Unit 4 Research Project

Unit 4 Research Project

Unit 4:Research Project


Bay maintenance on Extended Range Fuel tanks BUSL 204 Business ethics
HND Aeronautical engineering qcf
Unit 28 Research Project
August Patterson
Fig. 1
Contents
Topic| Page |
Abstract| 3|
Assignment 1:| |
1.1 Formulate and record possible outline project specifications| 4| 1.2 Identify factors that contribute to the process of project selection | 5| 1.3 Undertake a critical review of key references| 6|

1.4 Produce a research project specification | 6|
1.5 Provide an appropriate plan and procedures for the agreed research specification| 9| Assignment 2:| |
2.1 Match resources efficiently to the research questions or hypothesis| 9| 2.2 Undertake the proposed project in accordance with the agreed specification| 10| 2.3 Record and collate relevant data where appropriate| 11| Assignment 3:| |

3.1 Use appropriate project evaluation techniques | 11|
3.2 Interpret and analyse results in terms of the original research specification | 11| 3.3 Make recommendations and justify areas for further consideration| 12| Assignment 4: | |
4.1Use an agreed format and appropriate media to present the outcomes to an audience | 12| Annex contents lists| 13|

Extended Range Fuel Tanks

The Extended Range fuel Tank, ERT, is an aircraft asset that can be fitted to Mk2 and Mk3 Chinooks. It is primarily used to extend the aircrafts effective operational range. There are numerous reasons as to why the ERT was chosen as the subject of this project such as; Aircraft Technicians (SAC - Tech) specialising in airframes and propulsion at RAF Odiham Role bay routinely service and carry out bay maintenance on the ERT’s; Work carried out on the ERT encompasses everything from documentation, health and safety issues, manpower and resource management; other assets maintained by the Role bay may not encompass as many issues; The bay maintains and manages all Chinook role equipment based at RAF Odiham and prior to carrying out bay maintenance on ERT’s, the many requirements and specifications must be taken into account and will form the basis of my project. These include bay maintenance, assessing its repairable state, quality and standards checks and replenishment of consumables stores. This project will look at each of these reasons in greater detail, in the latter stages, and endeavour to propose recommendations of procedure amendments whilst presenting the data in report form and presentation form, using Microsoft PowerPoint.

 LO1 Understand how to formulate a research specification

1.1 formulate and record possible research project outline specifications

1.2 identify the factors that contribute to the process of research project selection 

1.3 undertake a critical review of key references 

1.4 produce a research project specification

1.5 provide an appropriate plan and procedures for the agreed research specification

 Formulate and record possible outline project specifications The Extended Range fuel Tank (fig. 1) is an aircraft asset that is fitted within the cabin of the Mk2 and Mk3 Chinook. It is primarily used to extend the effective operational range of the aircraft. Prior to carrying out bay maintenance on Extended Range fuel Tanks, ERT’s, the many requirements and specifications must be taken into account and will form the basis of this project. These include bay maintenance, assessing the repairable state of the ERT, quality and standards checks and replenishment of consumables stores. Bay maintenance is carried out on the ERT every two years, if the tank has not been stowed off aircraft for longer than six months, or every six months whilst the ERT is in storage. However, bay maintenance can be avoided whilst the tank is in storage if the technician who carried out the preventative maintenance filled the tank with AVTUR fuel, at a minimum of five per cent of the maximum capacity of the ERT. ERT records such as serial number, location and state are entered and stored into the station Role bay database (Annex 1). Each ERT is issued with its own Equipment conditioning label MoD 731 (Annex 2) and tracked using the Lifed Item Tracking System (LITS). The date the ERT is due bay maintenance can be ascertained manually using its 731, or highlighted to the LITS user in the aircraft 700 forecasts. When the ERT becomes unserviceable (U/S) or due bay maintenance, it is returned to the station Role bay. Upon receipt of the ERT, a qualified technician will carry out various examinations, as well as the necessary preventative and/or corrective measures to ensure that the ERT made serviceable, meets the high standards specified by aviation requirements. This work is carried out in accordance with the relevant Aircraft publications (AP106B-0102-6, Extract of procedure is available in Annex 4) wearing the correct Personnel Protection Equipment (PPE). All work carried out is documented in the bay job card log book 700c, on the MOD form 707A (N/O/A) and 707B(Annex 3). If an ERT has deteriorated beyond economically viable repair limits (as stated in AP106B-0102-6) it is cannibalised and scrapped, then removed from the Role bay database and LITS. A new ERT is assembled from the serviceable parts salvaged from the scrapped ERT, if any, and from the new parts taken from the spares located in the ERT consumable stores known as KAN BAN (Figure 2). The Role bay database and LITS are updated to reflect the correct state of the ERT. At any 24hr period there must be a minimum of 2 serviceable ERT’s held in the bay and ready to issue. These measures ensure that everything is utilised to its entirety and that the bay will meet the station and operational demands for serviceable ERT’s. Quality and standards checks are carried out by a Junior Non Commissioned Officer (JNCO) or higher rank. All work carried out on the ERT’s are recorded in the relevant 707B paperwork and require an over signature from a JNCO or above. All costs for works carried out on the ERT’s are covered at public expense by the MOD however it is imperative that resources are utilised to its maximum and wastage is kept to a minimum. This can reduce maintenance costs. Fig. 2

1.2 Identify factors that contribute to the process of project selection A Senior Aircraft Technician (SAC - Tech) specialising in airframes and propulsion at RAF Odiham Role bay would be inclined to choose a project topic that they regularly carry out and are deemed competent. The bay maintains and manages all Chinook role equipment based at RAF Odiham. The Extended Range fuel Tank was chosen as the subject of this project because it is routinely serviced and bay maintained. The work carried out on the ERT encompasses everything from documentation, health and safety issues, manpower and resource management. Other assets maintained by the Role bay do not incorporate as many issues.

1.3 & 1.4 Undertake a critical review of key references and produce a research project specification Monitoring methods:
As briefly described in 1.1, the ERT MoD 731 or LITS are used to monitor the serviceability and bay maintenance date of the ERT. The 731 is the hard copy record of the ERT which details the bay maintenance date, the life expiry date, the serial number and partial service history. A MoD 731 will always accompany the ERT whether it is issued/returned from/to the bay, where as LITS is the soft copy which is available to all users with the LITS terminal.

Operating Methods:
Operating methods are carried out in accordance with Air publications (AP106B-0102-6 Annex 4) and documented in MOD form 707B (Annex 3). The generic procedure that is carried out on a ERT due bay maintenance is as follows. * ERT is returned to the bay U/S or due bay maintenance. * JNCO will raise the job in the bay card job book 700c on the MOD form 707A (N/O/A). * JNCO will task a technician to carry out work.

* Technician will update the process control board (PCB Fig. 3) prior to work. The PCB in the ERT cell is a physical representation of the state of ERT’s in the bay, ERT’s issued to squadrons and ERT’s that are out of area (OOA) i.e. in theatre. * Technician will carry out various examinations, and affect the necessary preventative and/or corrective measures to produce a serviceable ERT. * All work carried out on the ERT will be documented by the technician in the MOD form 707B and over signed by the JNCO. * Upon completion of works technician will update the process control board. Carry out stock check on ERT KAN BAN. Order parts required to replenish KAN BAN and tidy up ERT cell. * JNCO will close and co-ordinate MOD form 707B and update the Role bay database. At all times the PCB should reflect the Role bay database.

Fig. 3
Procedure on updating the PCB
* When the ERT is received the serviceability state is amended. * ERT serial number, and SNOW number obtained from 707A, is entered into work in progress box. * Serviceability magnets are swapped over with tag work number to indicate that the ERT is being worked on. Risk analysis:

Each task carried out in the bay has a risk assessment and ‘Control of substances hazardous to health’ (COSHH) assessment and risk assessment (ref. to Annex 5), which must be read prior to any work being carried out. Lines of communication:

There are various lines of communication open to anyone that is trying to ascertain the serviceability status and location of ERT’s. As stated previously, the Equipment conditioning label MoD 731 and LITS not only contain the dates for bay maintenance and life expiration but also contain the partial and full service history of the ERT. This gives the technician a history of where the ERT was installed/removed, when it was installed/removed, who installed/removed it and a short description of why it was removed. This enables the technician to better understand the fault allowing efficient and effective diagnosis and to affect the correct rectification procedures.

Project group: Roles and responsibilities of individuals within the project group Bay maintenance carried out on a ERT requires a team of three personnel made up of a JNCO and two qualified technicians. The technicians generally carry out all maintenance work whilst the JNCO supervises.

The technicians must:
* Read and adhere to ‘control of substances hazardous to health’ (COSHH Annex 5), risk assessments (Annex 5) and Safety handbook (JSP (F) 395) before carrying out any work. * Ensure that correct PPE is worn at all times.

* Ensure that adequate levels of spares and consumables are available prior to starting the task. * Ensure all tools are tagged out in the correct manner. Upon completion of the task they are to ensure all tools are returned and ERT KAN BAN are replenished to the acceptable levels. * Ensure the Role bay database and PCB are updated.

 Project Development and Implementation for Strategic ManagersThe JNCO must:
* Raise the job in the bay card job book 700c on the MOD form 707A (N/O/A). * Provide 100 per cent supervision.
* At the end of each stage of maintenance the JNCO will provide an over signature on form 707B in accordance with (IAW) AP106B-0102-6. * After bay maintenance has been carried out, the JNCO will carry out a quality and standards check on the asset before closing and co-ordinating the job cards 707B and 707A. All work must be carried out in accordance with relevant Air Publications (AP106B-0102-6) and documented in job cards 707A and 707B. All work is carried out to the highest of standards. Aim and targets:

Our aim is to supply the demand for Extended Range fuel Tanks to all Chinook squadrons at RAF Odiham and hold in store a minimum of two serviceable ERT’s ready to issue. We target to carry out bay maintenance on an ERT within a maximum of eight hours allowing the possibility for any unforeseen complications.

1.5 Provide an appropriate plan and procedures for the agreed research specification The general operating plan of carrying out bay maintenance on a ERT is outlined in 1.3 operating methods. The maintenance work carried out on the ERT is in accordance with AP106B-0102-6 documented in MOD forms 707A and 707B (Annex 3). Personnel allocate a maximum of eight hours to produce a serviceable ERT. An estimated timescale for the bay maintenance of a ERT is found below.

Time (minutes)| Task|
30| Read relevant APs, COSHH and risk assessments. Tag out relevant tools and don correct PPE.| 5| Update PCB|
240| Carry out bay maintenance IAW AP106B-0102-6 on ERT.| 60| Complete paperwork, update Role bay database and PCB. Replenish KAN BAN stock (if req.)| 5| Return all tools and tidy ERT cell.|

| |
Note this is an estimation of bay maintenance carried out without complications showing a total estimated time of 5 hours and 40 minutes. As discussed in 1.1 and 1.3 the quality assurance systems, quality plans and monitoring plans.
LO2 Be able to implement the research project within agreed procedures and to specification

2.1 match resources efficiently to the research question or hypothesis

2.2 undertake the proposed research investigation in accordance with the agreed specification and procedures 

2.3 record and collate relevant data where appropriate

2.1 Match resources efficiently to the research questions or hypothesis This section and all points have been covered in 1.3 – Produce a specification for the agreed project.

2.2 Undertake the proposed research investigation in accordance with the agreed specification and procedures MOD form 707B illustrates actual time taken to carry out bay maintenance on the Extended Range fuel Tank Serial No. ODI/ERT/155. To illustrate the appropriate techniques for generating solutions, monitoring development, maintaining and adapting project plans and record of development/progress we have the 6s checklist and Issues and ideas capture sheet. The actual time taken to carry out bay maintenance (7 hours) is slightly longer than the estimated time (5 hours and 40 minutes) but within the maximum time allocated for bay maintenance. The actual timescale is documented in MOD form 707B (Annex 3). The task took longer because the flexible bladder contained inside the ERT had pulled away from the rigid housing. Although the rectification work to the bladder was minor adhesive used, to re-attach the bladder to the rigid housing, took an hour to cure, which contributed to a severe time penalty. Ensuring the ERT stack is taken out in the correct orientation and at an angle that will not adversely affect the flexible bladder was found to provide a solution to reduce the lengthy process currently used. The solution came in the form of a stencil. The stencil or outline of where the ERT should be placed under the overhead gantry, to ensure the integrity of the ERT bladder, was spray painted onto the floor the ERT workshop. Illustrated in Fig. 4

Fig. 4
The 6s checklist (Annex 6) is a procedure that is carried out every fortnight to ensure that project plans and timescales are maintained. After monitoring development, the issues and ideas capture sheet (Annex 7) is utilised by the technician to propose an adaptation to the procedures, which have been carried out in order to reduce the current timescales, man-hours and wastage of resources. 2.3 Record and collate relevant data where appropriate

All work that was carried out was recorded on the 707B job card that was raised from the 707A (N/O/A) entry as shown in the annexes. Prior to carrying out the work the ERT was allocated using the Role bay database. On completion of the task the database and PCB was updated to correlate the information found in the database.

LO3 Be able to evaluate the research outcomes

3.1 use appropriate research evaluation techniques

3.2 interpret and analyse the results in terms of the original research specification

3.3 make recommendations and justify areas for further consideration

3.1 Use appropriate project evaluation techniques
The technique used to evaluate the project is mentioned in 1.1 and 1.3 - Operating methods. Use of the Role bay database enables the user to view the ERT stock levels of the RAF Chinook fleet. The Role bay has a responsibility to maintain and service ERT’s. A procedure of how to use the Role bay database is outlined in Annex 8. The colour-marking guide enables the user to identify the state and location of the ERT. The column labelled bay maintenance indicates the due date and highlights red when overdue. Most importantly the database gives the user a visual indication of the number of ERT’s serviceable and confirms that there is enough to supply the demand required by squadrons and the amount required in store.

3.2 Interpret and analyse results in terms of the original research specification The team set out to provide 18/27 squadron with eight serviceable Extended Range fuel Tanks and two held in store ready for issue. Keeping a minimum of two serviceable ERT’s in store ensured that in the event that two of the eight ERT’s on squadron were damaged or unserviceable we would be able to instantly supply the squadron with serviceable ERT’s, thus keeping the aircraft operational. Furthermore, allocating eight hours to carrying out corrective and preventative maintenance on the ERT enables four technicians working a single shift to restock the stores to required levels. The team were able to carry out bay maintenance in 7 hours on a ERT. This time was over the estimated time of 5 hours 40 minutes but within the allocated time of 8 hours. The knock on effect of the degradation of the bladder seal was the reason for taking an extra 1 hour 20 minutes. This is the only maintenance on the ERT that would incur a heavy time penalty. Therefore we can assume that if the squadron requested two ERT’s, the bay would be able to supply that demand as well as producing the two serviceable ERT’s to be kept in store within the 24-hour period enabling us to achieve the projects targets and aims. 3.3 Make recommendations and justify areas for further consideration The issues and ideas capture sheet mentioned in 2.2 allows us to make recommendations and ensures that there is continual improvement to the way procedures are carried out. These recommendations/amendments to procedures is forwarded to the relevant parties who asses and, if found necessary, implement the changes. After working on ERT’s it was noted that if the ERT stack was removed at an angle not perpendicular to the base of the ERT the bladder seal would slowly start to perish. Having to carry out rectification to the bladder on top of the bay maintenance wasted time, resources and manpower. Therefore it was recommended that the stencil be made of the placement of the ERT under the overhead gantry, which would ensure correct removal of an ERT stack whilst carrying out bay maintenance. This was implemented and ensures that the bay remain efficient when carrying out maintenance tasks on ERT’s.
LO4 Be able to present the research outcomes

4.1 use an agreed format and appropriate media to present the outcomes of the research to an audience

Use an agreed format and appropriate media to present the outcomes to an audience Microsoft office power point 2007 was used to present a power point presentation to the Role bay chain of command. Please refer to Annex 8. All records of work carried out, data, results and procedures are shown in annexes and are discussed thoroughly in previous sections.

Annexes
Annex 1 Station Role bay database
Annex 2 Equipment conditioning Proforma MoD form 731
Annex 3 707A and 707B
Annex 4 Extract of bay maintenance procedure
Annex 5 Control of substances hazardous to health
Annex 6 6s check list
Annex 7 Issues and ideas capture sheet
Annex 8 Power point presentation 


 Unit 26: Facilitating Change in Health and social care

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