PRODUCT SUPPORT
GENERAL DATA
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Founded in Turin (ITALY) in 1978, SIPAL is the Engineering Company of the FININC S.p.A. Group since
1988 and represents in the national scene a strong and reliable partner, in both civil and military field.
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SIPAL is now active on the market in four main application areas:
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Product Engineering
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Manufacturing Engineering
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Integrated Logistic Support
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Civil & Infrastructure Engineering
GENERAL DATA
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SIPAL’s Turnover
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2013 > € 28.500.000 (+28%)
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2012 > € 20.500.000 (+27%)
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2011 > € 16.150.000
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2010 > € 15.100.000
SIPAL’s Employees
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More than 320 employees
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90% Technical Degree (Master & Bachelor)
OFFICES
GALLARATE
OPERATIONAL SITES
BOLZANO
CASSOLA
TORINO
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Via Caorsana, 79 - Piacenza
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Via Affile, 102 – Roma
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Via Calabria, 56 - Roma
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Via E. Gianturco, 23 - Napoli
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Via Grotta delle Fate, 41 - Livorno
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Corso Europa,3 - Grottaglie (TA)
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Viale Francia, 11 - Lecce
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C.so Giuseppe Garibaldi, 62 - Foggia
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Largo G. Camussi, 8 - Gallarate (VA)
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Via Monte Verena, 58/60 - Cassola
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Via Enrico Rainusso, 144 - Modena
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Via Volta, 06 - Bolzano
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Via Valdilocchi, 15 - La Spezia
PIACENZA
MODENA
LA SPEZIA
LIVORNO
FOGGIA
ROMA
GROTTAGLIE
NAPOLI
LECCE
HEADQUARTER
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Via Invorio, 24/A - Torino
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C.so Trapani, 71 - Torino
CLIENT PORTFOLIO
CLIENT PORTFOLIO
ENGINEERING ACTIVITIES
INDEX
LOGISTICS ENGINEERING & TECHNICAL PUBLICATIONS
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Introduction
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Spare Parts
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General Features
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Technical Publications
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RAMS Analysis
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Logistics Support Analysis
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LSA Process / DBL Organization
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LSA Process Application
•  System Study
•  CI Identification
•  MTA
•  Output
•  LCC / LORA
•  FMEA/FMECA
Process
Task Details
Implemented tools
LOGISTICS
ENGINEERING
INTRODUCTION
“…The essential condition for an army to be able to
withstand the strain of the battle is an adequate
stock of weapons, petrol, and ammunition. In fact,
the battle is fought and decided by the quartermaster
before the shooting begins. The bravest men can do
Logistics engineering was developed in
nothing without guns nor ammunition; and neither
military fields in order to provide support to
guns or ammunition are of much use in mobile
troops during war. It took root in the civil
warfare unless there are vehicles with sufficient
petrol to haul them around…” E. Rommel
sector in the early ’60 and aims at the
delineation of a maintenance program and
at appraising replacement warehouses of
any complex product.
GENERAL FEATURES
LE is the engineering discipline that mainly analyzes and designs the Integrated Logistics Support (ILS) of complex systems.
The expected analyses within ILS are of two kinds:
•  Concurrent engineering: during an item’s development, the
obtained synergy enable the quality improvement of the end-item
regarding efficiency and reliability;
•  Product support with the purpose of integrating and providing all
the necessary elements to guarantee an increase of operative
availability and a fair decrease of maintenance costs throughout
its entire lifespan.
RAMS ANALYSIS
The Logistics Engineering’s main objective is to work on manufacturing processes and provide support
regarding the end-item under analysis, optimizing the following activities:
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Quality analysis of furnished product;
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Easiness and low cost of the maintenance activity;
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Reliability and Availability;
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Operative and maintenance safety.
RAMS ANALYSIS
RELIABILITY
Guarantee a service continuity of the system
being designed, produced, or managed
AVAILABILITY
DESIGN
MANUFACTURE
MAINTENANCE
Minimize downtime, optimize production and
simultaneously ensure the efficiency of
“pending” systems
MAINTAINABILITY
Guarantee the prompt restoration of damaged
components
SAFETY
To produce while minimizing operator,
population, and environment risks
RAMS ANALYSIS
RAMS
RELIABILITY AVAILABILITY
MAINTENANCE SAFETY
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Logistic Breakdown Structure
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FMEA & FMECA (Failures Modes Effects & Criticality Analysis)
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Reliability
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FTA (Fault Tree Analysis)
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Availability
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Hazard Analysis
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Maintainability
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Testability Analysis
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MTA (Maintenance Tasks Analysis)
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Safety Analysis
LOGISTIC SUPPORT ANALYSIS
The Logistics Support Analysis (LSA) is the ILS discipline aimed to assess the ideal logistics support for the
end-item under analysis, by identifying:
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Candidate Items for the maintenance tasks;
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Maintenance tasks of preventive and corrective traits;
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Spare parts, equipment, and skilled personnel required for the maintenance tasks;
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Effective support at minimum cost;
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Ensure the timely provision of technical support under warranty (On site – Off site).
LSA PROCESS - LCC/LORA
Outputs resulting from LSA activities:
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List of candidate items for maintenance tasks;
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Maintenance Program;
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Spare parts and equipment list;
enable to verify if the Life Cycle Cost (LCC) and the Level Of Repair Analysis (LORA) reflect the desired results
and, mostly, if they meet what was foreseen by the LSA.
After aligning the information gathered, we hold all the necessary elements in order to begin the study and the
appraisal of the replacements needed for the item support during its life cycle.
MANUFACTURING ENGINEERING - AEROSPACE & DEFENCE
ALENIA AERMACCHI EF2000 ACS T/S
TRANSPORT TROLLEY
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Technical Manuals
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IPL/IPC;
• 
Technical Publications
LSA PROCESS - DBL ORGANIZATION
DATA INPUTS
FROM
ENGINEERING
CUSTOMER
REQUIREMENTS
DATA INPUTS
FROM
SUPPLIERS
END ITEM UNDER
ANALYSIS
CANDIDATE ITEM
LIST
LSA TAILORED
FIELD
RETURN
END ITEM - LSAR
MAINTENANCE
PLAN
TRAINING
REQUIREMENTS
MAINTENANCE
PROCEDURE
REQUIREMENTS
TOOLS AND
GS&TE
REQUIREMENTS
SPARE PARTS
REQUIREMENTS
SPARE PARTS - CALCULATION
In order to properly carry out an appraisal of the spare parts associated with a product it is necessary to define:
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An operative reference scenario;
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Ongoing premises and warehouse monitoring;
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The operative availability of the system;
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The respect towards the established maintenance program;
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An efficient and effective first level help desk;
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The management of field returns.
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Clear contracts with subcontractors;
THE APPRAISAL OF REPLACMENT LISTS IS NOT AN EXACT SCIENCE!
SPARE PARTS - CALCULATION
Usually, the calculation algorithm implemented for the calculation of the replacement lists is the Poisson
Algorithm. In order to obtain always more accurate data in relation to our expectations, and mostly to the
operative maintenance of the system, it is necessary to integrate the algorithm into the following correction factors:
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Need to comply with the economic budget;
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Replacement criticality;
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Timing of the replacement procurement by subcontractors;
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Replacement cost;
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Batch of replacement supplies
TECHNICAL
PUBLICATIONS
LSA - PROCESS
INPUT DATA
Engineering Data
(2D and 3D Drawing, EBOM,
Tech Pub
Specification, Field Survey)
of similar
templates
LSA
Data Base
Corrective maintenance tasks, programed
OUTPUT DATA
maintenance, replacement parts, equipment,
maintenance personnel, timing to perform
tasks, consumable materials.
Technical Specification
MIL-STD-1388-2B
TP (TECHNICAL PUBLICATIONS) PROCESS
OUTPUTS OBTAINED WITH PUBBLISHING TOOLS
Data Modules Drafting
(Compiler
and technical designer)
FLIGHT
MANUAL
DM1
DM3
DM4
PARTS
CATALOG
DM1
DM3
DM5
MAINTENANCE
MANUAL
DM1
DM2
DM3
Standard Output:
•  Pdf version of
manuals;
•  IETP (Interactive
Electronic Technical
Publications) in html
format.
CSDB
Common Source Data Base
DM1
DM2
DM3
DM4
Simulated Validation:
•  simulation on the object,
without running procedures
DM5
On-object Validation:
performance on the
maintenance object.
Validation
Process
LSA TASK DETAILS
To use LSA means:
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To identify a CIL (Candidate Item List) for each helicopter system based on the data resulting from engineering
such as technical designs, VENDOR manuals, ATP (Acceptance Test Procedure), data related to components’
MTBF;
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To realize a logistics breakdown based on CIL;
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To create the MAC (Maintenance Allocation Chart): identify maintenance tasks associated with each item,
replacement parts, consumable materials;
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To create the MTA (Maintenance Task Analysis): based on specific needs obtained during the implementation
of maintenance tasks, identify and indicate to engineering any special equipment necessary to carry out the
maintenance tasks;
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To carry out Reverse Engineering: point out design issues related to the maintenance activities;
TECH PUB TASK DETAILS
TO DEVELOP
TECH PUB
MEANS
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Based on data originated throughout the LSA activities, Technical Pubblications are developed in accordance with
the AECMA Spec1000D regulation.
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The specific approach is aimed at the «breaking» of information regarding traditional paper-based publications in
easily accessible units called Data Modules (DM) and at reusing this information in diverse manuals.
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The produced files have the LSA data as their input and the data modules in sgml-xml. format as their output.
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The DM are uploaded with a CSDB (Common Source Data Base) which will be implemented for the assembly of
the requested publications.
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Technical Publications realized in accordance with the S1000D regulation are in html format and can be empoyed
both stand-alone and on the web.
IMPLEMENTED TOOLS
The MY-TOK© suite is a complete solution for managing all aspects of the technical documentation life cycle,
from control to management, editing, printing and display.
The suite is made up of independent but highly integrated
modules
MY-TOK© CSDB - Document flow validation and management
MY-TOK© Printer - Hard copy
MY-TOK© LSA - Logistics Management in accordance with MIL-SPEC-1388-2B
MY-TOK© IPC - Illustrated Parts Catalogues management
MY-TOK© Viewer - Web content viewer
BUSINESS CASES
CLIENT
PROJECT
AM-X
TECHNICAL PUBLICATIONS
AIRCRAFT MAINTENANCE MANUAL
ILLUSTRATED PARTS CATALOGUE
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Spare Parts Catalogue
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NATO Coding
Maintenance Manual (all systems)
IETM / IETP
•  AMX IETP-P with plug-in web oriented
!
BUSINESS CASES
CLIENT
PROJECT
TRENO ALTA VELOCITA’ ETR1000
ATTIVITA’ DI MANUALISTICA
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Cataloghi illustrati delle parti di ricambio
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Manuali di manutenzione di 1° e 2° livello
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Manuali per il personale addetto alla condotta
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Tracciabilità difetti e requisiti
Documentazione per ricerca guasti
BUSINESS CASES
CLIENT
PROJECT
GAMMA ESCAVATORI GOMMATI
ATTIVITA’ DI TECHNICAL PUBLICATIONS
PRODUCT SUPPORT
USE AND MAINTENANCE MANUAL
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Bollettini tecnici
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Codifica Nato
Libretti di uso e manutenzione
Workshop Manuals WORKSHOP MANUALS
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Manuali di riparazione
ILLUSTRATED SPARE PARTS CATALOGUE
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Cataloghi parti di ricambio
BUSINESS CASES
CLIENT
PROJECT
EUROFIGHTER TYPHOON
ATTIVITA’ DI TECHNICAL PUBLICATIONS
ILLUSTRATED PARTS CATALOGUE
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AIRCRAFT MAINTENANCE MANUAL
(using S1000D Rules)
S2000M IPL and relative illustrations
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OPERATING MANUALS
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Flight Manual
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Performance Data Manual
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Mass and Balance Manual
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Check list Manual
General Vehicle Manual
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Job Guide Manual
General System Manual
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Wiring Manual
Schematic Diagram Manual
Air Battle Damage Repair Manual
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Structural Repair Manual
BUSINESS CASES
IPL/IPC AND TECHNICAL PUBLICATIONS
PREPARAZIONE ED EROGAZIONE CORSI PER
for AGE and Equipment
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(Selex Galileo, Lital, Microtecnica, Sicamb, MPG)
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NATO Coding
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IETM / IETP
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IETP for AMI (Alenia Aeronautica)
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National Publication Base Management
(Alenia Aeronautica)
MANUTENTORI
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Airworthiness activities
(attività di certificazione per aeronavigabilità)