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