference 2019

PW4000-94/-100 CONFERENCE 2019

This document does not contain technical data.

This document contains material which is proprietary to Pratt & Whitney and is delivered on the express condition that it is not to be used, disclosed or reproduced in whole or in part for any purpose without

Pratt & Whitney’s express written permission.

DAY 1 MORNING PRESENTATIONS

AGENDA – DAY 1

2 PW4000 2019 CONFERENCE

Pratt & Whitney Proprietary – Subject to the restrictions on the cover page / This page does not contain any export regulated technical data

MORNING / 8:00 AM - 12:00 PM

Welcome & Introductions Brian Ives

Opening Remarks Nancy Bordick-Cika

Austrian Airlines Presentation Rainer Kainzbauer

PW4000-94 Program Overview Ragini Potluri

PW4000-100 Program Overview Jeff Tracy

MRO Performance Eric Simard

Spare Parts Delivery Improvements Kelly Horan

HPC Airfoils Ed Hood

Airfoil Casting Travis Gracewski

Product Support Initiatives Ed Bendernagel

Repair Initiatives Norm Jeche

LPT Shaft Corrosion Lynn Boy, Eric Simard, Hank Hanrahan

LPT OTD Liberation Kurt Leach, Eric Simard

PW4000-94 PROGRAM REVIEW




RAGINI POTLURI PROGRAM MANAGER PW4000-94

OPERATIONAL COMMERCIAL ENGINES

PROGRAM OFFICE

4

PW4000 2019 CONFERENCE

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This page does not contain any export regulated technical data

PW4000-100 PROGRAM

HIGHLIGHTS



Meeting reliability and safety goals

~141 million flight hours, 30 million cycles

67 customers operating 410 aircraft

Passenger / Cargo: 50 / 50 split

In production through 2027

Spare parts challenging MRO TAT

PW4000-94 ORGANIZATION



RITA NEWMAN Airframer Manager

CAITLIN COFFLE Aftermarket Commercial

Manager

JESSICA PIETRONIRO Customer Integration

Manager

NORM JECHE Aftermarket Operations

ERIC SIMARD Integration Manager

ZACHARY CLOFT Deputy Integration

Manager

OPEN Deputy Integration

Manager

RAGINI POTLURI 94” Program Manager

BRIAN SEARS 94” Fleet Chief

BESERAT DEBEBE Model Manager

RICK KRUEGER 94” Chief Engineer

LUBOMIR RIBAROV 94” Systems Design

Manager

PW4000-94

CONTINUED INVESTMENT TO SUPPORT CUSTOMERS



PRODUCT SAFETY & CERTIFICATION Fuel nozzles / manifold brackets (TALON only)

HPT 1st inner air seal

HPC 12th disk fillet cracks

HPC 10th disk cracking

P-flange spacers

PRODUCT SUPPORT Lease engines

Engine EA / OTC support

Cat 1 suppliers

Acoustic liner

COST OF OWNERSHIP HPT 1st BOAS

HPT 2nd blade 2E mitigation

LPT shaft corrosion repairs

Fan case bolt hold corrosion

MRO PERFORMANCE Airfoil castings

Supply chain improvements

HPC short blade procedure

PRODUCT PERFORMANCE LPT robustness

HPT 2nd blade 2E mitigation

HPT 1st BOAS

Main gearbox bearing screw

Flex hose management

Sync ring runner

Fan exit liner bracket

THANK YOU

RAGINI POTLURI Program Manager PW4000-94

Operational Commercial Engines

Program Office

[email protected]

PW4000-100 PROGRAM REVIEW




JEFF TRACY PROGRAM MANAGER PW4000-100

OCE PROGRAM OFFICE

10




PW4000-100 PROGRAM

HIGHLIGHTS



285

233

PW4000-100 Engines by Configuration

ADV70 Non-ADV70

ESN 735190 Completed June 2017

Meeting reliability and safety goals

ADV70 on-wing time excellent

Challenges: scrap, repairs, TAT, cost

Fleet health IPMT

Nacelle 20 year buy

Part supply challenges

Cost focus

Industrial programs released

Limit expansions

Repairs

IMPT INITIATIVES TO IMPROVE FLEET HEALTH

FLEET HEALTH



Rapid AOG Response

Lease Engine

Availability

Fleet Operations

Critical Parts

Overhaul TAT

Near-term AOG

solutions

Current PWEL fleet size

UER volume

Constrained spare parts

and repair TAT

Extended shop TAT

Solve operational AOGs

Size fleet according to

WTW TAT

Corrective action plans

for top drivers

Drive pacing spare parts and

repairs to TAT requirements

TAT focus on all

overhaul shops

ISSUE ACTION

PW4000-100

CONTINUED INVESTMENT TO SUPPORT CUSTOMERS



PRODUCT SAFETY & CERTIFICATION Fuel nozzles / manifold brackets

TR latch beam

TR cascade aft support

T4 Inner air seal

T1 Inner air seal

HPC R12

Main Supply Line FM13

PRODUCT SUPPORT Lease engines

Nacelle SRM repairs

Cat 1 supplier management

Engine EA / OTC Support

Nacelle spare parts 20 year buy

COST OF OWNERSHIP LPT shaft corrosion repairs

Fan case bolt hole corrosion repairs

LPT blade repair & limit expansion

Part specific industry support

T3V bolt hole weld repair

MRO PERFORMANCE Turbine airfoil castings

Supply chain improvements

HPC short blade procedure

LPT Case super flange replacement

Exhaust nozzle TAT improvements

PRODUCT PERFORMANCE

Outer transition duct

T4 vane

T2 blade 2E mitigation

Anti-ice system

Combustor clamp

HPC 5th blade

No. 3 service tube heatshields

THANK YOU

JEFF TRACY Program Manager PW4000-100

OCE Program Office

[email protected]

MRO PERFORMANCE




ERIC SIMARD INTEGRATION

OCE PROGRAMS

16

PW4000 2019 WORLD CONFERENCE

Pratt & Whitney Proprietary – Subject to the restrictions on the cover page.

This page does not contain any export regulated data.

MISSION:

Improve on-time delivery of material

Reduce impact to customer

Develop and implement long term solutions for material issues


Pratt & Whitney Proprietary – Subject to the restrictions on the cover page. / This page does not contain any export regulated technical data.

MRO PERFORMANCE

2019 CONFERENCE:

HPC blades (10th & 11th)

Issue: Low yields

Solution: Process improvements, short blades, new source

Recovery: Q3 2019

LPT shaft

Issue: raw material capacity

Solution: Driving raw material, new repair

Recovery: Q4 2019

2017 CONFERENCE:

HPT 1st blade

Issue: Tool failure

Solution: Expedite tooling

Update: Increased output

HPT 2nd vane

Issue: Declining core yields

Solution: Expedite core tooling

Update: reduction in workstops since Q2 2018



MRO PERFORMANCE (PW4000-94 /-100)

SPARE PART DELIVERY PERFORMANCE

Kelly Horan, Senior Director Customer Solutions

HPC AIRFOIL TRANSITIONS

Ed Hood, Associate Director Strategic Sourcing, Airfoils

AIRFOIL CASTINGS

Travis Gracewski, Associate Director Procurement, Airfoil Castings



TOPICS AND SPEAKERS

THANK YOU

ERIC SIMARD Integration

OCE Program

[email protected]

SPARE PARTS DELIVERY IMPROVEMENTS




KELLY HORAN SENIOR DIRECTOR

CUSTOMER SOLUTIONS

22




Driving operations performance improvement for PW4000

SPARES PERFORMANCE METRICS – PW4000

COMMERCIAL SPARES & MATERIAL SOLUTIONS

Monthly Engine Workstops

2017 YE 2019 Q1 2018 YE 2017 Avg. 2018 Avg. 2019 Q1

Monthly Fill Rate Sold Overdue

2017 Avg. 2018 Avg. 2019 Q1

2019 Target



PW4000 CRITICAL PARTS SUMMARY

COMMERCIAL SPARES & MATERIAL SOLUTIONS

Part Family % of engine workstops Issues / Actions

Airfoils HPC 94”, 100” and 112” blades high workstop durations

Manufacturing & MAO strategies being worked

LPT blades and vanes key constraint in 2019 49%

HPC and LPT workstop durations are key risks

Small Hardware 36%

24

WS Trend

LLP 7% High value parts / top SOD drivers

Increased demand signal to internal business units

Improved from January

Fuel nozzles clear April AD, reduced demand

Increase focus on tools & actions



GREEN IMPROVING

YELLOW MAINTAINING

RED LAGGING

PW4000-100 CRITICAL PARTS

25

Parts Current Impact Recovery

HPT 1st Blade

56L601

HPC 7th Blades

50S107

LPT 7th Stg Blade

51N107

LPT Shaft

52A402-01

Raw material capacity

Casting tool die issue created gap in supply thru mid-May

New tool die qualification progressing

Improved deliveries June – December 2019

Raw material yield & capacity

Forging die location improvements complete

Forging run executed in March

New material deliveries resume Late May/Early June

CSA used material in-process for Q3 availability

Casting Cold Start

Casting commits increase began Q2 2019

On track for May castings commits for YE delivery increase

Expanding inspection dimensions for CSA serviceable material

Raw material capacity / Shaft corrosion driving demand

Gap driven by forging flow & forge trace issue

Raw material flowing / expediting finished goods

Part will be highly constrained until Aug 2019

GREEN IMPROVING / RECOVERED

YELLOW MEETING COMMITS

RED BEHIND ON PLAN

Driver/Actions

Q4 2019

Q1 2020

Q3 2019

Q4 2019



PW4000- 94 CRITICAL PARTS

26

HPC 10th Stg Blade

50S610-XX

HPC 11th Stg Blade

51S011-XX

Low Yield

Allocating +50 pieces per month April through June

Implementing MBM / 2019 yield target from 70% to 80%

CSA 10 engine part out Q32019

Licensing agreement

Low Yield

Mixed alloy issue corrected / Improved visibility pre & post heat treat

Implementing MBM 2019 / Yield target from 50% to 64%

CSA 10 engine part out Q32019

Licensing agreement

Q3 2019

Q3 2019

HPT 1st Stg Vane

52K671

Raw Material

Qualified tooling / capacity increase

Additional repair developed

Closed



GREEN IMPROVING / RECOVERED

YELLOW MEETING COMMITS

RED BEHIND ON PLAN

Parts Current Impact Recovery Driver/Actions

CRITICAL AND NON-CRITICAL PARTS

MATERIAL PLANNING & ESCALATION

27

Early Warning

Front to Back Tool

Critical Parts List

(Workstops)

Heat Map

(Systemic)

Supply & Ops

Priorities /

Performance

(Daily escalation,

Weekly VP meetings,

Dives)

Deliver Parts

Escalation Process Overview

Mitigation opportunities for WIP (Production engine material, Repair,

Serviceable solutions, Waterfall,

limit expansion)

Enhanced

focus area



GAP ANALYSIS AND CLOSURE METHODOLOGY INTEGRATED MATERIAL DELIVERY SOLUTIONS

Iterative process; Collaborate with Program Tiger Team

Exposure and replacement rates

Demand vs load analysis (SIOP)

Scrap rates

Integrated solutions by part

Line of balance view

Mitigation impact

Shop Visit Material Risk Tool Year gap analysis

Weekly review

Allocation optimization

Gap coverage

90-day look ahead ESN by ESN

New team with additional resources & new process focused on driving material gap closures

with new part deliver and alternative solutions to support Shop Visit Plan



Detailed plan by part One year view

SMALL HARDWARE MOD CENTER PERFORMANCE

29

Weekly onsite delivery review

Managing part priority

Focus on distributor oversight

NEAR TERM

End-to-end value stream

demand signal process mapping

Safety stock health monitoring

Early Warning System and event creation

MID / LONG TERM

(Tactical) TIME HORIZON (Strategic)

Distributor

PWA

OEM

Customer

D

E

M

A

N

D

S

U

P

P

L

Y



HPC AIRFOILS RECOVERY

30

Alignment of forge and delivery schedules

Pursuing used/serviceable options for WIP

Optimized Columbus Forge production flow

NEAR TERM

Machine All Over (MAO) sourcing

Model Based Manufacturing (MBM)

MID / LONG TERM

(Tactical) TIME HORIZON (Strategic)



PW4000 CRITICAL PARTS SUMMARY

REPAIR PART FORECASTING

31

Accumulation of

standardized

historical data

Normalization,

Intelligence

Adjustments

Shop Visit

Factorization

Early Risk

Identification

Flags

Repair Publications,

Customer Requests,

Program Intelligence

Process created

Future Enhancements

Today Historical Data

Repair Part

Forecast

Proactive alignment and prioritization of repair development

Drive forecast adjustment on

focus parts

Prioritization of repair development

Full repair capacity planning

across OCE

Alignment on part forecast mix

SUMMARY



DRIVING FLEET-WIDE IMPROVEMENTS

SUMMARY

Executive leadership committed to supporting and investing to drive recovery

Weekly executive reviews to drive recovery, including raw material starts

Continue to optimize allocation to support fleet health

Continue efforts with repair, limit expansions, and used serviceable availability to support fleet

Progressing with process improvement, proactive measures and additional resources focused on early warning

Driving supply chain throughput and accountability



THANK YOU

KELLY HORAN Senior Director

Customer Solutions

[email protected]

HPC AIRFOILS




ED HOOD ASSOCIATE DIRECTOR, STRATEGIC SOURCING

AIRFOILS

35




SOURCING STRATEGY

HPC AIRFOILS

AIRFOILS SOURCING STRATEGY

Growing capacity within current capability

Proactively adjusting strategy to mitigate future delivery risk

Developing new suppliers to increase available capacity for

short term / long term need

36

Compressor Airfoil Value Stream



AIRFOILS MANUFACTURING TRANSFORMATION

Precision forge process converting to machine all over process

Adapting to the change in technology

5 axis machining highly more sophisticated than 20 years

Yielding more consistent parts, higher yields



HPC AIRFOILS (94-100”) PARALLEL PATH APPROACH TO INCREASE CAPACITY

Increasing

capacity

for HPC Airfoils

EXTERNAL SOURCING / CAPACITY

Licensed offload (Stages 10 & 11)

Exploring transition to capable new supplier

Additional machine all over sources

INTERNAL CAPACITY: COLUMBUS FORGE BLADES (CFB)

Model Based Manufacturing

Immediate corrective action

ENHANCE INTERNAL CAPACITY – CFB

Model Based Manufacturing

Data based – improving yields

Real time process control

Immediate corrective action

Increasing deliveries

Organic capacity growth




http://www.pciga.com/

EXPANDING EXTERNAL CAPACITY

Working licensed offload (Stages 7, 10 & 11)

Lead time ~9 to 12 months

Successful transition on PW2000 program

Evaluating transition to Turbocam (Stage 6)

Capable / demonstrated supplier on technically complex parts

Will develop capable source for future maturing programs




Securing additional capacity

through additional sources

https://www.bing.com/images/search?q=turbocam+logo&id=C7FA84FD632124BE763B180E1C12EFE242BD7915&FORM=IQFRBA

THANK YOU

ED HOOD Associate Director, Strategic Sourcing

Airfoils

[email protected]

AIRFOIL CASTING




TRAVIS GRACEWSKI VALUE STREAM MANGER: TURBINE AIRFOIL CASTINGS

GLOBAL SUPPLY CHAIN

42




Core Mfg Wax Pattern Wax Assy Ceramic Dip Casting Pour Finishing


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HPT AIRFOILS INDUSTRY OVERVIEW

Value Stream Overview

Significant industry capacity constraints

Long tooling build and qualification lead times

Insufficient tooling inventory levels

High part technical complexity

Variable yield process

44

TURBINE AIRFOIL CASTING STRATEGY SOLVING A COMPLEX AND MULTIFACETED PROBLEM

STRATEGY

Supplier capacity expansions exceed 450,000 sq-ft

(42,000 m2) in new facilities by 2020

Develop new market entrants

Collaborating with partners to balance program needs

Tooling Governance launched in 2017 to achieve a

healthy portfolio by 2022

Tooling qualification process improvements

Established the “Turbine Airfoil Casting Team”

Supplier process trials and new material development

CHALLENGES

Capacity

Tooling

Technical


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TOOLING GOVERNANCE 5-YEAR JOURNEY

Defines how to manage a portfolio of tools distributed through

supply base

Identifies quantity of tools required and trigger points to launch

replacement

Establishes a review process to sustain healthy tooling inventory

Highlights:

3.5x increase in Pratt & Whitney tooling capital spend compared

to 2016

Provides redundancy for high risk tools

Quarterly tool health review and executive report-out

STAGE PROGRAM REMAINING TOOLING HEALTH

1ST Blade 94 / 100 3

2nd Blade 94 3

2nd Blade 94 / 100 3

1st Vane 94 0

1st Vane 100 0

2nd Van 94 / 100 1

4Q20 1Q21 2Q21 3Q21 4Q21 1Q22 2Q22 2Q19 3Q19 1Q20 2Q20 3Q20 1Q19 4Q19

Fulfil Governance

2Q22 2Q22



TOOLING GOVERNANCE

1V Core Die Tool

PW4000 Tools Qualifying Sustainment

PW4000-94 AND -100 PLAN

47

Tool loss in 2017 resulted in underperforming 2018 output

Early 2019, quality finding during requalification stopped deliveries for 3 months

Tooling issue resolved Q1 2019, work in process inventory stabilized

Low yield tooling expected replacement Q3 2019

PW4000-94 & -100 HPT 1ST BLADE, PN: 55L201 CRITICAL PART STATUS

4Q19 2Q18 3Q18 1Q19 2Q19 3Q19 1Q18 4Q18

New tool qualified

Stable deliveries, tooling limited

Production Stop

Yield stabilized



THANK YOU

TRAVIS GRACEWSKI Value Stream Manager: Turbine Airfoil Castings

Global Supply Chain

[email protected]

PRATT & WHITNEY ENGINE LEASING




ED BENDERNAGEL EXECUTIVE DIRECTOR

CUSTOMER SUPPORT

50




PWEL ORGANIZATION

MATT STONER Customer Support

Vice President

SCOTT CIKA Engine Leasing &

GFM Director

CARMEN D’ONOFRIO Entry Into Service & Product

Support Senior Director

ED BENDERNAGEL Customer Support

Executive Director

ED LAGOY Business Operations

Director

BOB MACIOROWSKI Interim Customer Training

Director

ANDREW DIXON OCE Senior

Manager

ED LACROIX GP7000/SV

Fleet Manager

BONNY PHILIBERT PW4000

Fleet Manager

RICHARD GRANT V2500

Fleet Manager

BRYAN GRAFFIN OPS Manager

KAREN FERNANDES OPS Analyst

BABITA MARALA OPS Analyst

ALPHONSO SAVAGE Logistics Manager

DANIEL PERRETTA Logistics Manager

GREG KLINE GTF Senior

Manager

KEVIN GRECO PW1100

Fleet Manager

DAVE MICHAUD PW1500/PW1900

Fleet Manager

KEITH LANZER GTF

Fleet Manager

CAROLINE TRUESDELL GTF Fleet Specialist

FRANK DAVIS V2500 / GTF

GFM Director

SARAH PORTER PW1100

Fleet Manager

JACEK ORZOL PW2000 / PW4000

GFM Manager

ZACH LOBMAN CBDP Rotational

Associate

LOU ZANETTE Engine Leasing

Associate Director

MARY HALL Customer Support

Senior Manager

WES SCHLAUDER Global Fleet Management

Associate Director

DAVID BERNARD Associate Director

FP&A

MARINKO VRACEVIC FP&A Specialist

FINANCE SUPPORT

ILIA O’HEARN Director &

Senior Counsel

JIMI MANGIO Sr. Manager

CHRISTINE PEASLEE Associate Director

General Legal

TREVENE

THOMAS-ODONKOR Contracts Specialist

LEGAL SUPPORT



ORGANIZATION

Alignment with customer facing groups

Leverage existing customer relationships and collaboration

Improved process integration and communication

Permanent and natural home




REORGANIZATION OF PWEL INTO CUSTOMER SUPPORT FROM AFTERMARKET

PWEL MISSION

Meet customers’ engine leasing needs through total fleet management services for P&W lease pools assets,

ensuring timely support through quality products, services and communication.

PWEL

Customer

Fleet Directors

Global

Operations

Center / 24

Hour Help

Desk

Entry Into

Service Team

Customer

Training Center

Field Service

Representatives

Customer

Service

PWEL BUSINESS



CURRENT & PROJECTED BUSINESS

14

12

28

25

13

26 25

22 23

30

28

19

112" 100" 94"

2016 2017 2018 2019 Plan

PWEL PW4000 & TOTAL FLEET CONTINUES TO GROW

PWEL BUSINESS



AOG & RISK STATUS

Monitoring health of worldwide fleet and managing AOG risk

94” WORLDWIDE FLEET Lease demand satisfied

2 customers parked

Periodic demand for lease engines

100” WORLDWIDE FLEET 2 active AOGs

1 customer parked

Additional AOG risk elevated

Supply of lease engines limited

112” WORLDWIDE FLEET Lease demand satisfied - no AOGs year to date

Increased risk of AOGs

Improving lease engine availability

PW4000-94 Worldwide Fleet PW4000-100 Worldwide Fleet

PW4000-112 Worldwide Fleet

PWEL BUSINESS



BUILDING THE LEASE POOL TO MEET DEMAND

Maintaining a stable lease pool Growing and building a strong lease pool

Demand Supply

Leased Requests Repair Acquisition

Demand Supply

Leased SV/Other

Current

Leases

2017 2018 2019

PW4000-112” PW4000-100” PW4000-94”

Current

Leases

Demand Supply

Leased Requests Repair Acquisition

Current

Leases

PWEL BUSINESS



BUILDING THE LEASE POOL TO MEET DEMAND – 100/112

INVESTING FOR A HEALTHY LEASE POOL TO SUPPORT CUSTOMERS

PW4000-100” Adding up to 6 additional engines in 2019, purchase & lease-in

100% of serviceable assets deployed

Less than 10% of lease pool in overhaul or repair

2019 PW4000-100 LE Serviceable Status and Totals 2019 PW4000-112 LE Serviceable Status and Totals

PW4000-112” Added 4 engines in 2019, lease-in

Assets available to support the fleet

Overhaul and repair plan to setup for next 5 years

PWEL BUSINESS



LEASE VOLUMES

NEW LEASE LEASE EXT TOTAL NEW LEASE LEASE EXT TOTAL

PWEL Entire Fleet Lease Volumes PW4000 Lease Volumes

2016 2017 2018 2019LE 2019YTD

PWEL PROCESS OVERVIEW & ROLES



COLLABORATIVE PROCESS BETWEEN P&W AND CUSTOMERS

Customer

Lease Request Duration & Timing

Insurance &

Deposits

Monthly Utilization

& Part Change Reporting

Engine Records

Pratt & Whitney

Engine Match w/ Customer / Global View

Engine Records

Post Lease Inspection

Lease Agreement Termination

& Engine storage

Customer/ P&W

Lease Agreement

Terms

Engine Logistics

Engine Logistics

Request Contract Delivery Lease Return Closeout

Optimized = 32-40 hours

Actual Range 1 to 30 days

Optimized timing = 3-7 days

Actual Range 3 to 14 days

Allocation

Customer Invoicing

& Payment

PWEL PROCESS OVERVIEW & ROLES



Added Lease Engine Assets

Increased PWEL headcount

PWEL joined Customer Support organization

Integrated GFM and PWEL – One Team

Created PWEL Operations team

Risk / Release of lease engines

Blanket export/ ITC approval engine shipment

Vendor Quality Business Reviews (QBR)

Universal Post Lease Requirements Checklist

IMPROVEMENT FOCUS CONTINUING IN 2019

ADDRESSING CUSTOMER MFA

PWEL BUSINESS



CUSTOMER FOCUS

Customer Support

Increased headcount &

reorganization

Vendor management

Increased number of

lease engine assets

Process improvement & refinement Flexible

solutions custom tailored

Fleet health

24/7 support

THANK YOU

ED BENDERNAGEL Executive Director

Customer Support

[email protected]

REPAIR INITIATIVES




NORMAN JECHE AFTERMARKET MANAGER

OCE PROGRAMS MANAGER

63




REPAIR INITIATIVES

64

IN 2017, PW4000 CONFERENCE COMMITMENTS TO OPERATORS WERE:

Convert repeat application EA’s into CIR or Engine Manual repairs

Improve turnaround time on shop visit material repair development EA’s

Expand GSE support globally

Develop material reclamation repairs and increase yield on highly constrained parts



REDUCE OTC DEMAND BY PROACTIVELY TRANSITIONING OTC’S TO EM REPAIRS

PW4000 ENGINE MANUAL REPAIRS

OBJECTIVE:

Identify opportunities to consolidate one time Engineering

Authorizations (EA’s) into new multi-use repairs

Incorporate previous multiple-use EA’s in Engine Manual

METHODOLOGY:

Survey customers and repair stations for EA’s repeated 3

or more times

Identify the complexity, fleet risk, and source of initial EA’s

BENEFIT TO CUSTOMER:

Reduction in repair TAT waiting for EA (New or Previous)

Increased GSE capacity



Identified 1Q18 2Q18 3Q18 4Q18 CarryOver

112" Identified EA's

100" Identified EA's

94" Identified EA's

DISQUALIFIED

Handling damage

Unique situation damage

54

34

17

35

PROPRIETARY

Status of OTC Conversion Effort

IN WORK

COMPLETE

CIR incorporations

OTC Conversion Burndown 2018

ADDING CAPACITY AND STREAMLINING PROCESSES

P&W GLOBAL SERVICES ENGINEERING (GSE) PRODUCTION

PW4000 REPAIR DEVELOPMENT PERFORMANCE

Averages (Dialogs and Repairs)

140 New requests per month

122 Completed tasks per month

53 EA New repairs per month

62 days TAT average

New GSE/Programs leadership forum providing greater

oversite to customer and fleet needs

Additional P&W Engineers and contract engineering sources

be added



FORWARD-DEPLOYED DESIGN / REPAIR / TECHNICAL SUPPORT ENGINEERING TEAMS

ENGINE LIFE MANAGEMENT TEAMS

Operations support

Rapid case dispositions for basic limits/repairs

Durability trending and proactive planning

Drive Engine Manual updates/maturity

Accelerate aftermarket return to service

Identify emerging distress and scrap modes

Support for maintenance cost solutions



ENGINE LIFE MANAGEMENT TEAM

SOLVING CRITICAL PARTS SHORTAGES THROUGH ENGINEERED SOLULTIONS

RECLAMATION REPAIRS HELPING IMPROVE REPAIR YIELD

Fan Case Friction Plug Weld

HPC Blades “K” blades

Under minimum length Pre-matched sets

Developing Tip Restoration Repairs

LPT Blades and Vanes



AFTERMARKET REPAIRS




PW4000-94/-100 HPC BLADE RECLAMATION REPAIR

ISSUE:

Material shortfall in HPC Manufacturing Business Unit

CHALLENGE:

Reclaim unserviceable blades without:

Engineering Change Engine performance impact No change to engine assembly procedure Maintain tip coating post rotor grind

REPAIR METHODOLOGY:

Expand part marking location

Accept shorter repair minimum length blades

Produce in blade length matched sets (“K” marked)

REPAIR READINESS:

Expanded the marking areas

Blade length reclamation available per EA 19KC131



Elapsed Turn Around Time

Receipt to Ship

EA

T d

ays

EAT Goal

(25.9)

EAT Avg

(24.8)

20.2

23.2

25.9

20.3

22 22.6 22.8

19.6 19.8 21.3

19.3

17.7

30.9 29.9 30

31.1 30.5

31.2

37.3

30.2

28.3 27.1

25.7

30

0

5

10

15

20

25

30

35

40

PW4000-94/-100 10TH AND 11TH HPC BLADE REPAIRABLE LIMIT EXPANSION

ISSUE:

Revise repairable limit to yield non-restricted blades

CHALLENGE:

Reclaim unserviceable blades without:

Engine performance impact

No change to engine assembly procedure

Maintain tip coating post rotor grind

REPAIR METHODOLOGY:

Accept shorter repair minimum length blades in normal

repair without blade set requirement

REPAIR READINESS:

Repair per EA 18KC428 (10th Blades) and EA 18KC881

(11th Blades) released

Will be part of normal blade overhaul repairs



Historical Repair limits “K” Blades Sets only

EA19KC131

New, Repaired, and

EA18KC428, EA18KC881

PART NUMBERS: 50S610, 59H510 (10TH STAGE), 51S011, 59H711 (11TH STAGE)

NEW REPAIR EA 428/881 EA 19KC131

PW4000-94/-100 3RD LPT BLADE INSPECTION LIMIT EXPANSION

ISSUE:

Airfoil casting constrained between 94” and 100”

Engine shop visit shipments being impacted

CHALLENGE:

Retain turbine durability and engine build interval

REPAIR METHODOLOGY:

Expand airfoil serviceable and repairable limits

Accept more surface imperfections

REPAIR READINESS:

EA released expanding visual limits

TOS processing parts to new limits



67.2%

51.3%

80.9% 85.5% 88.3% 82.8%

52.7%

66.7%

34.1%

62.4%

35.6%

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

Feb2018

Mar2018

Apr2018

May2018

June2018

July2018

Aug2018

Sept2018

Jan2019

Feb2019

Mar2019

50N203 and 50N203 Scrap Data

Scra

p %

Pie

ce

s

0

400

600

800

200

FIRTREE

SURFACES LEADING EDGE

SHROUD

ROOT

POCKET

(BOTH

SIDES)

PLATFORM

TRAILING

EDGE

AIRFOIL NOTCH

APPROXIMATELY 20% YIELD

IMPROVEMENT

PART NUMBERS: 50N203 (-94/-100), 51N203 (ADV70)

PW4000-94/-100 4TH AND 7TH LPT BLADE INSPECTION REPAIR

ISSUE:

High scrap rate and constrained supply

CHALLENGE:

Maintain service life and safety

REPAIR METHODOLOGY:

Refine and expand visual inspection areas

Expand visual inspection limits

REPAIR READINESS:

Initial revised limit on 4th blade 4% improvement

Collecting data to address further expansion



PART NUMBERS: 50N204, 50N704 (-94/-100), 51N004 (ADV 70)

CIR Visual Inspection Figure 4th blades

PW4000-94/-100 1ST AND 2ND HPT BLADE OPEN CORE WELD EXTENSION

ISSUE:

Cracking in tips outside of current open core weld areas

CHALLENGE:

Welded area cannot impact internal cooling flow

Blade durability and safety post repair

REPAIR METHODOLOGY:

Allow open core welding at trailing edge cavity tip

REPAIR READINESS:

Repair development underway

Global Services Engineering feasibility study Q3 2019

TOS readiness 2020



PART NUMBERS: 50A077 (-94), 52A402-01 (-100)

1st Stage HPT Blade Inspection Areas

PW4000-100 FRONT FAN CASE BOLT HOLE CORROSION

ISSUE:

Fan case no longer in production

Corrosion enlarging “B” flange holes

CHALLENGE:

Retain blade out containment strength

Repeatable repair of hand welding was difficult

Limited by edge distance and plug diameter

REPAIR METHODOLOGY:

Apply friction plug weld technology

Add an assembly corrosion preventer lubricant

Evaluate use on other flanges and cases

REPAIR READINESS:

Ability to complete up to 6 holes per case complete

Ability to repair up to 60 holes 3Q19



PART NUMBER: 52D523-01 (-100)

PW4000-100 NOZZLE FORWARD RING CRACKING REPAIR

ISSUE:

Cracking at the Forward Ring Holes

CHALLENGE:

Repair longer and larger cracks

Reduce cracking post repair

Develop standardized repair

Drive TAT to be under 60 days

REPAIR METHODOLOGY:

Expand weld repairs

Use a stiffener detail to strengthen forward ring

No FAA 8110 required driving CAMP modification

REPAIR READINESS:

Source Demo Proprietary Repair release May 2019

Repair details available from supplier end of Q2 2019

Repair ready beginning Q3 2019



PART NUMBERS: 76A002-31, -41, AND -51(-100)

Doubler added, as needed, to inner surface of Nozzle

PW4000-100 NOZZLE TAT



PART NUMBERS: 76A002-31, -41, AND -51

Shipment Volume

Ord

er

Cou

nt

Elapsed Turn Around Time

Receipt to Ship

EA

T D

ays

EAT Goal

(35.4)

EAT Avg

(98.0)

53.0

133.0 127.0

111.5

90.0

0.0

20.0

40.0

60.0

80.0

100.0

120.0

140.0

Jan-Mar 2017 Apr-June 2017 July-Sept 2018 Oct-Dec 2018 Jan-Mar 2019

1 1 1 2

5

0

1

2

3

4

5

6

Jan-Mar 2017 Apr-June 2017 July-Sept 2018 Oct-Dec 2018 Jan-Mar 2019

THANK YOU

NORM JECHE Aftermarket Manager

OCE Programs

[email protected]

PW4000-100 LPT SHAFT CORROSION

WARNING: This document contains technical data, the export of which is or may be restricted by the Export Administration Act and the Export Administration Regulations (EAR), 15 C.F.R. parts 730-774.

Diversion contrary to U.S. law is prohibited. The export, re-export, transfer or re-transfer of this technical data to any other company, entity, person, or destination, or for any use or purpose other than that

for which the technical data was originally provided by Pratt & Whitney, is prohibited without prior written approval from Pratt & Whitney and authorization under applicable export control laws – ECCN 9E991.



LYNN ERIC HANK

BOY SIMARD HANRAHAN CIPT LEADER INTEGRATION ENGINEERING

HOT SECTION OCE PROGRAMS MANAGER

ENGINEERING CTRP REPAIR

81




CORROSION EVIDENT ON LPT SHAFTS



Pratt & Whitney Proprietary – Subject to the restrictions on the cover page / U.S. Export Classification: EAR ECCN 9E991

External corrosion on LPT shaft

ISSUE:

Advantage70 LPT steel shaft (PN 52A402-01) corrosion

pitting on external surface

New emerging issue:

Corrosion found on internal bore of LPT shaft

Gathering additional data on LPT shafts at overhaul

CAUSE:

Protective coating not adhering to bond coat due to

oxidation layer present between two coatings


SOLUTION: COMPLETED

Improved coating application instructions for production and

repair completed

Standard Practices Manual SPOP-141 Updated

Production Specification PWA 36252 Updated

83

PRODUCTION AND REPAIR COATING APPLICATIONS ENHANCED



PRODUCTION PART STATUS RECOVERING


SOLUTION: PRODUCTION

CAUSE:

Demand increase due to corrosion

Raw material availability

DRIVER: SOLUTION:

Capacity constraints at raw material supplier Drove capital purchase

Increased lead-times by billet supplier Accelerated current forging WIP

Capacity constraint at integral testing Second source for testing

STATUS:

Deliveries to resume – Q3 2019

Raw material now at full WIP

Raw material at machining supplier

Recovery starts in Q4 2019



SOLUTION: REPAIR

ISSUE:

Corrosion pitting on steel shaft configurations

PW4000-100 Advantage70 (PN 52A402-01)

PW4000-94 (PN 50A077)

CHALLENGE:

Eliminate corrosion without impacting chapter 5

REPAIR METHODOLOGY:

Developed suite of repairs to machine and/or blend

REPAIR READINESS:

OD corrosion machining capability complete, first pieces machined

New lathe installed for increased capacity

ID Corrosion solutions being evaluated

85

PW4000-94/-100 LPT SHAFT CORROSION REPAIR DEVELOPMENT

4

5



STEEL

CONFIGURATIONS

100 94

Machining repairs to B/P

limits for barrel Areas 1-3

Complete

May 2018

Complete

Sept 2018

Machining repairs to B/P

limits for flange Area 4

Complete

Oct 2018

Re-planned

May 31, 2019

November 2018

Discovered residual barrel pitting/tie bolt

flange corrosion remains, and ID pitting

Machining repairs

beyond B/P limits for

flange Area 4

Complete

April 12, 2019

Plan

May 31, 2019

Acceptance Limits or

Repair of Internal

Corrosion Pitting Area 5

Feasibility

assessment

June 2019

Pending 100 results

THANK YOU

LYNN BOY CIPT Leader

Hot Section Engineering

[email protected]


OCE Programs

[email protected]

FRANK HANRAHAN Engineering Manager

CTRP Repair Organization

[email protected]

PW4000-100 LPT OUTER TRANSITION DUCT LIBERATION

WARNING: This document contains technical data, the export of which is or may be restricted by the Export Administration Act and the Export Administration Regulations (EAR), 15 C.F.R. parts 730-774.

Diversion contrary to U.S. law is prohibited. The export, re-export, transfer or re-transfer of this technical data to any other company, entity, person, or destination, or for any use or purpose other than that

for which the technical data was originally provided by Pratt & Whitney, is prohibited without prior written approval from Pratt & Whitney and authorization under applicable export control laws – ECCN 9E991.



KURT LEACH TURBINE INTEGRATED

PRODUCT TEAM

LEADER

HOT SECTION

ENGINEERING

88




ERIC SIMARD INTEGRATION

OCE PROGRAMS

LOCATION AND FUNCTION




OUTER TRANSITION DUCT AT LOW PRESSURE

TURBINE INLET directs airflow and provides sealing

PW4000-100 outer transition duct location

Outer

Transition Duct

(OTD)


ISSUE:

Outer Transition Ducts have liberated into gas path

Observed consequences include Engine Surge, IFSD,

Diversion, and Air Turnback

13 events have occurred, all with TALON IIB combustor

All events have been contained

Potential for Nacelle Uncontainment



Outer Transition Duct Liberation

OUTER TRANSITION DUCTS LIBERATING INTO GAS PATH


CAUSE:

Primary root cause:

Gas path temperature profile shifted outboard

Other root cause contributory factors:

Location of OTD liberations shows correlation with 2nd Stage

BOAS heavy spallation, locally increases end wall temperature

Operators with hotter turbine temperatures more susceptible to

OTD liberations



ELEVATED OD ENDWALL TEMPERATURE RESULTS IN OTD DEFORMATION AND LIBERATION

Black = Thermal Deformation

Purple = Nominal Model

Locally spalled BOAS down

to base metal LE-to-TE

leaves 0.150” gap Ingestion due to

step in gas path

Gas path air locally

bypasses 2nd blade,

creating hotter end wall


SOLUTION:

Material change provides better high-temperature capability

Improves hook dis-engagement life



OUTER TRANSITION DUCT RE-DESIGNED

Re-designed Outer Transition Duct

Duct Segment (Machine/Casting)

51N129 / 51N128

Anti-Rotation Pin

50N268

Rivet (5x)

ST1219-056 Flow Guide

50N496

REDESIGN AVAILABLE BEGINNING AUGUST 2019


FLEET MANAGEMENT:

INTERIM SOLUTION:

All engines with Talon IIB combustor installed

Replace with full set of zero-time existing OTD PNs during LPT OTD exposure

FINAL SOLUTION:

Replace with redesign OTD PNs

Service Bulletin June 2019 ; Hardware August 2019

Cat. 3 – Talon IIB combustor engines (Production, SB 72-214, 72-219 or 72-220)

Group A Engines:

Incorporate in 3 years upon SB release

Engine serial numbers in SB

If full set of zero-time OTDs installed at a prior SV, incorporate SB within 2,700 cycles since of that SV

Group B Engines:

Incorporate in 4.5 years upon SB release

Cat. 8 - Talon IIA and non-Talon combustor engines


Pratt & Whitney Proprietary – Subject to the restrictions on the cover page / This page does not contain any export regulated technical data.

REDESIGN ON PLAN


New material OTD complete set delivery on track for August 2019

Initial review of castings favorable

Castings poured 1 week ahead of schedule



Initial Casting – Redesign

Outer Transition Duct

Borescope

Part

Final

Part Delivery

8/16

Casting

Shipment

6/15

Base

Part

Final

Part Delivery

7/24

2019

Jan Feb Mar Apr May Jun July Aug Sep Oct

1st Pieces in

Metal

3/29

Casting

Shipment

4/30

1st Pieces in Metal

1/30

Cores

Available

3/1

THANK YOU

KURT LEACH Turbine Integrate Product Team Leader

Hot Section Engineering

[email protected]


OCE Programs

[email protected]

pw4000-94/-100 conference 2019

Documents

Transcript of pw4000-94/-100 conference 2019