Transcript Challenges
Air Force Materiel Command
WR-ALC
Maintaining the
Fleet
Maj Gen Polly Peyer
HQ WR-ALC/CC
26 Aug 2010
Integrity Service Excellence
Why Team for the Future?
Due to the rapid pace of technology, the
maintenance of an aging fleet requires teaming with
other organizations within the Government, Industry
and Academia
New technologies are needed to provide additional
capabilities and ensure the warfighter has the means
to defend against challenges from potential
adversaries
Challenges
Increased Aircraft Availability
Reduced costs
Enhanced competitiveness
Improved systems / processes
Added core competencies
Added partnerships
Constrained budgets
Increased Effectiveness
Increased reliability
Reduced maintenance
Improved safety
Enhanced suitability
Facing the Challenges
High Velocity Maintenance (HVM)
C-5 Avionics Modernization Program (AMP)
Systems Integrated Lab Integrated Aircraft
Test Environment
Corrosion Program
F-15 Rewire Program
Versatile Depot Automatic Test System
(VDATS)
High Velocity Maintenance (HVM)
Project Description
Why HVM?
An AFMC-wide initiative to dramatically transform production
operations in support of increasing aircraft availability, seeking
to better emulate industry’s high daily rate of touch-labor
maintenance
HVM examines all processes which impact aircraft
programmed depot maintenance across the enterprise,
including not only product flow, but also funding,
requirements, infrastructure, materiel support, and
information technology
Pilot Platform: AFSOC C-130 Fleet
Program Manager: Mr. Jerry Mobley
Velocity
(hrs/day)
1000
ISO
Stakeholders & Teaming Partners
MAJCOM Customers (AFSOC, AMC, AETC, AFRC, ANG)
AFMC (A4, C-130 SPO, 402 MXW, OC-ALC/HVM, OO-ALC/HVM)
AFGLSC
DLA
Flight Test Squadron
AFRL
Intergraph/AACL (Std Visual Work / PIIs)
Boeing (IETMs)
M1/DERCO (Supply Integrator / Task Kitting)
Robins-Gioia (PDMSS Support)
MERC (Industrial Engineering / Shadow Tools / Simulations)
ICF (Supply Chain Management Services)
Georgia Tech (Transition Planning & CAVE Development)
Simpler (Lean Sensei Support)
HSC ISO
•0
Aircraft Availability
GWOT, Aging Fleets, $ Constraints
Scheduled Maintenance Impacts Aircraft Availability
Inefficient Depot Maintenance Processes
Low velocity compared to Industry
Airline burn rate 500-900 hours/day
Industry
ALC PDM 145-220 hours/day
Velocity
Field and Depot not synchronized
Function as two independent sys
A/C condition not well known
PDM
USAF
Depot
Velocity Mx
Cycle
ISO
Benefits
Increased Aircraft Availability to the Warfighter
Reduced Depot Possessed Time
Dramatically Increased Burn-Rates (Touch Labor Time)
Synchronized Field Inspection & Depot Maintenance Programs
Mechanic-Centric Focus Yielding Greater Production Efficiency
Advance Condition Knowledge Greatly Improving Accuracy in
Supply Forecasting & Lead-Time Availability
Point-of-Use Task Kitting Supporting Mechanics based on
Known Requirements
Integrated Planning, Scheduling, Analysis, & Data Collection
Processes – Result: Actual Requirements Drive Choreographed
Execution of Scheduled Maintenance Tasks
Examples of HVM Technology
Insertion
Mechanic Centric Focus - Redesigned
C-130 maintenance stands
Pre-Planned Work – Task kits
Adherence to Standard Work – Andon system
Aircraft Condition – Pre-induction inspections utilizing borescopes
Automated Access to Tech Orders -Toughbooks for mechanics
Production Control Boards – Touch screen monitors
Fleet Mgt Tool – Eagle Modification Action Plan (EMAP)
C-5 AMP Systems Integrated Lab Integrated
Aircraft Test Environment
C-5 #840059 crash near
Dover AFB on 3 April 2006
402 SMXG participated in
post crash recovery efforts
C-5 AMP flight deck arrives at
Robins on 23 August 2006
Minor construction project
addition to Software
Support Facility Jan 2010
C-5 AMP Systems Integrated Lab Integrated
Aircraft Test Environment (Cont.)
Benefitss:
Establishes an organic independent verification and
validation capability at WR-ALC
Hardware in the loop aircraft test environment improves
fidelity of test
Reduction of in ground and flight testing; therefore
increasing aircraft availability
Improves Core compliance and 50/50
Commercial off the shelf solution
AF Corrosion Prevention and Control Office
Lavatory Assessment
Project Description
Assess the overall impact of corrosion
caused by aircraft lavatory/crew relief
systems
Develop recommendations, and aid
AFMC/CC directed lavatory IPT in
implementing optimal solutions.
Stakeholders & Teaming Partners
Platforms: B-1, B-2, B-52, C-5, C-17, C-130,
E-3, E-8, KC-10, KC-135, RC-135
Partnership: Industry, ALCs, and DoD
Contractors
Way Forward
Ensure lavatory refurbishment is mandated in all
PDM work packages
Recommend immediate action on issues facing
C-5, KC-10, and B-52
Encourage SPOs to actively engage w/field units
and hold annual CPABs
Include lessons learned and AFCPCO early in
future new acquisition process – KC-X
Benefits
Reduce corrosion damage and
repair/replace areas in and around
aircraft lavatory/crew relief systems.
Lavatory Corrosion and
Solutions
B-52 skin repair due to extensive corrosion in lavatory area
Lavatory Corrosion and
Solutions (cont)
Above and below: Typical
cannon plug corrosion under
lavatory
Above: Condemned toilet - Bad field
repair
Above: Possible replacement
for B-52s: C-130J type
Above: Leaking toilet on other A/C set
aside to be reinstalled without repair.
F-15 Rewire (Eagle Division)
Project Description
Replacement of 1970’s-era Kapton wire with new composite
wire in 176 long term F-15C/D aircraft
Estimated cost of program is $683M (engineering, val/ver
kits (3ea), production kits, labor, Wire Integrity Tester (WIT))
Landing gear, wings, some radar cables not included.
Estimated 5,000 man-hour PDM effort
Program Manager: Mr. Reggie Jenkins (WR-ALC/GRMAB)
Engineer: Mr. Alan Byrd (WR-ALC/GRMEA)
Stakeholders & Teaming Partners
MAJCOM Customers (ACC, USAFE, PACAF, AFMC, ANG)
DLA (kits)
Boeing (Engineering, kits)
InterConnect, Inc/Israel Aerospace Industries (IAI) (kits)
Korean Airlines (KAL) (PDM installs )
CK Technologies, Inc. (diagnostic tester)
Status
Three ( 3) validation/verification aircraft completed in CY08-09
of 3 distinct aircraft configurations, CV1, CV2, DV1. Aircraft
have returned to home stations.
Production installs began Oct 09 (FY10), end in FY15.
TCTO 1F-15-1551
7 complete @ WR-ALC, 5 complete @ KAL
5 in work @ WR-ALC, 6 in work @ KAL
Boeing, St Louis on contract for initial 99 shipsets.
Interconnect/IAI on contract for remaining 74 shipsets.
Benefits
Eliminates 30-60 down days per year, per aircraft , for wiring
related maintenance .
Eliminates funding associated with Depot teams required to
replace multiple harnesses/wires as a result of large-scale
burns.
Eliminates 143,520 man-hours of wiring related maintenance
annually.
Eliminates $44M in Line Replaceable Unit (LRU) exchange fees
annually due to false LRU removal.
F-15 Rewire (cont.)
Bay 5 Old Wiring
Bay 5 New Wiring
F-15 Rewire (cont.)
ECS Bay Old Wiring
ECS Bay New Wiring
Versatile Depot Automatic
Test System (VDATS)
VDATS is the standard family of tester
for the Air Force
Currently three different configurations:
DA-1, DA-2, and RF-1
Government owned
Supported Platforms
WR, OO, OC-ALC
B-2
F-15 IFF
F-16 IFF
Global Hawk
LAIRCM
MILSTAR
JSTARS
Space Crypto
CARA
AN/APX-119
Kadena Mini-Depot
VDATS POCs
Name
Joe Eckersley – Section Chief
Matt Mosely-PM
Jonathan Hill-PM
Jeff Burrows-ES
Larry Adams-Eng
Bob Pennington-SIL FLT Chief
Phone #
472-0255
472-0298
472-0308
472-0301
472-0295
468-1307
VDATS Benefits
Test Program Set standardization
Significant reduction in Automatic Test Equipment
(ATE) footprint
24 scheduled ATE replacements
From This…
To This!
Decreasing footprint, Combating obsolescence, and Reducing cost!
Teaming for the Future
• Benefits
– Reduced development and operations costs for the
Government
– Improved technology and capability for Government
– Improved responsiveness to the warfighter
• WR-ALC partnership efforts
– Use government sponsored development efforts
– Increase maintenance partnerships
– Foster performance based logistics solutions
Always seeking Opportunities
What is in the future?
More Joint Efforts
Continuous Condition Monitoring
Integrated systems health monitoring
Aircraft subsystem diagnostics
Prognostics based on existing data
Maintenance Acceleration/Increased Density
Cost reduction
Crack and corrosion detection and prevention
Reduce coating removal time
Bonded repair technology
Depot and maintenance shop improvement
Supply chain enhancements