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Ship Maintenance on the Horizon

Ship Maintenance on the Horizon RADM Clarke Orzalli Director, Fleet Maintenance 21 October 2009 Discussion Topics USFF 2010 N43 Initiatives Norfolk Waterfront MSMO way ahead Process Improvement Best Practices Maintenance History Reach Expected Service Life USFF 2010 N43 Initiatives

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Ship Maintenance on the Horizon

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  1. Ship Maintenance on the Horizon RADM Clarke Orzalli Director, Fleet Maintenance 21 October 2009

  2. Discussion Topics • USFF 2010 N43 Initiatives • Norfolk Waterfront • MSMO way ahead • Process Improvement • Best Practices • Maintenance History • Reach Expected Service Life

  3. USFF 2010 N43 Initiatives • 1. Partner with OPNAV, NAVSEA and other stakeholders to reduce warship Total Ownership Costs (TOC). • Specific initiatives: • Incorporate recent reductions of submarine life-cycle maintenance requirements into workload leveling efforts in public and private shipyards. • Award Spiral II Multi-Ship Multi Option contracts that increase incentives for cost control as well as continuous process improvement efforts. • Co-ordinate with operational schedules to level load ports and more efficiently utilize maintenance dollars. • Execute the total FY10 Ship Maintenance Requirement within the allocated resources through implementation of continuous process improvement initiatives. • Pilot cost reduction efforts in shipyard processes that have demonstrated performance in Intermediate Level activities.

  4. USFF 2010 N43 Initiatives 2. Establish an integrated strategy for Navy Logistics IT systems. Approve Navy Logistics IT strategic plan that is resourced in POM-12. 3. Partner with OPNAV, NAVSEA and other stakeholders to improve requirements definition for surface ships to achieve expected service life. Surface ship requirements reflect needed maintenance to support expected service life and funding requirements are well understood and support the PPBS process.

  5. 7000 FY-09 FY-10 FY-11 FY-12 1,094,473 RDs 714,205 RDs 6000 5000 Resources Per Day 4000 3000 2000 1000 0 O N D J F M A M J J A S O N D J F M A M J J A S O N D J F M A M J J A S O N D J F M A M J J A S O Norfolk Waterfront NSSA PRIVATE SECTOR WORKLOAD Preliminary projections based on ship schedules

  6. 4/22 Targeted Contract Award Date MSMO Timeline 2009 2010 2011 Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Spiral 2 Industry Day (Washington Navy Yard) Norfolk DDG Docker Norfolk DDG Non-Docker Mayport CG/DDG (New) San Diego LPD 17 (New) Norfolk LPD 17 (New) Norfolk LHA/LHD PAC NW FFG/DDG San Diego CG Spiral 2 Roll-out …

  7. Spiral 1 (FY05-09) Competitive awards CPAF Not exercising options Denial of sub-ktr consent TAR process Spiral 2 (FY10-14) Competitive awards CPAF/IF Not exercising options Denial of sub-ktr consent Strengthened TAR Process Contractor Purchasing Review System: places ceiling on AF pool at 80% Corrects bad teaming behavior EVMS cert: ktr value decision only Cost incentive (IF) in lieu of additional Small Business incentive fee Perf-based AF progress payments 1-year Rate Caps (in RFP) Invoke “excessive fee on fee” limitation clause in all contracts Pre-priced standard work-items Spiral 2 Contract Structure Changes (Enhanced Cost Control Mechanisms) • Navy also drives cost outcomes: • Port loading, AIT erosion, process differences • Recognized and vigorously managed: C-RMC, MCIT, ASN Policy (proposed)

  8. Process Differences

  9. Continuous Process Improvement

  10. Progressive Projected Future Engineered DDG-51 Class Depot Maintenance Programming History Rusting trunk and deck in DDG-53 Engine Room # 1 Intake Uptake trunk (01-174-0-Q). • PR-91 through PR-97: “Engineered Operating Cycle” Maintenance Strategy • PR-99 thru PR-09: “Progressive” Maintenance • POM-10 & Beyond: Return to more rigorous requirement determination to enable ships to reach ESL Deep Maintenance was Deferred for the Last Decade

  11. 400 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 300 Technical Foundation Paper Projection 200 100 0 Life Cycle Maintenance DDG Life Cycle Maintenance K-mandays DDG-51 was designed for 30 years but has an ESL of 40 years

  12. SSLCM Mission/Vision • Mission:SSLCM Activity shall provide centralized surface ship lifecycle management including; life cycle maintenance engineering, class maintenance planning and management closely aligned to the Fleet, Surface Warfare Enterprise (SWE), and NAVSEA’s needs and priorities. • Vision:SSLCM Activity will significantly influence, shape, and provide the engineering rigor for the maintenance, repairs, and modernization of the surface Fleet to ensure ships achieve Expected Service Life (ESL). SUSTAINED COMBAT READINESS REQUIRES SUSTAINED MATERIAL READINESS

  13. SSLCM Activity - 2012 SSLCM Act LNO (1) NWRMC SSLCM Act Headquarters (~70) Portsmouth, VA SSLCM Act Det (~6) Norfolk, VA SSLCM Act Det (~9) San Diego, CA SSLCM Act Det (~2) Mayport, FL SSLCM Act LNO (1) HRMC Manning Build (combined MIL/Govt/KTR) June ’09FY09FY10FY11 45 ~52 ~72 ~92 SSLCM Act LNO (1) JRMC

  14. Surface Ship Maintenance Continuum MRS Alliance / Stakeholders OPNAVNOTE 4700 Requirement Ship Sheets TFP 9-Step Process Modernization Plan Business Constraints Deferred maintenance $ BAWP Deferred JCNs Maintenance Philosophy (Aged notionals) MMBPs Docking Frequency CMP Midlife Philosophy Qualified Repairs Hot Wash AWP Execution Execute Avail CSMP • CMP Improvement Efforts • - MRS Tailorings • - SSLCM Quicklooks • SWE Assessment Program • MSMO Recommendations • ABS Hull Surveys (Pilot) • N81 DDG-51 Lifecycle Study • SSLCM/CLASSRON WGs SSLCM ACTIVITY TYCOM CLASSRON/RMCs/MT ProgrammingFYDP (6 Year)

  15. BAWP to AWP Process SSLCM Act “Lead” CLASSRON “Follow” CLASSRON “Lead” SSLCM Act “Follow” SSLCM Act / CLASSRON Joint Team Execution & Post Avail Close-out BAWP AWP Execution Closeout A-720 A-540 A-360 A-240 A-120 A-75 A-0 Process Business Rules & Continuous Process Improvement Metrics are Essential Increase Process Discipline, Work Package Visibility, & Document Deferred Risk

  16. SRA 1-1 SRA 3-2 SRA 1-4 Adjudicated Maintenance Requirements by Availability SRA 2-1 EDSRA SRA 2-4 SRA 3-1 ESRA SRA 3-4 • Each tab includes the notional work items for: • Required Maintenance Tasks • Qualified Tasks • Condition Based Tasks • Tank and Voids • Fleet Alterations • Growth/New work • Deferred Maintenance bow wave DSRA 1 SRA 1-3 DSRA 2 SRA 1-2 SRA 2-3 SRA 1-5 SRA 2-2 DSRA 2 SRA 2-5 ICMP Strengthening at the task level, improving the CMP and TFP Technical Foundation Paper (TPF): DDG-51

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