CBM SUCCESS STORIES

2. The Marine Corps has adopted a maintenance approach of “Observe, Orient, Decide, and Act” for their Light Assault Vehicle. The PM LAV has undertaken a Sense and Respond project that promotes continuous improvement and creates an environment that enables more agile logistics. With help from NCMS, they have applied RCM to determine what sensors and where to put them, what additional capabilities are needed, and what infrastructure is required to provide functionality.The Marine Corps has adopted a maintenance approach of “Observe, Orient, Decide, and Act” for their Light Assault Vehicle. The PM LAV has undertaken a Sense and Respond project that promotes continuous improvement and creates an environment that enables more agile logistics. With help from NCMS, they have applied RCM to determine what sensors and where to put them, what additional capabilities are needed, and what infrastructure is required to provide functionality.

3. The S&R Foundation is the Smart Platform This shows the components selected for sensors on the LAV.This shows the components selected for sensors on the LAV.

4. CBM Candidate Master Parts List53 Parts

5. Implementing CBM Today AWRs are under development AH-64 AWR releases will enable CBM process on instrumented A/C UH-60 AWR releases will enable CBM process on instrumented A/C

6. Benefit: Readiness & MMH Savings (Blk III Apache) This chart lays out the CBM benefits examined to date. Ao is the Availability objective Benefits were determined by part (10 CBM POP parts in total). Dark green boxes have a substantial quantitative analyses supporting stated benefit. Gold Boxes indicate quantified benefits are supported by limited data. Light green shaded boxes represent benefits which have not been quantified yet. As you move down the tree you see the CBM benefit category. As you move from left to right you see how the categorized benefit translates to multiple quantifiable benefits. The first categorized benefit is Inspection Hours Avoided. The effect of avoiding inspection hours is a reduction in maintenance man hours, reduction in aircraft down time translating to Ao, and a reduction in maintenance induced damage. Based on the Apache Block III Fleet (597 aircraft) and a peace time OPTEMPO of 20 hrs/month, 41,495 maintenance man-hours are avoided and 23,899 hours aircraft downtime (equating to .5% Ao) is avoided. Some inspections trigger maintenance test flights (MTF). Through CBM these particular inspections are avoided. Our initial analysis indicates an opportunity to avoid 4 MTF hours/aircraft/year through CBM. For example, when the Main Rotor Swashplate is inspected, the PC links are disconnect. Once reconnected, a maintenance test flight is required. Our estimate of 4 hours/aircraft/year is based on South Carolina National Guard experience with VMEP and an analysis of the MTF hours caused by Main Rotor Swashplate inspections. Collateral Damage (parts breaking parts) – More analysis is required to quantify CBM benefits in this area. Reduction to Event Driven Maintenance – Through monitoring, false alarms that trigger inspections can be avoided. More analysis is needed in this area. Extended Component Life – Out of the 10 Apache parts targeted for CBM, there is a strong likelihood that CBM could extend the usable life of Main Rotor Pitch Housing (currently retired at 1193 hours). Given a conservative 50% extension in life with CBM, 2,385 maintenance man-hours are avoided (this is labor associated with removing retired part and installing new part). An associate $254K/year in new parts is avoided. Reduction is Depot Washout & Repair Cost – CBM should allow for parts to be proactively repaired. Under CBM, the repairable part is in better condition thus reducing the time the repair item and reduces the risk of part washout. More analysis is required to quantify this benefit. Requisition Wait Time Impact Avoidance – Through improved prognostics, CBM will reduce downtime waiting for parts. CBM allows for parts to be order far enough ahead of maintenance events so that parts are on hand ready for the planned maintenance event. For the ten parts reviewed, avoiding the downtime associated with requisition wait time equates to a 4.4% increase in Ao (i.e., if FMC were 75% before CBM, with CBM FMC would be 79.4%). Applied to a Apache Block III fleet of 597 aircraft, this equates to gaining the combat power of one additional battalion per year. Although not quantified in this analysis, the benefit to the complete logistics supply chain of CBM prognostics could be significant. Knowing what part is needed and when its needed benefits the complete supply chain. Benefits could be Stock Availability rate increase without significant increases material procurement, smaller/smarter PLL & ASL with smaller/lighter deployments and so on. This chart lays out the CBM benefits examined to date. Ao is the Availability objective Benefits were determined by part (10 CBM POP parts in total). Dark green boxes have a substantial quantitative analyses supporting stated benefit. Gold Boxes indicate quantified benefits are supported by limited data. Light green shaded boxes represent benefits which have not been quantified yet. As you move down the tree you see the CBM benefit category. As you move from left to right you see how the categorized benefit translates to multiple quantifiable benefits. The first categorized benefit is Inspection Hours Avoided. The effect of avoiding inspection hours is a reduction in maintenance man hours, reduction in aircraft down time translating to Ao, and a reduction in maintenance induced damage. Based on the Apache Block III Fleet (597 aircraft) and a peace time OPTEMPO of 20 hrs/month, 41,495 maintenance man-hours are avoided and 23,899 hours aircraft downtime (equating to .5% Ao) is avoided. Some inspections trigger maintenance test flights (MTF). Through CBM these particular inspections are avoided. Our initial analysis indicates an opportunity to avoid 4 MTF hours/aircraft/year through CBM. For example, when the Main Rotor Swashplate is inspected, the PC links are disconnect. Once reconnected, a maintenance test flight is required. Our estimate of 4 hours/aircraft/year is based on South Carolina National Guard experience with VMEP and an analysis of the MTF hours caused by Main Rotor Swashplate inspections. Collateral Damage (parts breaking parts) – More analysis is required to quantify CBM benefits in this area. Reduction to Event Driven Maintenance – Through monitoring, false alarms that trigger inspections can be avoided. More analysis is needed in this area. Extended Component Life – Out of the 10 Apache parts targeted for CBM, there is a strong likelihood that CBM could extend the usable life of Main Rotor Pitch Housing (currently retired at 1193 hours). Given a conservative 50% extension in life with CBM, 2,385 maintenance man-hours are avoided (this is labor associated with removing retired part and installing new part). An associate $254K/year in new parts is avoided. Reduction is Depot Washout & Repair Cost – CBM should allow for parts to be proactively repaired. Under CBM, the repairable part is in better condition thus reducing the time the repair item and reduces the risk of part washout. More analysis is required to quantify this benefit. Requisition Wait Time Impact Avoidance – Through improved prognostics, CBM will reduce downtime waiting for parts. CBM allows for parts to be order far enough ahead of maintenance events so that parts are on hand ready for the planned maintenance event. For the ten parts reviewed, avoiding the downtime associated with requisition wait time equates to a 4.4% increase in Ao (i.e., if FMC were 75% before CBM, with CBM FMC would be 79.4%). Applied to a Apache Block III fleet of 597 aircraft, this equates to gaining the combat power of one additional battalion per year. Although not quantified in this analysis, the benefit to the complete logistics supply chain of CBM prognostics could be significant. Knowing what part is needed and when its needed benefits the complete supply chain. Benefits could be Stock Availability rate increase without significant increases material procurement, smaller/smarter PLL & ASL with smaller/lighter deployments and so on.

7. Condition Based Maintenance (CBM) Step with me into 2011 when we have modernized our aviation maintenance commensurate with the modernization of our platforms. The Vision of CBM … Aircraft send condition information to the Production Control Officers of the Multifunction Aviation Brigade HQs prior to landing so that they can be met by soldiers with the skills, tools, and parts to re-launch the fleet as soon as possible. to Platform Maintenance Environments which manage day to day operations (Note: Each PM is developing his own) To the Analytical Data Warehouse designed for logisticians, engineers, and platform managers who can track health, usage, and condition of the fleet, perform theater based forecasting, and set thresholds for proactive maintenance actions and finally to high quality data pushed to the Logistics Enterprise systems such as PLM+, LMP or the GCSS-A. The result is better proactive decisions at all levels AND fewer maintenance man-hours spent to keep the fleet healthy AND higher readiness AND lower O&S costs. The latter is due to fewer test flights, better supply chain management, footprint reduction, and less wear and tear on the platforms performing unnecessary maintenance. GCSS-A – Global Combat Support System (Army) PLM+ is Project Life Cycle Management Plus LMP – Logistics Modernization ProgramStep with me into 2011 when we have modernized our aviation maintenance commensurate with the modernization of our platforms. The Vision of CBM … Aircraft send condition information to the Production Control Officers of the Multifunction Aviation Brigade HQs prior to landing so that they can be met by soldiers with the skills, tools, and parts to re-launch the fleet as soon as possible. to Platform Maintenance Environments which manage day to day operations (Note: Each PM is developing his own) To the Analytical Data Warehouse designed for logisticians, engineers, and platform managers who can track health, usage, and condition of the fleet, perform theater based forecasting, and set thresholds for proactive maintenance actions and finally to high quality data pushed to the Logistics Enterprise systems such as PLM+, LMP or the GCSS-A. The result is better proactive decisions at all levels AND fewer maintenance man-hours spent to keep the fleet healthy AND higher readiness AND lower O&S costs. The latter is due to fewer test flights, better supply chain management, footprint reduction, and less wear and tear on the platforms performing unnecessary maintenance. GCSS-A – Global Combat Support System (Army) PLM+ is Project Life Cycle Management Plus LMP – Logistics Modernization Program

8. CLOE Benefits To The Warfighter

9. The JSF Autonomic Logistics (AL) system is a new and revolutionary supportability concept that will enable the F-35 to be better utilized throughout the life of the platform, and at a lower cost as compared with legacy aircraft. One of the key enablers of the AL concept is an advanced diagnostic, Prognostic and Health Management (PHM) system. The PHM provides the data, information, and knowledge through a comprehensive set of capabilities applied to every major system and subsystem on the aircraft. PHM capabilities include the ability to do high levels of automatic fault detection and fault isolation real-time, in-flight, on-board the aircraft with very low false alarm rates. Some of the other facets of PHM include fault prediction or real prognostics on selected components; parts life usage tracking on life limited components; performance trending; fault filtering and reporting; and recommended actions to the pilot only when action is necessary. Information will be electronically downloaded before landing. Most maintenance actions and lifing decisions will be based on the assessment of an actual material condition. The PHM architecture will provide data directly into the AL Information System (ALIS). Stringent PHM requirements have been identified and placed on the JSF Air System to enable the JSF AL support concept. Prognostics represent the main challenges for the design and logistics teams. The JSF Autonomic Logistics (AL) system is a new and revolutionary supportability concept that will enable the F-35 to be better utilized throughout the life of the platform, and at a lower cost as compared with legacy aircraft. One of the key enablers of the AL concept is an advanced diagnostic, Prognostic and Health Management (PHM) system. The PHM provides the data, information, and knowledge through a comprehensive set of capabilities applied to every major system and subsystem on the aircraft. PHM capabilities include the ability to do high levels of automatic fault detection and fault isolation real-time, in-flight, on-board the aircraft with very low false alarm rates. Some of the other facets of PHM include fault prediction or real prognostics on selected components; parts life usage tracking on life limited components; performance trending; fault filtering and reporting; and recommended actions to the pilot only when action is necessary. Information will be electronically downloaded before landing. Most maintenance actions and lifing decisions will be based on the assessment of an actual material condition. The PHM architecture will provide data directly into the AL Information System (ALIS). Stringent PHM requirements have been identified and placed on the JSF Air System to enable the JSF AL support concept. Prognostics represent the main challenges for the design and logistics teams.

10. Air Force Initiative: AIRCRAFT MAINTENANCE INTUITIVE TROUBLESHOOTING (AMIT) AMIT Tool Tech Data presentation that includes Electronic Tech Data Discrepancy, repair, and parts history Shop-level hints, notes, guidance as Log Book Entries Collaborative Tools All at the point of Maintenance (POM) Supporting technologies UID, Part number tracking, automated discrepancy reporting (POM-X, AC dowload, etc.), on-board sensors, diagnostics, prognostics, supply interface, POM AFTO-22, POM depot collaboration, EDCL FY 06 Field Tests