An MTU Aero Engines Company

Monitoring, understanding and managing engine data

Maintenance Cost Conference 2017, Panama

Silvan Brandt, Director Marketing & Sales Americas
 An MTU Aero Engines Company

Worldwide network and customer base

∑ 150+ airlines

Headquarters
Service locations and offices

September 2017 IATA MCC conference 2017 - Monitoring, understanding and managing data 2
© MTU Aero Engines AG. The information contained herein is proprietary to the MTU Aero Engines group companies.
 An MTU Aero Engines Company

An airline’s operating costs

Miscellaneous 2%
8% Tickets, sales and service
Fuel 30%
9% Taxes and fees

Engine MRO accounts for

15% A/C ownership 40-50% of an airline’s
maintenance expenses

11% Maintenance
(airframe & engine) Workforce and operation 25%

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© MTU Aero Engines AG. The information contained herein is proprietary to the MTU Aero Engines group companies.
 An MTU Aero Engines Company

ECM benefits: Cost reduction

• Early detection of potential failures to avoid/reduce

o secondary damage
o early shop visits

Operational • Enhanced fleet management

• Reduced maintenance cost

(early detection or shop visit avoidance)
• Lower unscheduled downtime cost
Financial • Optimized on-wing time

• Better shop visit cost estimates

• Improved customized workscoping
• Increased knowledge about engine on-wing behavior
MRO • Optimized shop capacity planning

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© MTU Aero Engines AG. The information contained herein is proprietary to the MTU Aero Engines group companies.
 An MTU Aero Engines Company

The development of engine health monitoring

today

Offline Diagnostics Prognostics Business intelligence

No health Reactive system Pro-active system Big Data analytics based
monitoring based on limited based on predictive on continuous data stream:
data collection algorithms/ snapshots all-encompassing engine data
– and beyond
• Standard shop visits • Tailored solutions • Earlier detection, • Precise forecast for MRO
based on EMM (workscoping) better identification of cost, scrap rates and removal
based on ETM results upcoming problems times
• Removal on
condition (EGT/LLP) • Limited unscheduled • Improved maintenance • Optimized engine/aircraft fleet
or “fly to failure” removals planning and management and operations
workscoping • ETM becomes a major fleet
• Unscheduled
engine removals planning tool
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 An MTU Aero Engines Company

Our system: All-in-one tool Diagnostics Prognostics

Business
Intelligence

Proprietary software based on full thermo-dynamic engine models

Continuous system enhancements
Advanced diagnosis, prognosis and analysis
Substantial experience since 2006
One platform for all engine types*

CF6-50/80C2 V2500 PW2000 CFM56-3/5B/7 CF34-8/10 GE90-110B/115B

* other engine types can be supported on request

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© MTU Aero Engines AG. The information contained herein is proprietary to the MTU Aero Engines group companies.
 An MTU Aero Engines Company

MTUPlus ETM: Automatic diagnosis Diagnostics Prognostics

Business
Intelligence

Automated root cause analysis

1. Pattern matching
Comparison of current trend pattern with
Delta EGT Delta FF Delta N2
historic failures stored in database
Flight reports (0 = newest flight data)

2. Simulation:
Thermodynamic model simulates failure
to determine root cause on module basis

September 2017 Aviation MRO Summit - Engine Trend Monitoring at MTU 7

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 An MTU Aero Engines Company

MTUPlus ETM: Prognosis Diagnostics Prognostics

Business
Intelligence

•Forecast for each flight report EGT margin Prognosis (days)

•Remaining days (cycles) on-wing until

Flight reports (0 = newest flight data)

a specific EGTM threshold is reached

•Smoothed deterioration gradient

calculated on EGTM trend history
Water
•Statistical smoothing excludes outliers wash

•Results for each engine can be

included in the periodical or fleet
ranking reports
2000 days
 Improves fleet management of =7340 cyc
performance (EGT) critical fleets

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© MTU Aero Engines AG. The information contained herein is proprietary to the MTU Aero Engines group companies.
 An MTU Aero Engines Company

MTUPlus ETM: Modular Deterioration Diagnosis Diagnostics Prognostics

Business
Intelligence

Next step: Modular deterioration diagnosis

EGT margin loss

• Diagnostics of module contribution to
Diagnostics Prognostics
performance loss
• Prognostics of future modular behavior

 Goal: Optimize workscope planning for

HPT the whole engine life

Booster
HPC Fan
LPT

Engine flight hour

Aviation MRO Summit - Engine Trend Monitoring at MTU 9

September 2017
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 An MTU Aero Engines Company

MTUPlus ETM: Fleet analysis Diagnostics Prognostics

Business
Intelligence

Workscope-specific deterioration

Deterioration matrix allows for historic data

EGT margin loss since installation

analysis:

WS#1 • fleet average and single engine

WS#2
deterioration rates

WS#3 • shop visit effects (regained performance)

WS#4 • performance information of mature

engines*

cycles since installation

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 An MTU Aero Engines Company

Our vision: Integration of all available data sources

• EGT, Fuel flow, N1 & N2 speed Workscope 

• Deterioration analysis/prognosis Hardware damage pattern 
• Bleed settings, valve positions Engine hardware configuration 
• EGT margin &N2 margin Engine MRO history 
• Thrust de-rate Testcell 
• Vibration, oil data

• Current weather conditions Line Maintenance Info 

• Airport altitudes & runway Mission Profil 
length Utilization Rate 
• Chemical Pollution Operation Region 
• Particle concentration (e.g.
sand, salt)

February 2017 Company overview 11

© MTU Aero Engines AG. The information contained herein is proprietary to the MTU Aero Engines group companies.
 An MTU Aero Engines Company

How will the data help improving operations?

Fleet management MRO management

• Engine fleet decision/growth • MRO

Simulation of performance in current Additional data further improves
mission prognosis of MRO requirements
• Mission change • On-wing services
Simulation of fleet performance under Visualization of services to extend
changed operations on-wing times, if e.g. outphasing is
• Aircraft allocation changed…
Matching of performance and mission
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© MTU Aero Engines AG. The information contained herein is proprietary to the MTU Aero Engines group companies.
 An MTU Aero Engines Company

The future: Our challenges

1. Adapt our IT structure

for growing amounts of
maintenance data
2. Realize an efficient
management of very large
data sets in nearly real-time
3. Generate benefits and
services for maintenance
and engine operation from
additional information w.r.t.
future engine/aircraft data

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© MTU Aero Engines AG. The information contained herein is proprietary to the MTU Aero Engines group companies.
 An MTU Aero Engines Company

Conclusion

Engine trend monitoring

… is a key instrument to improve engine operation and MRO
… faces enormous challenges with the high amount of data to be
analyzed in future
… offers great opportunities for fleet management improvements

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© MTU Aero Engines AG. The information contained herein is proprietary to the MTU Aero Engines group companies.
 An MTU Aero Engines Company

Thank you for your attention!