Interiors & Structures

Workshop
Gean Baldochi
Technical Support Manager
Embraer Commercial Aviation

Jean-Philippe Poisson
Program Manager, Customer Support
Zodiac Aerospace

David Rees
Product Support Program Manager
Zodiac Aerospace This information is property of Embraer and cannot be used or reproduced without written permission.
SUMMARY

AGENDA
• Solutions Available
• Escape Slide New Design
• Pax and Service Door Visual and
Lining Access
• Cockpit Door Issues
• Cabin & Cargo Floor Panels
• Cargo Compartment Redesign
• Beverage Maker
• Pilot Seat - Lumbar Support
• Drain Mast Reliability
• Toilet Flush Valve
• Food Tray Table

This information is property of Embraer and cannot be used or reproduced without written permission.
SUMMARY

AGENDA
• Solutions Available
• Escape Slide New Design
• Pax and Service Door Visual and
Lining Access
• Cockpit Door Issues
• Cabin & Cargo Floor Panels
• Cargo Compartment Redesign
• Beverage Maker
• Pilot Seat - Lumbar Support
• Drain Mast Reliability
• Toilet Flush Valve
• Food Tray Table

This information is property of Embraer and cannot be used or reproduced without written permission.
Solutions Available

This information is property of Embraer and cannot be used or reproduced without written permission.
 Solutions Available

Floor edge repair Floor finishing repair FIREX Cabin Floor Fly-by New escape slides

New Header assy

Mechanical Lumbar Support

EMDL- Second Source

Cargo Floor Finishing Lavatory Oxygen Supply PSU Electrical Connectors Ceiling cages
This information is property of Embraer and cannot be used or reproduced without written permission.
Solutions Available

Follow-up
Issue Report Related Main Efficacy
Implementation
Effectivity Publication Expected
(Solution) (E-Forum – Plan Assessment
(Issuance date) Benefits
FIP)

Conclusion: Dec/2013
Sicma Pneumatic Pneumatic Lumbar Efficacy: Expected
PILOT SEAT - SBs: 180-25-017 Chargeable 80% reduction of the
Lumbar Support (Dec/2012) events caused by
170: SN On attrition basis
180-25-018 lumbar support
331and on (Sicma SIL180-06)
Installation of (Dec/2012) Comfort development
F170-25-013 190: SN 461.
new valves for improvement Final Measurement:
481, 484,
better Effective in terms of
489 and on Mechanical Lumbar
pressure Sicma Mechanical project design
stability SB 180-25-023 Chargeable Current Status:
(Jan/2015) Mechanical Lumbar
available
Conclusion: Dec/2013
Cargo
Compartment Avoid flight Efficacy: Expected
Floor Finishing delays/maint 90% reduction on
170: SN 312 Chargeable enance events of panel
(LEXAN) SB 170-50-0009
and on (FOC condition actions due finishing ripping in
F170-25-003 SB 190-50-0009
190: SN 360 expired) to floor panel service
Enhanced (Jul/2010) finishing
and on Current Status:
LEXAN® ripping in Events in the world
Flooring service wide fleet decreased
Solution
79%

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Solutions Available

Follow-up
Issue Report Related Main
Implementation Efficacy
Effectivity Publication Expected
(Solution) (E-Forum – Plan Assessment
(Issuance date) Benefits
FIP)

Conclusion:
Avoid flight Dec/2013
Cargo
Compartment Floor delays/main Efficacy: Expected
Finishing tenance 90% reduction on
170: SN 329,
SB 170-50-0011 Chargeable actions due events of panel
(AERMAT™) 337 and on
F170-25-003 SB 190-50-0010 (FOC condition to floor finishing ripping in
190: SN 480
(Aug/2011) expired) panel service
Enhanced and on
finishing Current Status:
AERMAT™ ripping in Events in the world
Flooring Solution service wide fleet decreased
79%
Conclusion:
SB4A4011-25-429 Aug/2019
SB4A4030-25-428 Slide 170/190 Early Measurement:
Escape Slide Stuck SB170-25-0145 Chargeable / Aug/2017
and Door Stall No events
Jul/2014 Special condition for Efficacy: Eliminate
170: SN 415 pool customers of slide
F170-25-001 events with door stall
More consistent and on stuck/door
SB104003-25-430 and slide stuck.
escape slide stall
SB104005-25-438 Bustle 170/190 Current Status:
performance
SB190-25-0167 FOC until Jul/2024 Operators
Oct/2014 incorporating new
slide.

This information is property of Embraer and cannot be used or reproduced without written permission.
Solutions Available

Follow-up
Issue Report Related Main
Implementation Efficacy
Effectivity Publication Expected
(Solution) (E-Forum – Plan Assessment
(Issuance date) Benefits
FIP)

170: SN 494 Conclusion:

PSU and and on Jan/2017
handset interface 190: SN 696 Early
SB 170-44-0016 No events of
Electrical and on Measurement:
corrosion
connectors F175-25-001 Note: SB SB 190-44-0031 Chargeable Jan/2016
on electrical
revision for Dec/2014 connectors Efficacy: Eliminate
Avoid events of remaining events of electrical
corrosion fleet – connectors water
Jun/2015 ingression
Conclusion:
Jul/2017
AMM25-27-01-04
Early
AMM52-51-01-05 Improved
170: SN 437 Measurement:
Cockpit Door - overall
and on Jul/2015
Installation F190-52-005 Chargeable sequence of
190: SN 680 SB170-52-0063 Efficacy: 85%
Review installation &
and on SB190-52-0048 reduction on Pirep
adjustment
Nov/2014 rate for hinge
failure/difficult
operation.

This information is property of Embraer and cannot be used or reproduced without written permission.
Solutions Available

Follow-up
Issue Report Related Main
Implementation Efficacy
Effectivity Publication Expected
(Solution) (E-Forum – Plan Assessment
(Issuance date) Benefits
FIP)

Portable Fire
Extinguisher PN Comply with
RT-A1200 Not AIPC European
F170-26-005 Chargeable Not Applicable
- Comply with Applicable Sep/2014 Regulation
new authority requirement
requirement
Lavatory Oxygen
Generator SB 170-35-0008 Comply with
175: SN 410
- Comply with F170-35-003 SB 190-35-0008 Chargeable FAA Not Applicable
and on
new authority Jun/2014 requirement
requirement

This information is property of Embraer and cannot be used or reproduced without written permission.
SUMMARY

AGENDA
• Solutions Available
• Escape Slide New Design
• Pax and Service Door Visual and
Lining Access
• Cockpit Door Issues
• Cabin & Cargo Floor Panels
• Cargo Compartment Redesign
• Beverage Maker
• Pilot Seat - Lumbar Support
• Drain Mast Reliability
• Toilet Flush Valve
• Food Tray Table

This information is property of Embraer and cannot be used or reproduced without written permission.
Escape Slide New Design

Issue (E170/E175/E190/E195)
• FWD doors escape slide experienced door stall and pack drop issues

Background Information
• Maintenance interval reduction for FWD escape slide
• TSO SBs 4A4030-25A402 (E170/175) and 104003-25A403 (E190/195) - Released Jul/2011
• 18MO Repacking, slide lacing and lower cover flap replacement
• Does not reset time since overhaul 36 MO
• FAA AD 2011-18-04, released Oct/2011
• ANAC AD 2011-12-01 & AD 2011-12-02 – released Dec/2011

Pack drop Door stall

This information is property of Embraer and cannot be used or reproduced without written permission.
Escape Slide New Design

Final Resolution
• Main design changes
• Release Mechanism - torque tube system
• Lacing release system eliminated – improved release reliability

Current Design Upgraded Design

Packboard

Soft Cover

Release
Mechanism

This information is property of Embraer and cannot be used or reproduced without written permission.
Escape Slide New Design

Final Resolution (Cont’d)

• New design with modified mechanical release mechanism
• No special tooling required for installation
• No modification on door structure
• Bustle attachment redesigned
• Interfaces with hook instead of pins

Mirrored Bustle
E190/E195 AFT PAX

Bustle and Packboard

This information is property of Embraer and cannot be used or reproduced without written permission.
Escape Slide New Design

E170/E175 Slide Configuration E190/E195 Slide Configuration

Current configuration Current configuration New design configuration
similar to the new design (UTAS)

PAX SVC PAX SVC PAX SVC

• New FWD door P/N

• New FWD door P/N • New AFT door P/N
• New AFT door P/N • AFT-PAX is now mirror of AFT-SVC

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Escape Slide New Design

Implementation Plan
• E170/E175 AFT/FWD Doors – UTAS
• SB4A4011-25-429/SB4A4030-25-428 released Jul/2014
• Labor: 01 MH
• Commercial condition: US$5,927 per slide (upgraded)

• E170/E175 Bustle – Zodiac

• SB170-25-0145 released Jul/2014
• Labor: 2 MH per door (considering installation and rework)
• Commercial condition: FOC (10 years) - Bustle Rework
• Option 1: Bustle upgraded during shop visit
• One shipset of rotables will be provided
• Option 2: Rework on-wing (tooling, kits and ZOCI CAM support will be provided)
• Any additional spare units must be purchased

This information is property of Embraer and cannot be used or reproduced without written permission.
Escape Slide New Design

Implementation Plan (Cont’d)

• E190/195 FWD Doors – UTAS
• SB 104003-25-430 released Oct/2014
• Labor: 01 MH
• Commercial condition: $5,927 per slide (upgraded)
• E190/195 AFT Doors – UTAS
• SB 104005-25-438 released Oct/2014
• Labor: 01 MH
• Commercial condition: $5,927 per slide (upgraded)
• NOTE: It is necessary to specify which door the escape slide will be upgraded

• E190/195 Bustle – Zodiac

• SB 190-25-0167-00 released in Oct/2014
• Bustle Rework (FOC – 10 years) – FWD/AFT SVC Doors
• Labor: 2 MH per door (considering installation and rework)
• Option 1: Bustle upgraded during shop visit
• One shipset of rotables will be provided
• Option 2: Rework on-wing (tooling, kits and ZOCI CAM support will be provided)
• Any additional spare units must be purchased
• AFT PAX Door
• New Bustle unit will be provided FOC one per aircraft
• Any additional spare units must be purchased

This information is property of Embraer and cannot be used or reproduced without written permission.
Escape Slide New Design

Maintenance Requirement Improvement

Current
• FWD escape slide
• 18 MO Repacking
• 36 MO Standard Overhaul
• AFT escape slide
• 36 MO Standard Overhaul

New Design
• FWD/AFT escape slide
• 60 MO Standard Overhaul
• Repacking is not required

Overhaul cycle improvement of 67%

This information is property of Embraer and cannot be used or reproduced without written permission.
Escape Slide New Design

Maintenance Values

DESCRIPTION CURRENT SLIDE NEW UPGRADED SLIDE

Overhaul Interval 3 Year Interval 5 year Interval

Life Cycle 15 years 15 Years

Reduced Standard Overhaul Pricing

1st Overhaul : US$ 954
Overhaul Event Average US$4,180
(Only if SB upgrade was performed)
2nd and follow on : US$1,909

MTBUR 60,000 FH 220,000 FH

TAT Undefined 15 DAYS

1st & 2nd FOC

Repack Event Not required
Additional – Chargeable US$2,090/unit

*Pricing shown in 2014 economic conditions – fixed escalation formula for out years

This information is property of Embraer and cannot be used or reproduced without written permission.
Escape Slide New Design

Cost Benefit Expectative Along Equipment Life Cycle

• CASH FLOW – Escape Slide Life Cycle (15 years)

Total operating cost reduction ~45%

This information is property of Embraer and cannot be used or reproduced without written permission.
SUMMARY

AGENDA
• Solutions Available
• Escape Slide New Design
• Pax and Service Door Visual and
Lining Access
• Cockpit Door Issues
• Cabin & Cargo Floor Panels
• Cargo Compartment Redesign
• Beverage Maker
• Pilot Seat - Lumbar Support
• Drain Mast Reliability
• Toilet Flush Valve
• Food Tray Table

This information is property of Embraer and cannot be used or reproduced without written permission.
Pax and Service Door Visual and Lining Access

Issue (E170/E175/E190/E195)
• Main outcomes from E-Jets Door Workshop (Orlando, FL)
• Improvements on access and visual indication ergonomics

Pax & Service Door Visual Indicators

• Transparent lining – proposed by Virgin Australia
• Enlarging visual surfaces and color code change
• Wider angles for better visual coverage
• Trade-off between affecting or not the linings

Transparent cover
Pax & Service Door Lining Access Improvement
• Main/Surrounding lining splitting
• GSE alternative

Girt bar new color code

This information is property of Embraer and cannot be used or reproduced without written permission.
Pax and Service Door Visual and Lining Access

Door Visual Indicator Improvement

• Enlarging visual surfaces and color code change
• Wider angles for better visual coverage

CURRENT DESIGN RESULTED FROM APPLIED SOLUTIONS

Angle modification

Enlarge the indication

This information is property of Embraer and cannot be used or reproduced without written permission.
Pax and Service Door Visual and Lining Access

Door Lining Access Improvement

• Main lining splitting
• GSE alternative – for Pax doors only
• Main Handle can be moved down with door open

FROM

TO
Main Handle can be moved down with door open
(simulates door on ramps)

Main lining GSE alternative

This information is property of Embraer and cannot be used or reproduced without written permission.
Pax and Service Door Visual and Lining Access

Testimonial
• Operator that suggested clear cover has implemented on fleet (Virgin Australia)
• In-house solution
• 2 years operational
• 80% reduction on inadvertent slide deployments
• Cost effective on their perspective

Final Resolution
• Escope agreed with operators during Webex in Oct/2014
• Clear cover
• Embraer is in contact with company that developed the solution to Virgin Australia to verify the
possibility of offering it to other operators
• GSE to simulate door on ramps and allows to lower the main handle
• Easy access
• More effective time on adjustment
• Estimated ~70% labor reduction
• GSE availability schedule under development

Transparent cover
Virgin Australia implemented solution
This information is property of Embraer and cannot be used or reproduced without written permission.
SUMMARY

AGENDA
• Solutions Available
• Escape Slide New Design
• Pax and Service Door Visual and
Lining Access
• Cockpit Door Issues
• Cabin & Cargo Floor Panels
• Cargo Compartment Redesign
• Beverage Maker
• Pilot Seat - Lumbar Support
• Drain Mast Reliability
• Toilet Flush Valve
• Food Tray Table

This information is property of Embraer and cannot be used or reproduced without written permission.
Cockpit Door

Issue 1 (E170/E175/E190/E195) Hinge torsion

• Door difficult to open / close

Investigation
• Main contributors
• Door warp, interference, lack of adjustment and loosen parts
• Hard workload to removal and install the header
• L angle found bent

Upper
hinge
“L” ANGLE Upper
hinge
(BRACKET)
HEADER

GALLEY

Bushing interference Bent angle and galley interference

This information is property of Embraer and cannot be used or reproduced without written permission.
Cockpit Door

Final Resolution
• Cockpit Door installation / Adjustment
• AMM 25-27-01-04 and 52-51-01-05 revision to incorporate - (Nov/2012)
• Improved overall sequence of installation & adjustment
• New information related to shims and spacers
• FIM - Revision (Jan/2013)
• Mechanical failures & Adjustment
• Task 52-51-00-810-805-A - Cockpit Door Hard to Open/Close

This information is property of Embraer and cannot be used or reproduced without written permission.
Cockpit Door

Cockpit Door Improvement

• New hinge with higher tolerances

Ø 10 mm
• New door hinge bushing to eliminate potential interference with header
• Increased robustness to keep bulkhead positioning
• Structural beam keeps the distance between both bulkheads (533,4mm) New Bushing
• New header does not require removal of the cockpit ceiling panel

Structural Beam

New Header angle supports and structural beam

This information is property of Embraer and cannot be used or reproduced without written permission.
Cockpit Door

Implementation Plan
• SB170-52-0063 / SB190-52-0048 - Released Nov/2014 New support to fix cockpit
• Commercial condition: Chargeable and pax ceiling panels
• Labor: 06MH (replacement of current header)

New Header Assembly

This information is property of Embraer and cannot be used or reproduced without written permission.
Cockpit Door - Electromechanical Latch

Issue 2 (E170/E175/E190/E195)
• Cockpit door Electromechanical Latch events related to
• Cockpit door locking/Unlocking intermittently
• Considerable number of unscheduled removals

AS Avionics - EMDL

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Cockpit Door - Electromechanical Latch

Final Resolution
• Current EMDL PN AS-200-00075 has no more room for improvements
• Second source of Cockpit Door Control System developed by Adams Rite
• Keeps the same electrical harness, electrical connections and attachment points
• More robust system avoids damages in case of handle “emergency only“ is used inappropriately
• Additional alternative Lock/inhibit Knob

Alternate Lock Inhibit

Knob (manual) EMDL
Door Lock Idle position
Handle

RCDL
Manual
Lock /
unlock
knob

Reinforced Cockpit Door Lock (RCDL)

Adams Rite - Major components of locking system Alternate Lock / Inhibit

This information is property of Embraer and cannot be used or reproduced without written permission.
Cockpit Door - Electromechanical Latch

Final Resolution (Cont’d)

• Adams Control System incorporated in one operator - May/2014
• Possible configuration between Avionic X Adams

POSSIBLE CONFIGURATIONS
SUPPLIER ITEMS
A B C D

1) CDLCU – Cockpit Control Panel

2) CCP – Cabin Control Panel

AVIONICS 3) EMDL – Electromechanical Latch

4) RCDL – Reinforced Lock

5) Placard

1) CDLCU – Cockpit Control Panel

2) CCP – Cabin Control Panel

ADAMS RITE 3) EMDL – Electromechanical Latch

4) RCDL – Reinforced Lock

5) Placard

Implementation Plan
• Available through AIPC (Since Nov/2012)
• Commercial condition: Chargeable - Labor: 03 MH

This information is property of Embraer and cannot be used or reproduced without written permission.
SUMMARY

AGENDA
• Solutions Available
• Escape Slide New Design
• Pax and Service Door Visual and
Lining Access
• Cockpit Door Issues
• Cabin & Cargo Floor Panels
• Cargo Compartment Redesign
• Beverage Maker
• Pilot Seat - Lumbar Support
• Drain Mast Reliability
• Toilet Flush Valve
• Food Tray Table

This information is property of Embraer and cannot be used or reproduced without written permission.
Cabin & Cargo Floor Panels

Issue (E170/E175/E190/E195)
• Cabin & Cargo floor panels getting damaged during operation

Field examples of Cabin & Cargo floor panels

This information is property of Embraer and cannot be used or reproduced without written permission.
Cabin & Cargo Floor Panels

Immediate Actions
• Technical Publications Manufacturing Instructions – TPMI released Jul/2013
• Increased allowable damage limits areas (SRM 53-01-39) – Nov/2013

PRE SRM Revision POST SRM Revision

New limitations for insert and edge clearance

from 38.1 mm (1.5 in.) to 12.7 mm (0.5 in.)

This information is property of Embraer and cannot be used or reproduced without written permission.
Cabin & Cargo Floor Panels

Immediate Actions (Cont’d)

• SRM allowing operation with soft spot/delamination – Fly-by
• Galley and Aisle Panels – Released in Aug/2014
• Cabin and Cargo panels - Released in Dec/2014
• SRM allowing operation with temporary repair
• Extension (600FC to 6,250FC)
• Update about SRM revision expected by Apr/2015

Fly-by areas from E190 SRM 53-01-39 AD2

This information is property of Embraer and cannot be used or reproduced without written permission.
Cabin & Cargo Floor Panels

Final Resolution
• Cabin Floor Panels
• Panel improvements under evaluation for the most affected areas
• New panel sandwich – To avoid spongy condition
• Improved protection against liquid penetration
• Solution definition expected to be concluded by Mar/2015

DRY AREA WET AREA Potting Insert

This information is property of Embraer and cannot be used or reproduced without written permission.
SUMMARY

AGENDA
• Solutions Available
• Escape Slide New Design
• Pax and Service Door Visual and
Lining Access
• Cockpit Door Issues
• Cabin & Cargo Floor Panels
• Cargo Compartment Redesign
• Beverage Maker
• Pilot Seat - Lumbar Support
• Drain Mast Reliability
• Toilet Flush Valve
• Food Tray Table

This information is property of Embraer and cannot be used or reproduced without written permission.
Cargo Compartment Redesign

Issue (E170/E175/E190/E195)
• Improvements on cargo compartment to address cases of premature failure/deterioration,
difficult operation, exposition to impacts, better access aspects

Final Resolution
• Cargo Compartment Improvements – PSB solutions
• Floor panel trims
• Ceiling cages
• AMS duct cover
• Door hook bracket
• Main expected benefits to the customers
• Ergonomics
• Reliability
• Maintainability Ceiling cages
• Additional Information - Contact your Embraer Account Manager

This information is property of Embraer and cannot be used or reproduced without written permission.
Cargo Compartment Redesign

Floor panel trims improvements

• More robust trim maintaining the current attachment points
• New trim concept will increase the durability of the trims resulting less replacement parts and
minimizing the probability of luggage damages

Current Design Upgraded Design

The joints will be sealed

This information is property of Embraer and cannot be used or reproduced without written permission.
Cargo Compartment Redesign

Ceiling cages improvements

• Eliminated protuberant points
• Resulting in maintenance costs reduction
• Ergonomics improvements for ground personal

Current Design Upgraded Design

This information is property of Embraer and cannot be used or reproduced without written permission.
Cargo Compartment Redesign

AMS duct cover improvements

• Eliminated protuberant points
• Rounded profile can minimize the probability of duct cover damages due to baggage impact
• More robust material improving durability

Current Design Upgraded Design

This information is property of Embraer and cannot be used or reproduced without written permission.
Cargo Compartment Redesign

Door hook bracket improvements

• Improved fixation to stowage the rod – easy handling
• New magnetic concept improves the handling procedure (agility), avoiding jamming
• Parts durability

Current Design Upgraded Design

This information is property of Embraer and cannot be used or reproduced without written permission.
SUMMARY

AGENDA
• Solutions Available
• Escape Slide New Design
• Pax and Service Door Visual and
Lining Access
• Cockpit Door Issues
• Cabin & Cargo Floor Panels
• Cargo Compartment Redesign
• Beverage Maker
• Pilot Seat - Lumbar Support
• Drain Mast Reliability
• Toilet Flush Valve
• Food Tray Table

This information is property of Embraer and cannot be used or reproduced without written permission.
Beverage Maker

Issue (E170/E175/E190/E195)
• One event of smoke during flight in the FWD Galley caused by B/E Beverage Maker (Model 4510-
21UF-00)

Investigation
• Shop findings
• Relay failure (result of a crack on the ceramic substrate)
• More than 10,000 of these relays in the fleet since 2004
• Only one report for this failure mode
• Scenario evaluated by safety engineering
• Risk Index considered low (Severity x Probability + Level of control)
• Embraer will monitor the component behavior in the fleet

Recommendation
• Flight Attendant Manual (FAM) – Fire Fighting Procedures
• Galley Fire or Smoke
• Switch Master galley off (AC power is off)
• Pull the circuit brake (Turn off DC power)
• Wiring check on the aircraft Coffee Maker connector
• WM 25-31-50-01 and WM 25-36-50-1 Removed PC board

This information is property of Embraer and cannot be used or reproduced without written permission.
SUMMARY

AGENDA
• Solutions Available
• Escape Slide New Design
• Pax and Service Door Visual and
Lining Access
• Cockpit Door Issues
• Cabin & Cargo Floor Panels
• Cargo Compartment Redesign
• Beverage Maker
• Pilot Seat - Lumbar Support
• Drain Mast Reliability
• Toilet Flush Valve
• Food Tray Table

This information is property of Embraer and cannot be used or reproduced without written permission.
Pilot Seat - Lumbar Support

Issue (E170/E175/E190/E195)
• Lumbar support inflating/deflating complaints

Investigation
• Re-inflation during flight due to air valve sensitiveness to cabin pressure variations
Final Solution
Original inflatable Lumbar Support Replacement PN F0449997
lumbar (SB 180-25-018) - Chargeable

PN 180300-
180300-930-
930-0 New pressure relief
valves

Lumbar Support replacement Pressure relief valve replacement

(SB 180-25-015) (SB 180-25-017) - FOC
PN F0431133

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Pilot Seat - Lumbar Support

Implementation Plan
• TSO SB 180-25-017 - issued in Dec/2012
• To replace the pressure relief valve (POST MOD SB 180-25-015)
• Commercial Condition: FOC (Expired Dec/2013)

• TSO SB 180-25-018 – issued in Dec/2012

• Introducing lumbar support PN F0449997
• Applicable to pilot seats with lumbar support PRE MOD SB 180-25-015
• Commercial Condition: Chargeable

• Zodiac Seats France SB 180-25-015 (Oct/2011) is cancelled

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Pilot Seat - Lumbar Support

Efficacy Assessment
• Customers who incorporated PN F0449997 were surprised by new behavior
• SIL180-09 was issued to explain proper “normal” behavior
• No self-inflation when back pressure is applied
• If pilot removes back pressure, cushion will slowly inflating
• Pilot should re-adjust using setting button

P/N F0449997

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Pilot Seat - Lumbar Support

New Design of Mechanical Lumbar Support

• New option requires minor modification on the current seat structure
• Lumbar support will be fastened on the backrest new sheet metal
• New support provides a vertical and bending adjustment
• New backrest foam has a specific design in order to fit with the mechanical
• Backrest foam is designed to have the same external shape
• Validated with 03 operators in Sep/2014

Next Steps
• New Design of Mechanical Lumbar Support (optional)
• Zodiac Seats France SB180-25-023 expected by Jan/2015
New Sheet
• Labor: 05 MH
metal
• Commercial condition: Chargeable

Pneumatic Lumbar Support

Lumbar
Support

Mechanical Lumbar Support

Actuator

This information is property of Embraer and cannot be used or reproduced without written permission.
SUMMARY

AGENDA
• Solutions Available
• Escape Slide New Design
• Pax and Service Door Visual and
Lining Access
• Cockpit Door Issues
• Cabin & Cargo Floor Panels
• Cargo Compartment Redesign
• Beverage Maker
• Pilot Seat - Lumbar Support
• Drain Mast Reliability
• Toilet Flush Valve
• Food Tray Table

This information is property of Embraer and cannot be used or reproduced without written permission.
Drain Mast Reliability

Issue (E170/E175/E190/E195)
• Drain mast low reliability

Drain Mast

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Drain Mast Reliability

Investigation
• MTBUR steady at 20,000 FH (L12M – Jun/2014)
• Shop findings analysis
• 16% related to drain mast external damage
• 53% related to the Thermostat - analysis indicate failure caused by corrosion
• High number of drain mast messages on CMC
• CMC messages distribution: 70% FWD and 30% AFT
• Reports of ice formation on the drain mast

This information is property of Embraer and cannot be used or reproduced without written permission.
Drain Mast Reliability

Immediate Action
• Polyurethane Film on Drain Mast
• New tape PN 8663HS to improve protection
• AMM 53-00-40-200-801-A – Fuselage Polyurethane Film – Inspection
• AMM 53-00-40-000-801-A – Fuselage Polyurethane Film – Installation

• CMC Messages - Drain Mast System

• Functional check (AMM Task 30-71-02-720-801-A)
• Troubleshooting for FWD/AFT Drain Mast (FIM 30-71-00-810-80X-A)

• FOC repair in case of functional test fails

• Beyond Economical Repair -> new PN current design
• Valid until the new design is available

Fairing external damage

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Drain Mast Reliability

Solution Proposal
• New design modifications
• Heating element seal
• New Thermostat (improve vibration resistance)
• Sensor re-positioning
Current Sensor Installation
Next Steps
• Halt Test to be conducted at Zodiac facility – Testing to start Mar/2015
• To be performed on the Drain Mast Components
• Sensor / Thermostats / Heater

• New Design In Service Evaluation

• Scheduled to start by Mar/2015
• Conclusion expected by Jun/2015

• Service Bulletin expected by Jul/2015

• Assuming successful ISE conclusion
Proposed Sensor Installation

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SUMMARY

AGENDA
• Solutions Available
• Escape Slide New Design
• Pax and Service Door Visual and
Lining Access
• Cockpit Door Issues
• Cabin & Cargo Floor Panels
• Cargo Compartment Redesign
• Beverage Maker
• Pilot Seat - Lumbar Support
• Drain Mast Reliability
• Toilet Flush Valve
• Food Tray Table

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Toilet Flush Valve

Issue (E170/E175/E190/E195)
• Toilet Assembly PN15800-029A1/A2 removals requiring cleaning restoration only
• Flush Valve PN 14330-230 malfunction in service
• Toilet continuous flushing or not flushing at all

Investigation
• Shop findings revealed that parts are returned due to flush valves stuck/jammed
• Toilet Assembly returned to service after cleaning
• Flush Valve accumulates waste inside housing
• Position indicating proximity switches looses adjustment

Paper and waste build up

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Toilet Flush Valve

Interim Action
• SNL 170-38-0022/190-38-0023 – Flush Valve Cleaning & Maintenance (Sep/2012)
• AMM Task 38-32-15-07 - Vacuum Waste System Lines - Cleaning (Nov/2012)
• FIM Tasks 38-32-00-810-809/810-A included servicing per CMM (Sep/2012)
• AMM Task 38-32-02-07 - Toilet Rinse Valve Screen – Cleaning revision (Jul/2013)

In-Service Evaluation (ISE) Results

• New valve ISE concluded in Aug/2013 – considered not effective
• Waste ingression identified

Final Resolution
• Zodiac developed new flush valve
• Test reached 120K Cycles with good results
• Business disposition to occur by Feb/2015

This information is property of Embraer and cannot be used or reproduced without written permission.
SUMMARY

AGENDA
• Solutions Available
• Escape Slide New Design
• Pax and Service Door Visual and
Lining Access
• Cockpit Door Issues
• Cabin & Cargo Floor Panels
• Cargo Compartment Redesign
• Beverage Maker
• Pilot Seat - Lumbar Support
• Drain Mast Reliability
• Toilet Flush Valve
• Food Tray Table

This information is property of Embraer and cannot be used or reproduced without written permission.
Food Tray Table

Issue (E170/E175/E190/E195)
• Elite Pax Seat Food Tray Tables (PN41191074-XXX) cracks on top surface

Visible crack on the top side (LH/RH) of the tray – pivot assembly

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Food Tray Table

Immediate action
• SIL 41190000-25-61 (Elite Food Tray Tables)
• Visible cracks until 1.25 inches can remain in service

Investigation
• Shop findings analysis
• All returned trays shows cracks at the same location
• A gap is created between the bonded aluminum block and top support rib (plastic skin)
• This gap creates a concentrated stress area initiating the crack

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Food Tray Table

Investigation (Cont’d)
• Production line assy
• Injection molding parameter
• Mold tool includes sharp corner that creates potential failure points
• Inappropriate cleaners can degrade the plastic material

Test Set-Up

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Food Tray Table

Solution Proposal
• New encapsulate pivot block onto cavity of plastic housing
• Block is fully secure all around plastic cavity, eliminating the concentrated stress zone

Next Step
• Endurance test current is ongoing at ZOCI and Embraer facilities
• Solution definition expected by Mar/2015

This information is property of Embraer and cannot be used or reproduced without written permission.
This information is property of Embraer and cannot be used or reproduced without written permission.