Spare Component Ownership Planning for Aircraft Maintenance

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Solution Overview

Problem

In the airline industry, determining the optimal number of spare components required for maintenance and flight operations is challenging, as excess components lead to financial burdens while insufficient spares result in delays, and existing methods lack precision in accounting for complex operational conditions.

Innovation Solution

A system utilizing simulations and mathematical models to calculate the recommended spare ownership number, incorporating factors like repair processes, borrowing between aircraft, scrapping, and shop capacity, with tools like the Shop Pool Calculator and Engines Spares Calculator to provide accurate estimates for spare part availability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If more spare components are acquired to support maintenance and flight operations, then equipment availability is improved, but financial cost increases

Engineering Contradiction:

Improveequipment availabilityVSAvoidspare inventory level

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The system dynamically adjusts spare component parameters (ownership number, inventory levels) based on changing operational conditions, repair statistics, and fleet composition. By continuously updating these parameters rather than using fixed thresholds, the system optimizes the balance between availability and inventory cost.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The system incorporates feedback loops that monitor actual repair outcomes, component utilization rates, and availability metrics. This feedback informs iterative adjustments to spare component strategies, allowing the system to learn from operational data and refine inventory recommendations over time.

Inventive Principle:

Principle #23Feedback

2Reliability

If more spare components are acquired to support maintenance and flight operations, then equipment availability is improved, but financial burden increases

Engineering Contradiction:

Improveequipment availabilityVSAvoidfinancial cost

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

Inventive Principle:

Principle #23Feedback

3Quantity of substance

If fewer spare components are maintained to reduce financial burden, then cost is reduced, but equipment availability and timeliness deteriorate

Engineering Contradiction:

Improvespare inventory levelVSAvoidequipment availability

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The system performs preliminary calculations and simulations to determine optimal spare component levels before implementation. By pre-calculating the impact of different inventory strategies on availability and cost, the system can make informed decisions about minimum necessary inventory levels.

Inventive Principle:

Principle #10Preliminary action

4Device complexity

If traditional methods are used to determine spare component numbers, then simplicity is maintained, but precision in accounting for complex operational conditions deteriorates

Engineering Contradiction:

Improvesystem simplicityVSAvoidspare ownership calculation accuracy

Core Design Contradiction:

Device complexityVSMeasurement precision

Solution Approach 1:

The system replaces manual estimation and simplified calculation methods with automated computational models. By using software-based simulations and mathematical optimization, the system can process complex operational data and repair statistics with high precision without requiring manual intervention.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system creates virtual replicas of the repair process and operational conditions through simulation models. These digital twins allow for testing and optimization of spare component strategies in a virtual environment before implementing changes in the actual operational system.

Inventive Principle:

Principle #26Copying

Data Source

PatentUS10062053B1Spare component ownership planning system and method

Publication Date: 2018.08.28 AMERICAN AIRLINES INC

AI summary

A system and method according to which a recommended quantity of spare engine components is generated. In several exemplary embodiments, the components support aircraft maintenance and flight operations and are designed to be repaired periodically. In an exemplary embodiment, the recommended quantity is a number of available spare engine components that supports the aircraft maintenance operations but avoids excess spare engine components in inventory.