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WR-ALC Maintaining the Fleet

Air Force Materiel Command. WR-ALC Maintaining the Fleet. Maj Gen Polly Peyer HQ WR-ALC/CC 26 Aug 2010. Integrity  Service  Excellence. Why Team for the Future?.

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WR-ALC Maintaining the Fleet

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  1. Air Force Materiel Command WR-ALC Maintaining the Fleet Maj Gen Polly Peyer HQ WR-ALC/CC 26 Aug 2010 Integrity  Service  Excellence

  2. 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

  3. Challenges Increased Aircraft Availability • Reduced costs • Enhanced competitiveness • Improved systems / processes • Added core competencies • Added partnerships • Constrained budgets Increased Effectiveness • Increased reliability • Reduced maintenance • Improved safety • Enhanced suitability

  4. 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)

  5. High Velocity Maintenance (HVM) Project Description Why 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 Industry Velocity Stakeholders & Teaming Partners Benefits Velocity (hrs/day) • 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) • 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 500 USAF Depot Velocity Mx Cycle 0 ISO HSC ISO PDM ISO

  6. Examples of HVM Technology Insertion • Mechanic Centric Focus - Redesigned C-130 maintenance stands • Pre-Planned Work – Task kits • Adherence to Standard Work – Andon system • Aircraft Condition – Pre-induction inspections utilizing borescopes • Automated Access to Tech Orders -Toughbooks for mechanics • Production Control Boards – Touch screen monitors • Fleet Mgt Tool – Eagle Modification Action Plan (EMAP)

  7. C-5 AMP Systems Integrated Lab Integrated Aircraft Test Environment C-5 #840059 crash near Dover AFB on 3 April 2006 402 SMXG participated in post crash recovery efforts C-5 AMP flight deck arrives at Robins on 23 August 2006 Minor construction project addition to Software Support Facility Jan 2010

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

  9. AF Corrosion Prevention and Control Office Lavatory Assessment Project Description 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 • 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. Stakeholders & Teaming Partners Benefits • 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 Reduce corrosion damage and repair/replace areas in and around aircraft lavatory/crew relief systems.

  10. Lavatory Corrosion and Solutions B-52 skin repair due to extensive corrosion in lavatory area

  11. Lavatory Corrosion and Solutions (cont) Above and below: Typical cannon plug corrosion under lavatory Above: Condemned toilet - Bad field repair Above: Possible replacement for B-52s: C-130J type Above: Leaking toilet on other A/C set aside to be reinstalled without repair.

  12. F-15 Rewire (Eagle Division) Project Description Status • 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) • 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. Benefits 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. • 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)

  13. F-15 Rewire (cont.) Bay 5 Old Wiring Bay 5 New Wiring

  14. F-15 Rewire (cont.) ECS Bay Old Wiring ECS Bay New Wiring

  15. Versatile Depot Automatic Test System (VDATS) • VDATS is the standard family of tester for the Air Force • Currently three different configurations: DA-1, DA-2, and RF-1 • Government owned Supported Platforms VDATS POCs NamePhone # 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-ALC • B-2 • F-15 IFF • F-16 IFF • Global Hawk • LAIRCM • MILSTAR • JSTARS • Space Crypto • CARA • AN/APX-119 • Kadena Mini-Depot

  16. 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!

  17. Teaming for the Future Always seeking Opportunities 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

  18. What is in the future? More Joint Efforts Continuous Condition Monitoring • Integrated systems health monitoring • Aircraft subsystem diagnostics • Prognostics based on existing data Maintenance Acceleration/Increased Density • Cost reduction • Crack and corrosion detection and prevention • Reduce coating removal time • Bonded repair technology • Depot and maintenance shop improvement • Supply chain enhancements

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