Field events scorecards

CFM56-7B

CFM56 Symposium
June 2017 – Milan
CFM56-7B Scorecard
April 2016 to March 2017
IFSD ATO Interruptions Removals Dep. Reliability Total Maintenance
(Fleet Average
(Events/1000 EFH) (Events/1000 Departures) (ATB+DIV) (Events/1000 (Events/1000 EFH) (% On Time)
Departures) MH/Engine/Year)

0.0017 0.0050 0.009 0.016 99.69% 18 hours

>0.005 >0.015 >0.020 >0.040 >0.02 >0.03 >0.040 >0.050 <99% <98% >25 >30

Statistics Top Issues

Engines in fleet : 13,300
(includes install & spares) Fan Blade SB 72-1019 & 72-1024 – On Wing UT Inspection
Total aircraft: 6,270

Total no. of operators: 274 OFDPS Faults SB 73-0219 – 7BW2 Software

Spares / Lease 780/350 #3 Fwd Air Oil Seal 72-1023 – Borescope Inspection
Remote Diagnostics / CNR available
Total engine time: 311,109,000
Tailpipe Fires – Oil Implement new CVT SB72-0921
Total engine cycles: 162,042,000 On wing replacement of CVT damper seals

Fleet Hours per month: 2,959,000

Fuel Leaks SB 73-0224 new MFP shaft Seal
Fleet Cycles per month: 1,533,000 FCOM Updates

High Time Engine: 86,600

High Cycle Engine: 44,500

Stats as of March, 2017

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March 2017
Engine Hours/Cycles Distribution
600

500 * ~61% of engines with no SV

Includes all SV Workscopes – Min to Heavy
SV Count
400 Avg 15k CSN/30k TSN to SV1 (any workscope)
5+
300 4
3
200
2

100 1
0
0

Hours
800

700 *
600
SV Count
500 5+

400 4

300 3

200 2
1
100
0
0
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
11000
12000
13000
14000
15000
16000
17000
18000
19000
20000
21000
22000
23000
24000
25000
26000
27000
28000
29000
30000
31000
32000
33000
34000
35000
36000
37000
38000
39000
40000
41000
42000
45000
Cycles
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IFSD Rate: April 2015 – March 2017
CFM56-7B IFSD Rate
0,006 37 000 000

CFM Threshold 36 000 000

0,005
35 000 000

Engine Hours per Year

0,004 34 000 000
IFSD per 1k hours

33 000 000
0,003
32 000 000

0,002 31 000 000

Total – 0.0017 30 000 000

Basic – 0.0012
0,001
29 000 000

0 28 000 000

Basic IFSD Total IFSD Engine Hours 12 M

IFSD Rate Stable for >2 years

Non-Basic events increasing – Maintenance related Drivers
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 IFSD Causes: April 2016 – March 2017
Last 12 Months: Engine Flight Hours : 36,297,000; Engine Flight Cycles: 18,388,000
Cause Quantity Status
AGB 5 3 Line 4 Bearing ;
2 Line 3 Bearing
HPT Blade 3 Below platform failures – Not detectable with BSI

#4 Bearing 3 2 – Between 31,000, and 46,000 hours

1– \Low TSV (2000 TSV)

Starter 3 2- Pre-SB Configuration Clamp

1 – Starter Turbine Seal Leakage
Data for engine:

# 3 FWD Seal 3 PTFE blockage of sump scavenge line – low Oil Qty/Pressure

Air/Oil Separator 3 Oil loss – Pre-SB configuration (3 weld housing)

Clogged Oil Filter 2

#3 Bearing 1 Non-Nitrided Bearing

HMU 1 VSV EHSV

NFF 1

MFP 1 Assembly aid clip liberated from MFP and affected HMU Valve

HPC Pin Liberation 1

Combustor Liner 1

Fire Detection Harness 1

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 IFSD Causes: April 2016 – March 2017
Last 12 Months: Engine Flight Hours : 36,297,000; Engine Flight Cycles: 18,388,000
Cause Quantity Status
Investigation 10 3 – Low/No Oil pressure In Flight
2- EGT Exceedance
1- Under NTSB Investigation
1- Engine parameters shift
1- Fuel Flow Cut in Cruise
1- Stall
1- Loss of thrust
Data for non-engine:

Maintenance 12 4 – Lube Unit Missing o-ring and insert pulled out

3– Fuel gasket damaged at HMU/FOHX
1– Improper torque of the FSV tube\
1– Engine Ant-ice Duct Clamp not secured
1- Lever arm assembly error
1- MFP run dry Damaged O-ring
1- N1 N2 bearing support misassembly at prior SV

NOEC 10 5 – Fuel Qty indication

4- Fire Detection System
1 –Crosfeed Valve

FOD 4

No new field issues driving IFSD rates

Improper Maintenance remains single largest IFSD driver
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TOA Rate: April 2016 – March 2017

CFM56-7B TOA Rate

0,025 19 000 000

18 500 000
CFM Threshold
0,02
18 000 000
TOA per 1k Departures

Departures per Year

17 500 000
0,015
17 000 000

16 500 000
0,01
16 000 000

15 500 000
0,005
Total – 0.0042
Basic – 0.0014 15 000 000

0 14 500 000

Basic TOA Total TOA Engine Cycles 12 M

TOA Rate decreasing for >2 years

0 HPTB TOA’s April 2016 – March 2017
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 ATO Causes: April 2016 – March 2017
Last 12 Months: Engine Flight Hours : 36,297,000; Engine Flight Cycles: 18,388,000
Cause Quantity Status
Engine Control Light/Warning 6 2– FFDPS
2 – NFF
1- T3 sensor
Data for engine:

1- EEC
Tailpipe fire 4 Oil Leakage
Under Investigation 2 High EGT + Stall
HPC Pin Liberation 1 Stall

FOD/Bird Strike 11

Maintenance 6 1– Fuel Pump Run Dry; 2 – Detergent Water Wash

1- Damaged on packing on HMU Supply Pipe Nozzle
1 –Rear Cone Misinstalled ; 1 – HMU gasket damaged
Data for non-engine:

NOEC 6 1– Pitot Tube Clogged; 1 – Slow Acceleration

1- DEU Failure; 1- Low Oil Qty
1- Cowl Anti-Ice; 1- Excessive Lube On BSI Plug
A/C System 2 1 –Runway Excursion; 1- Thrust Lever Angles Mismatched
Crew Error 1 1– No N1 stabilization Before TO

0 HPTB TOA’s April 2016 – March 2017

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Total UER: April 2016 – March 2017

CFM56-7B Unscheduled Engine Removals UER Cause – Top 15 UER Count %

0,05 37 000 000
LPT Stage 1 Nozzle Distress 40 6.5%
36 000 000 High Oil Consumption 40 6.5%
CFM Threshold (0.04) HPT Blade 39 6.3%
0,04
35 000 000
Fan Disk 36 5.8%
Particles In MCD/Screen 32 5.2%
34 000 000
Oil Leak 28 4.5%
UERs per 1k hours

Engine Hours
0,03
33 000 000 Foreign Object Damage 24 3.9%
VSV Actuation Ring 20 3.2%
32 000 000
HPC Rotor Blade (Damage) 18 2.9%
0,02
0,0166 Vibration 17 2.8%
31 000 000
#3 Bearing Forward Air / Oil Seal PTFE
Disbonding 17 2.8%
30 000 000
0,01 Fan Case 14 2.3%

29 000 000 Particles in MCD/Screen - AGB/TGB 13 2.1%

Center Vent Tube 9 1.5%
0 28 000 000 AGB/TGB Other 9 1.5%

Total UER Engine Hours 12 M

Stable UER rate despite increase in #3 FWD seal related HOC

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 Shop Visit Rate: April 2016– March 2017
SV Cause- Top 20 Quantity %
CFM56-7B Shop Visit Rate LLP 424 44.2%
0,12 37 000 000 HPT Blade 113 11.8%
LPT Stage 1 Nozzle Distress 78 8.1%
CFM Threshold 36 000 000
Customer Convenience 59 6.2%
0,1
35 000 000 Lease Return 27 2.8%
SB Compliance 12 1.3%
Shop Visits per 1k hours

0,08 34 000 000 #3 Bearing Forward Air / Oil Seal 37 3.2%

Engine Hours
#3 Bearing Aft Air / Oil Seal 10 1.0%
33 000 000 HPC VSV 25 2.6%
0,06 CVT 18 1.9%
32 000 000
Oil System 17 1.8%
0.033 HPT Nozzle 16 1.7%
0,04 31 000 000
Combustor 15 1.6%
30 000 000 EGT Deterioration 13 1.4%
0,02 #4 Bearing 10 1.0%
29 000 000 Quality - Shop 9 0.9%
Line Maintenance Error 8 0.8%
0 28 000 000 HPC Blade 9 0.9%
201510
201504
201505
201506
201507
201508
201509

201511
201512
201601
201602
201603
201604
201605
201606
201607
201608
201609
201610
201611
201612
201701
201702
201703

Accident / Incident 8 0.8%

HPT Shroud 6 0.6%
EGT 5 0.5%
Total Shop Visit Rate Engine Hours 12 M

LLP and Convenience > 50% of all SV’s

HPTB and LPTN AMM criteria available to manage distressed hardware
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Delay and Cancellation Top Causes: Apr 2016 - Mar 2017
Last 12 Months: Engine Flight Hours : 36,297,000; Engine Flight Cycles: 18,388,000
1200

1000

800

600

400

200

0
fuel leak no oil leak ofbp ecl ffbp FOD eec vibrations hmu
start/inproper
start

600 350
500 300
Fuel Leaks 250 No/Improper Starts
400
200
300
150
200
100
100 50
0 0
No Fault Within Main Fuel HPTACC VSV Starter Air Ignition No Fault Igniter Exciter
Found AMM Pump Valve Actuator Valve Turbine System Found
Supply Starter

FCOM Update realizing D&C and RTG Improvements Boeing/HON released new SAV 1Q17
MFP Seal update coming 3Q17

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CFM56-7B Leading Recommendations

HMU Improvements AGB

73-0194 – Upgrade to P16 Cat 3 (SN 5946 – 8599)
HPC
72-0825 – On wing inspection of IGV actuation ring
72-0617 – Inspect line 3 inserts at SV
72-0564 – New hand cranking pad cover
72-0879 – New line 3 pad/hand cranking pad cover
72-0368, 72-0927 – Line 4 bearing at shop visit

Starter Clamp
Aft Air oil separator 80-0016 – Improved Durability Machined Clamp
72-0904 – 6 weld bead configuration

Fuel Oil Heat Exchanger

EEC Software 79-0026 – New FOHE with Key Locked Inserts
73-0219 – 7BW2 software

HPT Blades
72-0696, 72-0821– HPT Blade Management Plan

2017 CFM56 Symposium Topic

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 Thank You – Grazie

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