08.01.2020DAU Weekly WebcastProfessor Brian DuddyDAU Midwest – Program Management

Fleet Modernization:Planning and Challenges

Agenda

• Introduction• Where is Your Fleet Headed - Requirements Definition?• Upgrade vs. Sustainment Planning and Design• Configuration and Data Management• Testing and Verifying Your Modernized Design• Impacts to Training and Training Devices• Producing Your Modernized Design• Scheduling Your Fleet Modernization• Other Modernization Considerations

Introduction

This seminar will discuss planning considerations and challenges encountered

and based on lessons learned when initiating modernization programs for fleets of

DoD Weapons Systems. We will give you things to think about and questions to ask and investigate as you structure your modernization program.

Modernization - Where Is Your Fleet Headed?

1978

2018

Lightweight Fighter

To Lightweight Freighter

1975 -- 2019

Where Is Your Fleet Headed?

Requirements Definition – Where Is Your Fleet Headed?

• As with any other acquisition program, your first question when planning for modernization is – What are the requirements?

• What is driving your modernization program?– Field failures or reliability problems– Mission changes or expansions– Threat changes, environment changes– Interoperability with new systems/platforms– Obsolescence, DMS, Technology Refresh– Configuration standardization– Warfighter “Roadmaps”– Mandatory/regulatory compliances – Significant delays in the fielding of follow-on systems

Requirements Definition• Ensure you capture and document all your relevant

modernization requirements “up-front and early.”• Are changes expected or required to existing capability

documents – ICD, CDD?• Will requirements come via some other method? (e.g. Air Force

Form 1067, PQDR/field failures, Tech Refresh, DMS)• Use the Systems Engineering process to translate capabilities

into specific system requirements that industry can bid on.• Will it be one “big program” or multiple increments and does

your requirements document support those increments ?• What is the required fielding date or IOC?

Requirements Definition

• Is your modernization program an Upgrade (i.e. performance improvement,) or for Sustainment (Form-Fit-Function) only?

• What is the projected service life of your fleet – will this modernization program impact or extend that?

• Does your POM funding profile support this modernization program – proper years and colors?

• Do you have a credible cost est.?

Upgrade vs Sustainment Planning and Design

• Is your program strictly Upgrade or Sustainment or both combined?• How will you integrate an Upgrade program along with Sustainment

programs – either planned or on-going?– Example: system mods like avionics along with structural mods

• What is your acquisition strategy for the program – contractor, organic, mix? Competition vs Sole Source ECP to an OEM? Do you want to break an “OEM Lock?” Does your program schedule support a competitive Source Selection period?

• When your system design begins will you know the exact configuration baseline you are starting with, esp. in light of other parallel programs?

• Is your program a candidate for Section 804 Middle Tier or Rapid Acquisition status?

Design Considerations• Does your modernization strategy

support “bundling” several improvements together into one, more comprehensive Service Life Extension Program? (save cost and schedule?)

• Will your new design impact PESHE, Interoperability, Airworthiness, or other certifications?

• If new or modified software will be involved how will those changes be integrated into an existing periodic/cyclical software build-update schedule for your system? Will it impact future releases or require a special, out-of-cycle release?

Additive Manufacturing (AM)• Additive Manufacturing (3D Printing) is gaining more

acceptance in the DOD as a means to prototype and build even very sophisticated production parts.

• AM uses a computer-driven printer to deposit layers of polymer, metal, or other media – from the bottom up –to create simple or intricate objects, as dictated by a three-dimensional, digital design file of the object.

• AM can be used in modification and sustainment operations to print spare parts as needed or to create very large tooling and molds for traditional forms of manufacturing.

• Optimum application is a small number of complex mechanical parts, needed in a hurry.

• The quality of AM parts is impressive!• Is your program a good candidate to employ AM to

accelerate your modernization schedule?

Configuration and Data Management• Does your program have a sufficient Tech

Data Package on the system to accomplish a modernization program?– Drawing package, including process

information (!) and the Data Rights– Interface Control Documents/Interface

Data– Lower Tier Specifications

• If you do not have sufficient data on a legacy system, consider ‘reverse engineering’ your own TDP. Modern techniques like 3D laser scanning and modeling may be sufficient to construct tech data you do not currently have.

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Digital Engineering• Digital engineering is the

Department of Defense’s (DoD’s) initiative to transform the way it designs, develops, delivers, operates, and sustains complex systems in a changing threat environment. It is defined as “an integrated digital approach that uses authoritative sources of systems’ data and models as a continuum across disciplines to support lifecycle activities from concept through disposal.”

• Give consideration to digitizing your data on your system as you go forward.

Configuration and Data Management• What Data Rights do you have on your legacy data? Are you able to

provide legacy data to third parties to compete and participate in the program?

• Determine the Data Rights you want to acquire with your modification package – what do you need going forward?

• How will you handle fleet configuration management during the modernization process?

• A modernization program that plans to add new capability or equipment may require changes or additions to your Program Work Breakdown Structure (WBS).

• Be sure to plan for and schedule Configuration Control Board approval of any modified designs – prior to both testing and production!

– Permanent Mod itself, plus Temporary Mod for test instrumentation and data collection

Configuration and Data Management• Is your fleet all in the same configuration? Are there different variants in the

fleet that have to be accounted for in the design of the modernized system? • Have all previous modifications been documented so you “know where

everything is?” Have all previous mods been removed as necessary and those changes documented in the drawings and tech data package?

• Consider a fleet configuration survey prior during RFP development if you are unsure of the status and condition, or add a survey task in the SOW.

Testing and Verifying Your Modernized Design

• What is the DT and OT strategy for your design?• Combined DT/OT or dedicated OT?• Is First Article Testing called for?• Will you need a SIL and is one available?• How many test assets will be required?• Have you scheduled the range or facility time you will need?• Any other agencies besides your own need to be involved (for example

JTIC Interoperability Testing, AIMS office, SEEK EAGLE, FAA Certification?) – Budget time for that in your implementation schedule.

• Is Live Fire Testing or recertification required?• How will you manage the configuration of your test fleet (modified vs

baseline systems) as you implement successive mods?

Training and Training Devices• What is the impact of performance upgrades on the overall system?• Does the user prefer one big upgrade to minimize training impact, or can

they work with incremental changes?• Does it require re-training or new training of users and maintainers?• Are upgrades or changes required for the training devices to keep them in

the same configuration as the fielded systems?

Producing Your Modernized Design• What is your production strategy for your modernized

items?• Consider the breakout of Group A vs Group B components

and how they will be produced and packaged.• Are you buying “Kits and Installs” or just end items?• Plan for a Physical Configuration Audit and a Production

Readiness Review (or perhaps incrementals of each.)• How will you inspect and accept the kits –

at delivery or after installation?• Will the kits need to be stored at multiple mod locations in

advance of installations?• Be sure to develop an executable acceptance criteria for

the modified system at the end of the production line.• Does your TCTO development support your production

and install plan?• Review your program plan with relevant DCMA offices that

may be involved or that you will need to assist you with acceptance.

Scheduling Your Fleet Modernization• Strategy and scheduling for the installation

of your modernized design items may end up being the most challenging part of managing the program.

• You will need plan extensively and perhaps develop multiple alternatives for installation with appropriate costs.

• Think critically and creatively when developing alternatives.

• Remember to include Government approvals, contracting lead times and milestones in your master program schedule along with strictly Contractor events. 19

Scheduling Your Fleet Modernization• What is the best strategy for installation?

– Programmed Depot Maintenance (PDM) period– Prime contractor install line– Contract Field Team (Third Party) Installation– Field-Level Modification

• Get a good projection on the difference in labor rates for each install alternative to cost out the installation phase.

• De-conflict from other on-going work or other mods in parallel and consider sequencing.

• Where is your fleet located? Will you be able to get access to do field mods, or bring them back to depot?

• Consider mission availability, downtime + install time when developing install schedule to meet the IOC date.

• How will you “catch the ones you miss” if they are in PDM?• Ensure you have spares and SE available as modified units

are returned to service.

• What systems will be available for installation and when will they be available?– Does your kit production schedule integrate smoothly with your install schedule.

• What is the depot capacity – infrastructure, labor, tooling, training.• How quickly could the depot surge if required and how many installs can be done

at one time?• What systems need to be installed first and over what time period?• Are your Support Equipment and Trainer updates congruent with your fleet mod

schedule?• Will the Gov’t supply system be involved, and if so, include their reps in your

planning.• Use the Depot Determination Process to understand depot and supply abilities

and constraints.

Scheduling Your Fleet Modernization

Other Modernization Considerations• Will new or modified support equipment be required to

support fielding of your modernized system?• Develop and agree to a prioritization process with the using

command(s).• Try to bundle mods to include “must-haves” (regulatory

requirements and users needs) and then what low-hanging fruit you can also include.

• Modernization approach should be integrated across the acquisition/development organization, sustainment organization and using command.

Robins AFB Installs

Mode 5 IFFVia Contract Field Team

Wright Patt installsAMP Increment 1

ADS-B-OutVia CFT

Robins Installs8-Bladed Prop,

Engine Controls

Wright Patt InstallsAMP Increment 2

Glass Cockpit

And by the way, these aircraft also have to gothrough PDM as well for everything else…….

One Example: ANG/AFRC C-130H Fleet Avionics and Systems Modernization – One Aircraft, Multiple Mods and Organizations

Other Modernization Considerations• Is your modernization concept such that

your system will now need greater security protection, storage or facilities ($)?

• International Customers – are they/will they participate? If so, how - cooperative development, or procurement of end-item kits?

• Does your new design drive any changes to your long-term support strategy for the system?

– For example, dramatically increased reliability of your system may now result in a negative business case for continuing organic repair capability.

Convert as many “unknowns” to “knowns” as you can in the planning phase before you begin implementation!

Summary

• Modernizing your fleet can be an enjoyable challenge!• Prior planning will prevent poor performance –• Requirements, requirements, requirements! • Get all your functional team members involved early.• Everyone has a role in modernization!

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For Additional Assistance DAU On-Line and Other Resources

• Defense Acquisition Guidebook: Ch. 3 Systems Engineering and Ch. 4 Life-Cycle Sustainment

• CLE 003 - Technical Reviews• CLM 012 - Program Scheduling• CLM 013 - Work Breakdown Structures• CLM 031 - Improved Statement of Work• CLE 036 - ECPs for Engineers• CLC 063 - Sole Source Proposal Technical Evaluations• CLE 068 - Intellectual Property and Data Rights• EVM 263 - Principles of Schedule Management – 3 day residence class• LOG 204 - Configuration Management• LOG 215 - Technical Data Management

Contact

Professor Brian DuddyDAU Midwest – Program Management

937-781-4022brian.duddy@dau.edu