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April, 2008

Saudi Aramco Aviation System for Aircraft Maintenance. April, 2008. Agenda. Introduction to SAP ERP Key SAP Processes SAP Maintenance Tracking. 4Q99. 3Q00. 2Q02. 3Q02. 4Q02. 2Q04. 2Q05. 4Q01. IS Healthcare. PS. HR. IS Oil, Sales. SAP Core, SCM/PM Big Bang. FI/CO.

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April, 2008

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  1. Saudi Aramco Aviation System for Aircraft Maintenance April, 2008

  2. Agenda • Introduction to SAP ERP • Key SAP Processes • SAP Maintenance Tracking

  3. 4Q99 3Q00 2Q02 3Q02 4Q02 2Q04 2Q05 4Q01 IS Healthcare PS HR IS Oil, Sales SAP Core, SCM/PM Big Bang FI/CO IS-A&D 4.6C TSW&APO, Payroll SAP Implementations for Saudi Aramco • 2007 - Aramco Aviation upgraded to latest SAP version: • SAP Aerospace & Defense Version ECC 6.0 • 400 users across 3 Maintenance Bases

  4. SAP Aerospace & Defense (IS A&D) • Aerospace & Defense Solution has specific enhancements developed to meet the needs of Major Aerospace Operators, Manufacturers and Defense Industry • Aramco Aviation is using SAP Aerospace & Defense Solution as the basis of their Maintenance and Materials Management System

  5. Enterprise Management Strategic Enterprise Management Management Accounting Financial Accounting Corporate Governance Financial Supply Chain Management Business Analytics Sales & Marketing Marketing Service Sales Spare Part Sales Billing & Credit Management Analytics Engineering & Configuration Management Technical Document Management Maintenance Program Management Configuration & Compliance Management Asset Induction & Retirement Asset Health & Predictive Maintenance Reliability & Performance Analytics Enterprise Management Strategic Enterprise Management Management Accounting Financial Accounting Corporate Governance Financial Supply Chain Management Business Analytics Enterprise Management Strategic Enterprise Management Management Accounting Financial Accounting Corporate Governance Financial Supply Chain Management Business Analytics Maintenance Planning Advanced Maintenance & Service Planning Visit Planning Line Maintenance Planning Shop Planning Workforce Planning Sales & Marketing Marketing Service Sales Spare Part Sales Billing & Credit Management Analytics Sales & Marketing Marketing Service Sales Spare Part Sales Billing & Credit Management Analytics Spare Parts & Tools Management Forecasting & Requirements Planning Sourcing & Procurement Inventory & Warehouse Management Rotables Management Warranty Management Tools & Equipment Management Dangerous Goods Management Engineering & Configuration Management Technical Document Management Maintenance Program Management Configuration & Compliance Management Asset Induction & Retirement Asset Health & Predictive Maintenance Reliability & Performance Analytics Engineering & Configuration Management Technical Document Management Maintenance Program Management Configuration & Compliance Management Asset Induction & Retirement Asset Health & Predictive Maintenance Reliability & Performance Analytics Airframe Maintenance Electronic Logbook Discrepancy Handling Production Control Work Execution & Record Keeping Work Closure Maintenance Planning Advanced Maintenance & Service Planning Visit Planning Line Maintenance Planning Shop Planning Workforce Planning Maintenance Planning Advanced Maintenance & Service Planning Visit Planning Line Maintenance Planning Shop Planning Workforce Planning Engine & Component Maintenance Engine Shop Control Component Shop Control Work Execution Subcontracting Work Closure Spare Parts & Tools Management Forecasting & Requirements Planning Sourcing & Procurement Inventory & Warehouse Management Rotables Management Warranty Management Tools & Equipment Management Dangerous Goods Management Spare Parts & Tools Management Forecasting & Requirements Planning Sourcing & Procurement Inventory & Warehouse Management Rotables Management Warranty Management Tools & Equipment Management Dangerous Goods Management Human Capital Management Employee Life-Cycle Management Employee Transaction Management HCM Service Delivery Workforce Deployment Airframe Maintenance Electronic Logbook Discrepancy Handling Production Control Work Execution & Record Keeping Work Closure Airframe Maintenance Electronic Logbook Discrepancy Handling Production Control Work Execution & Record Keeping Work Closure Business Support Procurement Environment, Health & Safety Travel Management Incentive & Commission Management Fixed Asset Management Engine & Component Maintenance Engine Shop Control Component Shop Control Work Execution Subcontracting Work Closure Engine & Component Maintenance Engine Shop Control Component Shop Control Work Execution Subcontracting Work Closure Human Capital Management Employee Life-Cycle Management Employee Transaction Management HCM Service Delivery Workforce Deployment Human Capital Management Employee Life-Cycle Management Employee Transaction Management HCM Service Delivery Workforce Deployment Business Support Procurement Environment, Health & Safety Travel Management Incentive & Commission Management Fixed Asset Management Business Support Procurement Environment, Health & Safety Travel Management Incentive & Commission Management Fixed Asset Management SAP Aerospace & Defense - Solution Map Best Practice - Full Business Suite for IS Aerospace & Defense Enterprise Management Strategic Enterprise Management Management Accounting Financial Accounting Corporate Governance Financial Supply Chain Management Business Analytics Sales & Marketing Marketing Service Sales Spare Part Sales Billing & Credit Management Analytics Engineering & Configuration Management Technical Document Management Maintenance Program Management Configuration & Compliance Management Asset Induction & Retirement Asset Health & Predictive Maintenance Reliability & Performance Analytics Maintenance Planning Advanced Maintenance & Service Planning Visit Planning Line Maintenance Planning Shop Planning Workforce Planning Spare Parts & Tools Management Forecasting & Requirements Planning Sourcing & Procurement Inventory & Warehouse Management Rotables Management Warranty Management Tools & Equipment Management Dangerous Goods Management Airframe Maintenance Electronic Logbook Discrepancy Handling Production Control Work Execution & Record Keeping Work Closure Engine & Component Maintenance Engine Shop Control Component Shop Control Work Execution Subcontracting Work Closure Human Capital Management Employee Life-Cycle Management Employee Transaction Management HCM Service Delivery Workforce Deployment Business Support Procurement Environment, Health & Safety Travel Management Incentive & Commission Management Fixed Asset Management

  6. Aviation SAP - Solution Map Asset Induction Aircraft/Parts/ Equipment Engineering & Planning Work Execution Reliability & Warranty Corporate Finance Materials Management Maintenance Program Management Update Counters Warranty Management Cost Controlling Aircraft Master Data Alteration & Configuration Control Hangar & Line Maintenance Reliability Management Financial Reporting Equipment Master Data Work Packaging & Scheduling Refurbishment Surplus/ Disposal Project Planning Project Execution Deferred Work Management

  7. Aviation Key SAP Process Overview

  8. Key SAP Processes • Manufacturer & Regulatory Service Info & Directives Management • Aircraft Maintenance Item (AMI) • Aviation Maintenance • Configuration Control • Line Maintenance • Component Repair • Parts Management • Tools Management • Reports • Quality Control

  9. Key SAP Processes • Manufacturer & Regulatory Service Info & Directives Management

  10. Manufacturer & Regulatory Service Info & Directives Management • SAP is used for recording all applicable: • Service Bulletins/ Service Letters/ Service Changes etc. • Airworthiness Directives • Creation of Routine/Non Routine Work Forms • Integration to Maintenance Planning

  11. Key SAP Processes • Manufacturer & Regulatory Service Info & Directives Management • Aircraft Maintenance Item (AMI)

  12. Aircraft Maintenance Item (AMI) AMI is the SAP representation of the Planned Aircraft Maintenance task. It Defines: Applicability - Links task to Aircraft Fleet/Tail Intervals/Frequencies: Threshold & Repeat Days/Flight Hours/Cycles/APU/RINs etc. Communicates to Maintenance Planning to schedule a task

  13. Regulatory Directives & MFG Service Documents AMI’s SAP TDR SAP AMI Manufacturer Regulator SB/SL/etc. AD Hardcopy Filing Tech Library Engineering Engineering Non- Applicable Applicable All TDR Applicable AMI SAP Maintenance Planning

  14. FAA Inspection Programs AMI’s Applicable SAP (PRT) Document SAP AMI Manufacturer Regulator Operator FAR&AWL Tasks & Intervals MFG Tasks & Intervals Service Experience Hardcopy Filing Non-Applicable QC-Tech Advisory Group Task Card Package Free Running/ Out of Phase AMI SAP Maintenance Planning

  15. SAP PRT SAP AMI MFG Inspection Programs AMI’s Regulator Manufacturer Operator Service Experience FAR&AWL Tasks & Intervals MFG Tasks & Intervals Hardcopy Filing Non-Applicable Planning Applicable Task Card & Inspection forms Package Free Running/ Out of Phase AMI SAP Maintenance Planning

  16. Key SAP Processes • Manufacturer & Regulatory Service Info & Directives Management • Aircraft Maintenance Item (AMI) • Aviation Maintenance

  17. Aviation Maintenance Planned Maintenance (Mx) Aircraft Maintenance Item (AMI) (Represents a Task in SAP) Maintenance Task List (Task Card) Hierarchical Task List (Tasks for Check Interval) Maintenance Plan (MP) Routine/Non Routine Workcard: Notification (Workcard Issuance) Work Packaging Work Order (Workcard Completion)

  18. Unplanned Maintenance (Mx) Unplanned Mx - Squawks/Work Arising Log Entry/Routine/Non Routine Workcard: Notification (Workcard Issuance) Work Order (Workcard Completion)

  19. Key SAP Processes • Manufacturer & Regulatory Service Info & Directives Management • Aircraft Maintenance Item (AMI) • Aviation Maintenance • Configuration Control

  20. Configuration Control • Identification of Technical Objects • View of Current Aircraft Structure • Fit/Remove/Swap with Integration to Materials Management and Maintenance Planning • Traceability/History Recording

  21. Configuration Control Current Aircraft Configuration Functional Locations Aircraft Registration N737A Serial number 30181 N737A Air Conditioning N737A-21 N737A-21-20 Actuator N737A-71 Engine Location Equipment Engine Fan Inlet LP Interm. Comp Diffuser Material • All Aircrafts and Assemblies • Fully represented in SAP as • Technical Objects HP Drive Turbine LP Drive Turbine

  22. N737A Configuration Control SAP has Full Traceability of Rotables • Scheduling of Maintenance • Plans Stopped/Started by Fit/Remove • Transactions for Time Controlled • Items Removal 03.20.08 Installation 01.01.07 Usage list 01.01. - 03.20.08 N737A 05.06. - 03.20.06 N738A

  23. Key SAP Processes • Manufacturer & Regulatory Service Info & Directives Management • Aircraft Maintenance Item (AMI) • Aviation Maintenance • Configuration Control • Line Maintenance

  24. Line Maintenance • Defect Capturing – capture all defects in the form of SAP Notifications • Planning and Execution of all Line Maintenance Tasks Defect capturing Defect Analysis Release to Service Routine Maintenance Defer defects Analyzed defects ExecutionPlanning Execution Planning Certification Material requirements Spare Parts Provisioning

  25. Key SAP Processes • Manufacturer & Regulatory Service Info & Directives Management • Aircraft Maintenance Item (AMI) • Aviation Maintenance • Configuration Control • Line Maintenance • Component Repair

  26. Aircraft • Management of Rotables Repair • Management of Serviceable/ Unserviceable status • Integration to Materials Management for key processes of: • Stock Management • Exchange • Refurbishment • Subcontracting Install Component Repair Dismantle Stock Scrap Procurement Serviceable Unserviceable In-house Repair External Repair

  27. Component Repair Complete work order cycle recorded in SAP Notification 1 Part No. Serial No. Date Description Malfunction 2 Planning Operations Material Internal/external resources Tools Scheduling Order release Capacity leveling Shop Papers Availability check 3 Execution Planned/unplanned material withdrawal External procurement 4 Completion Time confirmation Order settlement Technical completion Business Completion 5 History Material usage, orders, notifications, usage list

  28. Key SAP Processes • Manufacturer & Regulatory Service Info & Directives Management • Aircraft Maintenance Item (AMI) • Aviation Maintenance • Configuration Control • Line Maintenance • Component Repair • Parts Management

  29. Parts Management • Serial number tracking/history (Equipments) • Manufacturer part number - Interchangeable Parts: 1-Way/Restricted/Full Interchangeability Configuration Interchangeability Procurement Interchangeability Planning/MRP Interchangeability Consignment IPC Actual Configuration FFF-Class FFF-Class MPN MRP Set 1 MPN MRP Set 2 Selection Valid Configuration Procurement PART-A PART-D Supplier Stock PART-B PART-E PART-C Allowed Configuration FFF-Class Leading parts Maintenance engineer Material planner Sales

  30. Parts Management • Full Integration from Maintenace Processing to • Materials Management in SAP Material require-ments planning Procurement Maintenance Stores / stock Maintence Work Order Creation Direct Charge/Service requests Material reservatn. MRP flag Material requirmnt.planning Material provision Purchase requisition Planned Material Order Order processing Shelf Life Cont. Order completion Purchase order Material issue Goods receipt Invoice receipt

  31. Key SAP Processes • Manufacturer & Regulatory Service Info & Directives Management • Aircraft Maintenance Item (AMI) • Aviation Maintenance • Configuration Control • Line Maintenance • Component Repair • Parts Management • Tools Management

  32. Tools Management Special Tools Managed in SAP via Maintenance Plans: Scheduling of Maintenance Requirements Calibration Scrapping

  33. Key SAP Processes • Manufacturer & Regulatory Service Info & Directives Management • Aircraft Maintenance Item (AMI) • Aviation Maintenance • Configuration Control • Line Maintenance • Component Repair • Parts Management • Tools Management • Reports

  34. Fully Customizeable Reports) SAP Reports Cost Controlling Compliance Information Systems List Edit Goto View Extras Settings System Help ALV WBS-Element Act. Network CCenter Cost Element Actual Costs P.1234.1000 10 6004056 1000 400000 10,000.00 P.1234.1000 20 6007843 1000 420000 12,000.00 P.1234.1000 30 6009977 1000 450000 23,000.00 *1000 10 1000 45,000.00 P.1234.1000 20 6003433 1200 600000 30,000.00 P.1234.1000 30 6005678 1200 240000 36.000,00 *1200 1200 620000 66,000.00 **P.1234.1000 111,000.00 10 1200 24,000.00 20,000.00 4731 10 COPC-FINI-2 1200 40,000.00 36,000.00 4745 10 COPC-CONFIG-1 36,000.00 Maintenance Due Dates Structures ProgressAnalysis Order ReportsReservationsPurchase RequisitionsPurchase OrdersStock/Requirements List

  35. Key SAP Processes • Manufacturer & Regulatory Service Info & Directives Management • Aircraft Maintenance Item (AMI) • Aviation Maintenance • Configuration Control • Line Maintenance • Component Repair • Parts Management • Tools Management • Reports • Quality Control

  36. Role: Inspector Activities: Review task completion Perform quality checks Certify airworthiness / release aircraft to service Inspector Quality Control Certification • Objectives: • Meet regulatory requirements • Duties: • Review task completion • Perform quality checks • Aircraft Work • Closing and Sign off for Work Order • Configuration Control

  37. Quality Control Release to Service for Aircraft/Components • Set completion status • Notification • Order • Revision • User status for Serviceability • Functional Location • Equipment

  38. SAP Aviation Maintenance Planning

  39. Maintenance Plans • A maintenance plan contains the information for maintenance tasks to be performed on a regular basis and for automatically creating maintenance notifications. • It consists of: • One or several maintenance items: • Technical objects to be serviced (e.g. Tail number, Equipment) • Maintenance schedule • Frequency/Offset • Maintenance tasks to be performed • Task List

  40. MaintenancePlans • SAP has an enhanced scheduling program • Forecasting of Future Maintenance Dates • Adjustment of Future Maintenance Dates • Change Log • Change documents created for all changes to maintenance plans/items/schedules

  41. Due Dates are adjusted 221 Cycles A1 Check A2 Check 124h 40 Day A1 40 Days A2 221 Cycles A3 Maintenance Plans • Performance basedcheck • approach for A/C Maintenance • Dynamic Scheduling • Checks occur according • to Counter Sequence • or Calendar Plan Performance Time 221 Cycles 221 Cycles A3 Check 124 h 124h 124 h 40 Day 40 Day

  42. Maintenance Scheduling Traffic Light warning System in place for early warning as Due Dates get closer. If overdue: Red – A/C immediately OOS Planned Routine Work Maintenance Plan Counters Notification Notification Scheduling Check A2 Check A1 02/14/2008 01/05/2008 • Maintenance Plans are scheduled daily to update planned dates based on A/C performance • System forecasts future planned • notifications based on Annual estimate • for flying hours 221 Cyc A1 221 Cyc A2 124 H 124 H 40 Days 40 Days Check Intervals

  43. Work Packaging (Base Maintenance) SAP Maintenance Event Builder (MEB) • MEB is SAP’s function for Packaging & Sequencing of Maintenance Requirements: • One tool for displaying all outstanding maintenance requirements for: • Aircraft • Fleet • Planning of work packages early in advance to: • Efficiently combine outstanding maintenance requirements • Ensure regulatory compliance • Central monitoring of critical maintenance requirements • Elimination of redundant tasks within work package • Automatic sequencing of tasks according to project plan

  44. Manuallycreatedfrom MEB Revision • Revision number • Planning plant • Description • Functional Location • Dates / Times • Responsible work center / Plant • PS Network • Status Management • Change documents Work Packaging • Revision • Revision represents work package to be performed during one maintenance event – Maintenance Check

  45. Maintenance Event Builder Maintenance Event Builder Scheduled Maintenance Project Network Directives Revision Notifi cations Output: Work Order Creation Deferred Work Task Lists / Task Cards • Automatic generation of Work Orders • Allows unpackaging for further deferral

  46. THANK YOU

  47. Flight Hours Recorded

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