Systecon takes LORA (Level of Repair Analysis) to the next level

6 November 2014

Level of Repair Analysis (LORA) is a method of analysis used to determine where to repair each component in a system, and whether it is more cost effective to discard an item rather than attempt to repair it. For a large system over many years, significant cost savings can be realized if the right decisions are made.

A number of years ago, Systecon introduced an entirely new way of approaching LORA by optimizing the entire logistics solution simultaneously. Now, we introduce an enhanced LORA-XT module –one of the big news in the next version of Opus Suite. For example, the LORA process may reveal that replacing a component involves a real cost that is hundreds of times greater than the purchase price, when all costs are considered (maintenance staff, testing equipment, inventory, shipping, etc.). If this item is replaced frequently over the course of many years, this presents an opportunity to save money by adjusting the repair process to generate economies of scale (improve reliability, component repair, etc.)

Using LORA, a complete system support solution can be developed. It determines where to perform the required maintenance, what resources must be available to perform the maintenance, and what type of support the logistics infrastructure must be capable of delivering throughout the operational life of the system. For this reason, LORA is one of the most important types of analysis performed prior to the introduction of a new system. For instance, the method is prescribed by the United States Department of Defense, and naturally this is one of the reasons we are focusing on enhancing the LORA-XT functionality in Opus Suite.

Much has been written about the LORA methodology, and a lot of it is accessible on the Internet. The old American standard, MIL-STD-1390, is still a living reference document, even though the standard as such was cancelled back in 1997. The Aerospace and Defence Industries Association of Europe (ASD) is conducting some standardization work, and the classic LORA methodology is described in some detail in their specification 3000L for Logistic Support Analysis. Systecon recently assisted Saab in preparing a corporate manual to support Saab's various business units in customizing the LORA methodology for each individual project.

One major limitation of the traditional LORA methodology, which has been used in developing logistics solutions for a long time, is that it is based on considering one component at a time. This approach can work well when implementing a smaller system within an existing large, symmetrical organization. However, when implementing an entirely new major system, such as a new aircraft fleet, a new series of ships or a new fleet of vehicles, or when the maintenance needs of the organization arise quite asymmetrically, there is a strong risk of locking in suboptimal solutions. Only being able to see individual components one at a time with no overall assessment also means that it is difficult to predict how different decisions will work together and impact the total cost. With a new aircraft fleet, for instance, what's best for the engine may not be what's best for the whole aircraft, or aircraft fleet.

For this reason, Systecon introduced an entirely new way of approaching LORA by optimizing the entire logistics solution simultaneously. Instead of starting with each individual component and its maintenance needs, we started at the other end – how much flight time does the airline want, and at what cost? Instead of making a large number of sequential calculations, Opus Suite reviews all possible solutions simultaneously to identify maintenance measures and calculate optimal solutions based on all available information. Is it more efficient to repair or discard a defective component? What is the optimal place to perform repairs on the different components? How many spare parts of each type are needed, and what other maintenance resources are needed to get the most out of a set budget? We decided to call this more sophisticated approach LORA-XT, and we transformed the meaning of the “L,” from “Level” to “Location.”

However, the current version of LORA-XT contains some restrictions. For instance, the optimization is confined to primary components, i.e., components that are replaced directly in the system. As for components on the underlying indenture levels, the logistics solution must be defined explicitly. Furthermore, the optimization does not take preventative maintenance into account.

Since more of our clients have switched to the LORA-XT module lately, we have been asked whether the current restrictions can be eliminated. This is the main reason why a new, more sophisticated LORA-XT module will take center stage when the next version of Opus Suite is released.

Systecon’s Ph.D. Patrik Alfredsson, the original developer behind the LORA-XT module, is the brains behind the fundamental changes in the model and the development of the algorithms that are now being implemented, and we expect to have more to say about this news at our upcoming User Group in London.