Modernizing complex MRO processes
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The document highlights the challenges manufacturers face in managing maintenance, repair, and overhaul (MRO) processes, particularly within the Department of Defense and commercial aviation. It emphasizes the benefits of utilizing a modern electronic Quality Management Solution (QMS) like TIPQA to streamline complex MRO workflows, enhance compliance, and reduce operational costs. A case study demonstrates the successful implementation of TIPQA by a major engine manufacturer to improve their MRO processes while ensuring adherence to various regulatory requirements.
Modernizing complex MRO processes
- 1. 1 MODERNIZING YOUR MRO PROCESSES CAN CREATE A COMPETITIVE ADVANTAGE Presented by TIP Technologies
- 2. Manufacturers Face Complex MRO Processes A huge percentage of the Department of Defense (DoD) budget is allocated for operations and maintenance. This is not surprising, given the number of systems the DOD supports every day. The commercial aviation world faces similar challenges. Massive investments in operations and maintenance are required to maintain their fleets of aircraft and jet engines in peak operating condition. The processes in place to keep equipment up and running are complex, and often lack proper automation.
- 3. A Modern QMS Can Streamline Processes and Improve Outcomes Managing the maintenance or overhaul of complex assemblies with intricate work processes and ever-changing instructions is a frightening task. Use of an electronic based Quality Management Solution (QMS) streamlines and modernizes complex, often error-prone maintenance, repair and overhaul processes, lowering your maintenance expenditures and the overall compliance risk to your organization. A modern Quality Management Solution will provide real-time status of work-in- process to the shop floor, supported by real-time incident support and resolution that can encompass your supplier networks.
- 4. Reduce Complexity to Achieve Improved Results Companies in highly regulated industries will experience immediate impact.
- 5. 5 Robust Inspection Capabilities Provide delivery of inspection measurement requirements, comments and attachments, giving inspectors the power to launch, record, and complete standard and non-standard work instructions where mandatory. Measurable Benefits of Improved MRO Processes Fast and Easy Tracking Modernized and Streamlined Processes Easy, at your fingertips access to detailed tracking or disassembly and reassembly data related to complex products with multiple components and subassemblies. Improved processes create an improved user experience. Access to inspection requirements specified as part of the work the instructions, include data collection and certification requirements.
- 6. 6 Task Planning and Continuous Improvement for Complex Repairs As more tasks become planned over time, the knowledge gained from working on each component is captured and used to improve work instructions for future components, with full revision and change control. Measurable Benefits of Improved MRO Processes Full Integration with Quality and Risk Management Management Alerts and Dashboards Digital tracking, notifications, signatures, and escalations to management ensure that no service incident ticket or Nonconformance is missed. User configurable dashboard provides real- time status with visual alert queues for past due and pending actions. Each service component, and subassembly is carefully tracked to determine if the unit is ready for reassembly. Workflow control at the operation level with skills management and nonconformance status, provide an integrated solution to minimize risk
- 7. Positive Change in the MRO Market Case Study: One of the “Big 3” engine manufacturers had a critical MRO requirement for both military and commercial aircraft parts. The required processes needed to be in full compliance with FAA, EASA, ITAR and others, both internationally and in the US. They chose to partner with TIP Technologies and use its TIPQA solution to effectively manage their MRO processes. The basics of the TIPQA solution when used for repairs starts with bringing in a component for inspection, and then verifying that it has not been tampered with to determine whether it is a warranty or billable repair.
- 8. 8 Operations Become Automated At this point a simple routing is created in the ERP/MES/ Manufacturing platform which automatically flows into TIPQA through the bi-directional interface, and then the component or part is run through 5 basic operations: Initial Inspection 1 2 3 4 5 Testing to Verify Failure Mode Repairs Final Test Final Inspection
- 9. TIPQA tracks the serial numbered units through these processes with a combination of In-Process Inspection, Serialized Test/Inspection, and detailed task plans for the required repair activities. All required skill levels for the FAA, EASA and other certification requirements for employees are validated in the TIPQA Training Management Module as being fully trained, qualified and certified. Data is maintained within the module and is fully integrated throughout the repairs process. Transactional data is being collected using the TIPQA Inspection Modules and is communicated back to the ERP/MES system for generation of accurate, complete, as-maintained records. Effective MRO Tracking Tooling, test devices, and other required equipment traceability data is collected via the TIPQA Gage & Tool Module and validated back to required calibration and re-certification intervals.
- 10. Increased speed of scheduling and estimating Increased accuracy with procedural enforcement Increased quality with fewer errors Re-use of the as-built production configuration from the QMS system within the repair process Re-use of the assembly instructions in the rebuild process Generation of accurate, complete as-maintained configuration records The Return on Investment for MRO Organizations typically see an ROI of one year or less due to: An investment in a best-of-breed Quality Management Solution pays for itself.
- 11. Gain a Competitive Edge with Improved MRO ►Built to support aerospace and defense innovation ►Streamlines Workflows ►Schedules preventative and calibration maintenance activities ►Ease of use saves time and money ►Seamless integrated solution complements an enterprise installation ►Measurable ROI Many industry leaders choose TIPQA for MRO and Quality Operations
- 12. Request a Demo of the TIPQA Solution TIPQA is the undisputed leader in quality. Contact us to learn more about TIPQA Quality Management Solutions Follow us on social media for the latest news on TIP Technologies: For More Information Contact: TIP Technologies (262) 544-1211 www.tiptech.com sales@tiptech.com