Integrity Service Excellence

WR-ALC Maintaining the

FleetMaj Gen Polly Peyer

HQ WR-ALC/CC26 Aug 2010

Air Force Materiel CommandAir Force Materiel Command

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 AvailabilityReduced costsEnhanced competitiveness Improved systems / processesAdded core competenciesAdded partnershipsConstrained budgets

Increased Effectiveness Increased reliabilityReduced maintenance Improved safetyEnhanced 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)

Why HVM?Project Description

Benefits

High Velocity Maintenance (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

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 ALC PDM 145-220 hours/day

Field and Depot not synchronized Function as two independent sys

A/C condition not well known

1000

500

• 0

Vel

oci

ty

(hrs

/day

)

Industry Velocity

PDMISO ISOHSC ISO

MxCycle

USAF Depot

Velocity

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)

Stakeholders & Teaming Partners 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 standsPre-Planned Work – Task kitsAdherence to Standard Work – Andon systemAircraft Condition – Pre-induction inspections utilizing borescopesAutomated Access to Tech Orders -Toughbooks for mechanicsProduction Control Boards – Touch screen monitorsFleet Mgt Tool – Eagle Modification Action Plan (EMAP)

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 IntegratedAircraft Test Environment

C-5 #840059 crash near Dover AFB on 3 April

2006

402 SMXG participated in post crash recovery

efforts

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

C-5 AMP Systems Integrated Lab IntegratedAircraft Test Environment (Cont.)

Project Description

Benefits

AF Corrosion Prevention and Control Office Lavatory Assessment

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

Stakeholders & Teaming Partners

Reduce corrosion damage and repair/replace areas in and around aircraft lavatory/crew relief systems.

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.

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

B-52 skin repair due to extensive corrosion in lavatory area

Lavatory Corrosion and Solutions

Above and below: Typical cannon plug corrosion under

lavatory Above: Condemned toilet - Bad field repair

Above: Possible replacement for B-52s: C-130J type

Lavatory Corrosion and Solutions (cont)

Above: Leaking toilet on other A/C set aside to be reinstalled without repair.

F-15 Rewire (Eagle Division)

StatusProject Description

Benefits

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)

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)

Stakeholders & Teaming Partners

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.

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.

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)

Supported Platforms VDATS POCsName Phone #

Joe Eckersley – Section Chief 472-0255 Matt Mosely-PM 472-0298 Jonathan Hill-PM 472-0308

Jeff Burrows-ES 472-0301 Larry Adams-Eng 472-0295

Bob Pennington-SIL FLT Chief 468-1307

WR, OO, OC-ALCB-2 F-15 IFFF-16 IFFGlobal HawkLAIRCM

MILSTARJSTARSSpace CryptoCARAAN/APX-119 Kadena Mini-Depot

VDATS is the standard family of tester for the Air Force

Currently three different configurations: DA-1, DA-2, and RF-1

Government owned

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 OpportunitiesAlways seeking Opportunities

What is in the future?

More Joint Efforts Continuous Condition Monitoring

Integrated systems health monitoringAircraft subsystem diagnosticsPrognostics based on existing data

Maintenance Acceleration/Increased DensityCost reductionCrack and corrosion detection and preventionReduce coating removal timeBonded repair technologyDepot and maintenance shop improvementSupply chain enhancements