Up Time Magazine - February/March 2009 - (Page 37) Once the rogue components were identified and resolved, it was possible to surplus 20 of the spares. Each computer cost approximately $12,000 (US), so the cost of acquiring the excess inventory totaled around $240,000 (US). Of course, when components are sold on the surplus market, only a small fraction of the initial outlay is recovered. fault each time it is installed and the problem is resolved when that specific serial number is removed from service. The final step is to provide the OEM with the in-service data pertaining to the rogue component, so the shop test can be amplified to identify that particular failure when components are returned for repair in the future. effectiveness of various optimization initiatives, such as Six Sigma, Lean, Lean Six Sigma, and the like. Rogue components have also proven to be a significant contributing factor in causing those initiatives to fall short of expectations – but since they are so well hidden, everything else takes the beating. Thomas Carroll has been involved with aviation maintenance since 1972, where he served seven years in the USAF as an Avionics Instrument Systems Specialist. After that he joined US Airways, working in the Instrument Shop and the Avionics Maintenance Control department. He was the first Component Reliability Engineer in the company, and then was promoted to Manager of Reliability Engineering, where he overhauled all the existing reliability programs and processes. He established the reliability program at NetJets, Inc. and is currently serving as Director of Maintenance Technical Services. He has spoken on the subject of component reliability and performance measurement at industry meetings and conferences, written articles for several publications, and conducted training classes at OEM component repair facilities and aircraft manufacturing sites. Rogue Component Control Given the fact that rogue components will develop, what can be done? The first step is to develop a good record keeping process, capturing maintenance events and tracking components by part and serial number. Then a rogue component surveillance program needs to be developed, that will flag individual parts by serial number that experience repeated consecutive short in-service periods. Once the program identifies potential rogue components, the next step is to separate them from those that appear to be fully functional. A review of the system maintenance records will show a bona fide rogue component has manifested the same system Conclusion If the asset management program utilizes repaired, reconditioned or overhauled components, it is inevitable that rogue components will develop. Their negative impact will ripple across many facets of the organization. If that unique component failure is not identified and resolved, the rogue population will continue to grow, compounding the negative effect. Detailed record keeping will provide the foundation for building a comprehensive rogue component identification and control program. In addition to minimizing their effect across the organization, this program will also be the catalyst for improving the Announcing the NATIONAL TECHNICAL TRAINING SYMPOSIUM (33rd ANNUAL MEETING) Vibration Institute A NOT-FOR-PROFIT CORPORATION June 23-26, 2009 Hilton Harrisburg Harrisburg, Pennsylvania ONE-DAY TRAINING Time Waveform Analysis and Signal Processing Measurement and Analysis of Rotor Vibrations KEYNOTE ADDRESS The Development of Powered Machinery Dr. Neville F. Rieger Monitoring Applications Signal Processing Vibration Analysis Journal Bearing Analysis For information: Phone: (630)654-2254 Fax: (630)654-2271 Email: vibinst@att.net www.uptimemagazine.com Gearbox Analysis Rotor Dynamics Electric Motors Isolation and Damping See Web Site: http://www.vibinst.org for details THE VIBRATION INSTITUTE 6262 South Kingery Highway, Suite 212 Willowbrook, Illinois 60527 37 http://www.vibinst.org http://www.vibinst.org http://www.uptimemagazine.com
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