Integrity Service Excellence

Life Cycle Approach

to Maintenance

Planning

Mr. Jim Yankel

HQ AFMC/A4

16 Nov 10

Air Force Material Command

2

Purpose

Discuss the challenge of an effective

"cradle-to-grave" reliability, availability, &

maintainability (RAM) strategy and typical

associated metrics

2

3

Overview

• Background

• Key Policies

• Acquisition Initiatives

• Sustainment Initiatives

• Challenges

3

Background RAM challenges with Military Systems

• Poorly defined or unrealistically high RAM requirements

• Lack of priority on achieving R&M

• Too little engineering for RAM - Inadequate lower level testing at component or subcomponent level

- Reliance on predictions instead of conducting engineering design analysis

- Failure to perform engineering analyses of commercial-off-the-shelf (COTS)

equipment

- Lack of reliability improvement incentives

- Inadequate planning for reliability

- Ineffective implementation of Reliability Tasks in improving reliability

- Failure to give adequate priority to the importance of Integrated Diagnostics

(ID) design influence on overall maintainability attributes, mission readiness,

maintenance concept design, and associated LCC support concepts

4

DODI 8115.02

IT Portfolio Management

30 Oct 2006

Policy Flow Down

CJCSM3170.01C

Sustainment KPPs

1 May 2007

AFPD 63-1, 20-1, and

AFI 63-101, Acquisition

and Sustainment

Lifecycle Mgmt,

3 & 17 Apr 2009

DODI 4151.22

CBM+

2 Dec 2007

Reliability, Availability &

Maintainability Policy

Memo

21 Jul 2008

Logistics Enterprise

Architecture (LOGEA)

24 May 2007

AFI 63-1201, Life Cycle

Systems Engineering

23 Jul 2007

AFMCI 63-1201, Implementing Operational Safety

Suitability and Effectiveness (OSS&E) and Life Cycle

Systems Engineering (LCSE) , 14 Oct 2009

• DOD I 4151.22, Condition-Based Maintenance Plus (CBM+) – 2007

Services shall:

– …pursue CBM+ solutions to sustain and maintain the inherent capabilities of new

and fielded equipment

– Ensure reliability analyses are implemented, including RCM

– Direct PMs to design, develop, demonstrate, deploy, and sustain equipment in

accordance with CBM+ guidance and procedures to achieve required materiel

readiness at best cost

• Young Memo: Reliability, Availability, and Maintainability (RAM)

Policy – 2008

– Understand and document user needs and constraints

– Design & redesign for RAM

– Produce reliable maintainable systems

– Monitor field experience and sustain RAM performance

6

Key DOD Policies

DOD CBM+ Definition

….. “ the application and integration of appropriate processes, technologies, and knowledge-based capabilities to improve the reliability and maintenance effectiveness of DoD systems and components …..

….. uses a systems engineering approach to collect data, enable analysis, and support the decision-making processes ….. ”

Ref: DoD CBM+ Guidebook

7

The AF CBM+ Strategy has always been to use legacy systems as test

beds and feed lessons learned back to acquisition to improve design

AF “To Be” CBM+ Operational View

Development

Mission Planning

Maintenance

Logistics

Integrated Systems Health Management

Data Recorders

Sensor

Data

Remaining

Useful

Life

Data

Manipulation •Pre-Processing

•Feature Extraction

•Signal

Characterization

Diagnostics/

Health

Assessment Determine current

health of system or

subcomponents

Prognostics Project future health of

the system, taking into

account estimates of

past and future operation

profiles RUL

Continuous

Process

Improvement

Inspections

Inspection

Data

Feedback loops in place to allow

continuous process improvement

Fleet

Level Avionics Engines Structures

Condition

Monitoring/

State Detection Compare features against

expected values or

operational limits

System

Level

Key AF Policies

• AFI 63-101 Acquisition & Sustainment Life Cycle Management – 2009

– AF/A4/7 AND AFMC/CC will: Ensure Serialized Item Management (SIM), Reliability

Centered Maintenance (RCM) and Condition Based Maintenance Plus (CBM+) concepts

and functions are developed and implemented as applicable

– PMs/SPMs will: Develop and implement, as applicable, Condition Based Maintenance

Plus (CBM+) functions AND establish an effective quality management system to ensure

product quality (e.g., design, manufacturing, performance, reliability, maintainability, and

military flight operations) throughout the life cycle

– PMs shall collect, report, and analyze sustainment metrics to measure program life cycle

sustainment outcomes that satisfy the sustainment KPP/KSAs defined by the user in

accordance with CJCSM 3170.01, as a minimum, include the following areas: availability,

reliability, cost of ownership, and mean down time (MDT)

9

Key AF Policies

• AFMCI 63-1201 Implementing Operational Safety Suitability and

Effectiveness (OSS&E) and Life Cycle Systems Engineering (LCSE) -

2009

– Implements AFI 63-101, AFI 63-1201 and System Engineering Plan (SEP) impacts

resulting from Weapon Systems Acquisition Reform Act (WSARA, 2009)

– Describes relationship between AF Systems Engineering Assessment Model (SEAM) the

Defense Acquisition Guide Book (DAG) and AFI 63-1201

– Directs SPMs to develop and implement an approach to continually assess, maintain, or

improve a system’s reliability, availability, maintainability and supportability

10

Acquisition Initiatives

• ASC RAM Initiatives

– Process Guide For Systems Reliability, Planning,

Tracking, and Reporting • Defines an approach to improve weapon system reliability

which aligns with the Office of the Secretary of Defense (OSD)

vision to acquire reliable weapon systems that satisfy user

needs with measurable improvements to mission capability at a

fair and reasonable price.

– Weapon Systems Integrity

• Ensures accomplishment of weapon system integrity are

consistent with the paragraphs provided in AFPD 63-1 and

similarly through the implementation of OSS&E as called forth

in AFI 63-1201 and AFMCI 63-1201.

11

Lifecycle Sustainment

Outcome Metrics • Materiel Availability

― A measure of the percentage of the total inventory of a system operationally capable

(ready for tasking) of performing an assigned mission at a given time, based on materiel

condition.

• Materiel Reliability

―A measure of the probability that the system will perform without failure over a specific

interval. Generally expressed in terms of a mean time between failure.

• Mean Down Time

―The average Total Downtime required to restore an asset to its full operational

capabilities. Includes time from reporting of an asset being down to the asset being given

back for operations/production. Modified to mission capable for A/C.

• Ownership Cost

―Provides balance to the Sustainment solution by ensuring that the Operations and

Support costs associated with materiel readiness are considered in making decisions.

12

“The goal for these 4 material readiness outcomes should be established early in the

concept decision process, refined throughout the design development process, and then

carried through as program baseline goals until system retirement.” Bell Memo, 2007

Flow diagram System Reliability Analysis,

Planning, Tracking and Reporting (RAPTR)

Lagging Indicators

Planning • RMI• Reliability funding & schedule

RAM Mgt Strategy

RAM Requirements

Pre MS B

RFP/SS

Post MS B

Track RAM activities against schedule & cost

Post MS C

Internal program tracking of

laboratory & early LRIP lifecycle

outcome metrics

IOC & FOC tracking lifecycle outcome metrics

& reported through DAES

Lifecycle outcome metrics reported

through DAES

ECPS/CCPSassessed against Law, AF Policy,

current RMI Tool

New Capability

Report through PEO to ASC/EN

DAES Reporting

Internal to Program

Leading Indicators

Execute RAM Mgt Strategy

(Update RMI)

13

• Aircraft Availability Improvement Program

(AAIP)

– AF wide base lining and tracking of Sustainment

KPPs/KSA per AF I 63-101

– Managed at AFMC by the Director of Logistics &

Sustainment

– Required for all non-development programs

– Development programs must have AAIP strategies

documented in the Life Cycle Management Plan (LCMP)

by M/S C

– Additional Sustainment Metric calculation and LCMP

guidance can be found in AFPAM 63-128

14

Sustainment Initiatives

Aircraft Availability Measures

• Mission Area Enterprise View – Dashboard Format based on Aircraft Availability (AA) for MDS

• Weapon System Drill-Down from Mission Area Enterprise View

– Depicting all categories of AA metric

• AA – Aircraft Availability

• NMCS – Not Mission Capable-Supply

• NMCM – Not Mission Capable-Maintenance

• NMCB – Not Mission Capable Both

• UPNR – Unit Possessed Not Reported

• Depot

– Two Bar Charts

• Multi-Year trend (Actual vs. Target)

• Current fiscal year-to-date Non-Availability categories (Actual vs. Target)

• Data Source

– Logistics, Installation, and Mission Support – Enterprise View (LIMS-EV)

• Quarterly assessments

15

Aircraft Availability

16 10WarWar--Winning Capabilities Winning Capabilities …… On Time, On CostOn Time, On Cost

AA Slide #1

Aircraft Availability Glide Slope

Standard Ops

NMCS Initiatives

NMCM Initiatives Depot Possessed Initiatives

BPNR Initiatives

30

40

50

60

70

80

90

100

FY03 FY04 FY05 FY06 FY07 FY08 FY09 FY10 FY11

Perc

en

tag

e A

A AA STD

%

Standard Ops

AA Initiative Summary (FY11-16)

•Availability to the

•Warfighter increased

•≥ 5.0% by FY16

• 18.4 a/c

17

•NMCM

•Reduce by

•≤ 8.0 a/c

•UPNR

•Reduce by

•≤ 1.0 a/c

•NMCS

•Reduce by

•≤ 1.8 a/c

•Depot

• Possessed

•Reduce by

•≤ 7.6 a/c

•NMCB

• Scheduled Inspections – 2.3 a/c

• Propulsion Improvements – 1.5 a/c

• Reliability Centered Mx – 2.2 a/c

• Other Initiatives – 2 a/c

• Depot WIP Reduction – 2.7 a/c

• Quality Improvement– 0.6 a/c

• Workload Planning – 1.5 a/c

• Other Initiatives – 2.8 a/c

• Forecasting– 0.5 a/c

• Supply Chain Improvements– 0.6 a/c

• Cross Cutting Initiatives – 0.3 a/c

• Other Initiatives – 0.4 a/c

• B and Z Time Reduction – 1.0 a/c

•Enterprise View of Aircraft Inspections (EVAI) Initiative

18

Challenges

• Develop guidance delineating the relationships between CBM,

RAM, Life Cycle Management and Systems Engineering

• Eliminate redundancies and enforce the most pertinent policies

• Establish a functional organization responsible for looking across both acquisition

and sustainment (ensure AF I 63-101 is functionally executable)

• Ensure most critical policies are supported with resources/necessary tools

• Provide guidance on priorities in a constrained financial environment

• Lifecycle Management resources

• Product Data Acquisition (PDAQ) - Culture of “don’t buy data” needs to be replaced

with a culture of “contract for or price data at each phase” or justify not doing so

• Engineers need data and tools to support failure mode analysis, RCM, etc

• Dedicated funding needed to support R&M initiatives (RTOC is insufficient)

• Practitioners need guidance (checklists, decision trees, standard language, etc.)

• Future ERP (ECSS) requires standardized data to deliver planned benefits

• Document the high level effects and capabilities necessary to properly generate,

manage, and protect Technical Information