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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.
