data management as the key to prognostic capability · six-sigma is achieved via incremental...
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Fly – Fight – Win
Headquarters U.S. Air Force
1
Data Management as the Key to Prognostic
Capability
Mr. Russ AlfordWarner Robins Air Logistics Center
System Sustainment Division13 Nov 2007
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2Fly – Fight – Win
IT Strategy/Expeditionary Combat Support System (ECSS)IT Strategy/Expeditionary Combat Support System (ECSS)AF Smart Ops (AFSO21) Change Management (CM) AF Smart Ops (AFSO21) Change Management (CM) CapabilityCapability--Based Programming (CBP)Based Programming (CBP)
eLog21 Campaign Initiatives
Product Supportand Engineering
• Total Life Cycle System Management
• Prod Supt Camp• AAIP
• Condition Based Maintenance+
• Asset Marking and Tracking• Demand Management• Product Life Cycle Mgmt
Logistics EnterpriseArchitecture (LogEA)Logistics EnterpriseArchitecture (LogEA)
PortfolioManagement
PortfolioManagement
Air ForceData Strategy
Air ForceData Strategy
Performance ManagementPerformance Management
ARCHITECTURE & GOVERNANCE
Centralized Asset Management
Centralized Asset Management WorkforceWorkforceAgile Combat Support (ACS)/Assured ConnectivityAgile Combat Support (ACS)/Assured Connectivity
ENABLING PROCESSESENABLING PROCESSES AND TECHNOLOGYAND TECHNOLOGY
• Integrated Planning System (IPS/APS)
• AFFVESA, JPPC-AF, ACP-AF, NWC Consolidation
• Purchasing Supply Chain Management (PSCM)
• Next Gen Log Read Sdqn• Strategic Distribution• Weapon System Supply Chain
Management
Supply Chain Management
• WFHQ/ Agile Combat Support C2
• AF Common Operating Picture
• A4/7 COP• Decision Support Tools
Expeditionary Operations and C2
Maintenance, Repair and Overhaul
• Maintenance Strategic Plan
• Repair Enterprise 21• Single Off-Equip Net
• Re-engineering Depot Maintenance (DMT)
• AF Lean Maintenance Enterprise Integration
Global Log Supt Center
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3Fly – Fight – Win
Future Process Model
Seamless end-to-end supply chain operations delivering the right support, at the right price, in the right place, at the right time -- every time
Seamless end-to-end supply chain operations delivering the right support, at the right price, in the right place, at the right time -- every time
Integrated ProcessesIntegrated Processes
Optimized ResourcesOptimized Resources
Integrated TechnologyIntegrated Technology
Enterprise ViewEnterprise View
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4Fly – Fight – Win
Improve warfighter capability by transforming AF Logistics' business processes and leveraging ongoing initiatives & capabilities that IT can deliver today
Objectives
Establish near real-time modernized information system
Apply best commercial practices
Utilize COTS based solution
Plan and execute obsolete legacy retirement (~250 systems)
Increase equipment availability by 20%
Reduce annual O & S cost by 10%
ECSS Program Overview
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5Fly – Fight – Win
COTs Lessons Learned
Past COTs attempts have generally failed
Weak governance and functional oversight
Didn’t really understand the business processes
Little or no change management and training
Immature products & undercapitalized vendors
No incentives to implement
Data cleanup effort under appreciated & under valued
Limited testing and test environment
Same lessons observed in Industry MUST ADDRESS TO SUCEED MUST ADDRESS TO SUCEED
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6Fly – Fight – Win
Maintenance Data Collection
Data is collected to serve a process not just to collect dataEngineering and Product DataProduction and QualitySupply Chain
Maintenance data quality is poor but so is all of our dataFat fingering, discipline, lack of edits, interfaces
Maintenance data is underutilized – mostly reactiveMissing key elements e.g. IUID and depot inputsProcesses do not drive to use of data e.g. engineering
Near and Long term efforts underway to address maintenance data
This problem and solutions are not limited to maintenance data
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7Fly – Fight – Win
Data Improvement Initiatives
Understanding the Problem:AFMLA and AFMC/A4 conducting a studies on mx & supply data to help guide the clean up of legacy data
Addressing Fat fingers:IT driven improvements are/will help improve near term collection e.g. CAMS GUI, POMX, REMIS Edit rehosting
Addressing DisciplineIUID Implementation will address serialization needs Product Life Cycle Management (PLM) initiative addresses product data clean up and conversion ECSS dramatically changes production & quality data
ERPs demand a significantly more disciplined data approach than anything we have ever done
Addressing UtilizationD&SWS Life Cycle System Engineering – Sustainment is driving a relook at what we collect and how we use it
Predictive use – RCM, Condition Based Maintenance, et al
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8Fly – Fight – Win
AFLMA Near Term Efforts
AFMLA Data integrity study of IMDS & REMISBounding and prioritizing the quality issues Developing repeatable process to support ECSSCapturing the functional impact of data quality issuesBenchmarking the level or effort to identify, recommend and act on data quality issuesDefining remediation criteria (Fix-Now, Fix prior to or during ECSS Migration, Fix after migration to ECSS)
Focus on Metrics DataIdentify near-term process or technology improvements in reporting accurate status and utilization informationAddress lead-time ECSS data migration issues
Collaborating with ECSS on a common method and toolbox
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9Fly – Fight – Win
The AIT Enabled Data Collection
AIT eliminates the need to collect the what (item/part, IUID, location, time, date, description, quantity, etc.)
The human in the loop captures the how (receipt, shipment, removal, install, disposal, etc.)
The technology feeds the airman information vs. the airman feeding the technology data
Manufacturers/Suppliers
Transportation/Supply/Theater
Depots/TDCsPOEs/PODsDistribution
Centers/Depots Customers
PASSIVE ACTIVE PASSIVE
Minimizes human inputs: Data is captured not entered
Bar CodeBar Code
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10Fly – Fight – Win
Product Life Cycle Management (PLM)
Centralized Data Management for:TOsBOMsDrawingsIllustrated Part break-downRepair Manuals & ProceduresKey Performance ParametersRequirements & Specifications Interchanges and Substitutions
Standardizes Data Management Processes across commodities
Stores data for root-cause and product improvement analysis and planning
Demands AF & OEM Integration and digital technical data vs. paper
MRO
Design
CollaborationSupply
Chain
Collaborat
ion
OEM
Collaborat
ion
Workflow &Process
Management
Secure Access Control
ProductStructure
ConfigurationManagement
Product DataVault
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11Fly – Fight – Win
ECSS Legacy Deconstruction
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12Fly – Fight – Win
ECCS Impact on Data Collection
Deconstruction and Transformation
ECSS must be initialized with clean data from the legacy environment
Not all data for ECSS is equal
Not all Legacy Data will be Migrated
99.9999 should be the long-term quality goal
Six-Sigma is achieved via incremental Good-enough's
Start with the most unforgiving data sets
Understand and Manage the impact of quality compromises
Fix the process and the data
Manage Functionals and IT by Metrics
Clean data is an Air Force ResponsibilityClean data is an Air Force Responsibility
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13Fly – Fight – Win
Technical Control & Management: Technical & Design Reviews, Architecture, Tech Maturation/DEMO, Tech Measurements (KPP, TPM, Metrics), Decision Analysis, Certifications, Ops Monitoring, Deficiency Reporting, Training.Inspection & Maintenance: RCM Updates, FEMCA Updates, Reviews, TO Updates (-6 & -06), Workspec & MRRB Updates, CBM+, Prognostics, RAM, System Monitoring, System Performance Analysis.
Systems Engineering
Weapon System Integrity
Individual Aircraft ManagementIndividual Aircraft Management
LCSE (Pre-Milestone C)
System Mgt, Requirements Mgt, Verification &
Validation, Technical Control & Mgt, Configuration Mgt, SOR & SOS Certification,
Planning, Design, Risk Mgt, Inspection & Maintenance
FSIPAVSIP PSIP
MECSIP ASIP
OtherHSI, AIP & MFOUQA, MQ&A, MOSA, CSI, System Safety, etc
Transition Planning
LCSE (Post Milestone C)
System Mgt, Requirements Mgt, Verification &
Validation, Technical Control & Mgt, Configuration Mgt, SOR & SOS Certification,
Planning, Design, Risk Mgt, Inspection & Maintenance
Current Life Cycle Systems Engineering
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14Fly – Fight – Win
Weapon System Integrity Programs (WSIP): ASIP, FSIP, ENSIP, MECHSIP, AVSIP, and Individual Aircraft Tracking (IAT)Technical Control & Management: Technical & Design Reviews, Architecture, Tech Maturation/DEMO, Tech Measurements (KPP, TPM, Metrics), Decision Analysis, Certifications, Deficiency Reporting, and Training.Inspection & Maintenance: Reviews, TO Updates (-6 & -06), PDM Work Specifications, and MRRB Updates
Systems Engineering
LCSE (Pre-MS C) System Mgt, Requirements
Mgt, Verification & Validation, Technical Control & Mgt,
OSS&E, Configuration Mgt, SOR & SOS Certification,
Planning, Design, Risk Mgt, Inspection & Maintenance
PLM
OtherHSI, AIP & MFOUQA, MQ&A, MOSA, CSI, System Safety, etc
Transition Planning
LCSE-SCBM+, RAM, WSIP, Prognostics (RUL/SLA), Diagnostics
Monitoring, EAVI, R&M System Performance Metrics, ELMP & FSMP, RCMA/FEMCA, and Corrective Actions
or New Requirements
LCSE (Post-MS C)System Mgt, Requirements
Mgt, Verification & Validation, Technical Control
& Mgt, Configuration Mgt, SOR & SOS Certification,
Planning, Design, Risk Mgt, Inspection & Maintenance
Life Cycle Systems Engineering with LCSE-SPOMX, IETM, ECSS MRO (IFS),
Data Workbench (EPAE), Prognostics Toolkit,
AIT/AMT, CAM,MFOQA
Initiatives with strong interfaces/links with LCSE-S: Notional
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15Fly – Fight – Win
Life Cycle Systems Engineering -Sustainment
Represents the integration of eLog21 and AFSO21
Process Improvements and Objectives for:Product Lifecycle ManagementCondition Based Maintenance Plus/ PrognosticsWeapon System Performance AnalysisWeapon System Performance Improvement
Defines data needs and metricsKey EventsEvent ThresholdsSensors and ControllersMRO Data
Drives Engineering Analysis
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16Fly – Fight – Win
Systems Engineering - Current State
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17Fly – Fight – Win
Monitor - Current StateCore – Process Map (How is the data monitored?)
Understand System
Perform ace Requirements
Review FMECA for Potential
Failure Points
Determine How Sub-System Must Perform to Meet Requirements
Determine Which Characteristics are
Indicators of Performance
Determine/Set UCL/LCL on
Characteristics
Transfer to Auto Form
Determine How to Measure
Characteristics
Provide Reports to
Users/Mngrs
ID Transmission
Means
ID Data Destination Transmit Data Store Data Retrieve Data Analyze Data
Validate
Critical Aspects?
Auto or Manual
Collection?
Can We Measure?
Is Performan
ce w/in Limits?
Input into SE Process
ID Transmission
Means
ID Data Destination Transmit Data Store Data
•Compare Actual Performance to Predicted/Reqd•ID Patterns/Trends•Predict Future Events (Failures/Demands)•List Analysis Tools
YES
NO
A
M
YES
YES
NO
Allocates Requirements
NO
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18Fly – Fight – Win
Monitor - Future StateCore – Process Map (How is the data monitored?)
Obtain System Performance
Reqs
Digitize
Transmit Data Analyze Data
Input into SE Process
Provide Reports to Users/ Managers
Automated or
Manual Data?
Perf/ Trends
w/in Limits?
Use Common Automated tool to determine criticality
(FMECA) which characteristics are indicators of performance, upper and lower bounds, and if
it is measurable
ID transmission means, data destination, transmit data,
store data in automated system
Validate (Automated)
Use Tool to retrieve data and ask appropriate/ meaningful questions
Decompose System
Requirements
Compare actual performance to predicted
requirements from system performance
requirements
Use automated method for identifying patterns/trends
and to predict future events (failures/demands)
ID Critical Components
(FMECA)
ID Critical Characteristics (Measurable)
Set Bounds (U/L)
Change to digital format utilized by automated
systems
Provide Reports to Users/ Managers
YES
NO
A
M
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19Fly – Fight – Win
Summary
Improved Maintenance Data Collection is being addressed by:Transformation
Life-cycle Systems Engineering – SustainmentCondition Based MaintenanceIUID
Technology EnablersAIT (Near-Term)PLM ( Near-Term & Long-Term)ECSS (Long-Term)
AnalysisAFLMA (Near-Term)ECSS Legacy Deconstruction and Migration (Near-Term)
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20Fly – Fight – Win
QuestionsQuestions
Briefings/PMR Dunn 9Mar0420