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AMCOM Update DAU-South Acquisition Conference

AMCOM Update DAU-South Acquisition Conference. Gary Nenninger G-3 Operations Aviation & Missile Life Cycle Management Command 18 February 2009. Agenda. Support to the Aviation Warfighter Aviation Field Maintenance Transformation Reset Condition Based Maintenance (CBM).

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AMCOM Update DAU-South Acquisition Conference

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  1. AMCOM UpdateDAU-South Acquisition Conference Gary Nenninger G-3 OperationsAviation & Missile Life Cycle Management Command 18 February 2009

  2. Agenda • Support to the Aviation Warfighter • Aviation Field Maintenance Transformation • Reset • Condition Based Maintenance (CBM)

  3. AMCOM Support to the Warfighter 2,456,568Total Hours: 01 Feb 03 – 15 Jan 09 Army Fleet in OIF Support To The Warfighter AH-64 479,959 Hours MC: 82.0% OPTEMPO: 58.0 UH-60 726,335 Hours MC: 84.0% OPTEMPO: 45.0 • ~ 3000 Aircraft Preset/Reset • Aviation Field Maintenance • Condition Based Maintenance • Supply Support • Provisioning • Worldwide Onsite Technical Assistance (LARs / CFSRs) • Fwd Deployed Repair/ Sustainment Activities: TAMP, TASM • TMDE Calibration and Repair • MWO Applications • Depot Maintenance • Technical Publications • Airworthiness & Safety of Use CH-47 123,070 Hours MC: 73.0% OPTEMPO: 44.7 Fixed Wing 140,381 Hours MC: 91.0% OPTEMPO: 59.9 UAS 569,920 Hours Shadow 323,342 hrs Hunter 38,244 hrs Sky Warrior 75,001 hrs Raven 133,309 hrs gMAV 23 hrs OH-58 416,903 Hours MC: 84.0% OPTEMPO: 72.2 OEF Plus Up 389,768 Total Hours:01 Feb 03 – 15 Jan 09 Army Fleet in OEF AH-64 94,947 Hours MC: 87.0% OPTEMPO: 50.0 UH-60 114,928 Hours MC: 85.0% OPTEMPO: 42.0 CH-47 77,946 Hours MC: 78.0% OPTEMPO: 51.6 Fixed Wing 19,926 Hours MC: 87.0% OPTEMPO: 51.4 UAS 43,496 Hours Shadow 19,529 hrs Hunter 910 hrs Sky Warrior 4,953 hrs Raven 18,104 hrs OH-58 38,525 Hours MC: 85.0% OPTEMPO: 80.4

  4. Support to the Warfighter • Aviation Field Maintenance Transformation • Reset • Condition Based Maintenance (CBM)

  5. Aviation Field Maintenance Transformation • What We Did? • Realigned All AMCOM Aviation Field Maintenance Responsibilities Into One Organization • Established Aviation Field Maintenance Directorate (AFMD) • Why We Did This? • Fragmented Aviation Maintenance Responsibilities Highlighted in Recent Aviation Maintenance Issues • Mission Explosion for OLRs (Beyond MWO Application) Required Readjustment of Management Structure Need to Go Back to the Basics With Aviation Field Maintenance

  6. Aviation Maintenance Hierarchy • Commander’s Intent: • “Establish Unity of Command for AMCOM Below Depot Aviation Maintenance Activities” • Depot • Airframe • Component • Special Projects • AMCOM Managed • Organic • Contracted • Consolidate AMCOM Structure • Standardize Processes and Business Rules • Common Metrics & Oversight • Transform How The Army Operates • SINGLE ARMY AVIATION MAINTENANCE MANAGER • Below Depot / Above Unit • Unit Overflow • Limited Depot Repair • MWO Application • Reset • Multiple Managers • AMCOM • NGB • DOL/ALMD • User • AVUM • AVIM • Scheduled Services & Inspections • Authorized Repairs • Unit Managed • Organic Military • CFT Augmentation

  7. Support to the Warfighter • Aviation Field Maintenance Transformation • Reset • Condition Based Maintenance (CBM)

  8. The Reset Process • Reset Is NOT: • Routine Scheduled Maintenance • Depot Overhaul • Reset IS: • 100% Disassembly of the Aircraft and Dynamic Components (Engines, Rotor Systems, Drive Trains, Flight Control Systems) • 100% Cleaning of All Airframe and Component Elements • 100% Serviceability Inspection of All Airframe and Component Elements • Application of DA Directed Modifications • 100% Review and Correction of Historical Records • Refurbishment and Replacement of All Components to Serviceability Standards • Correction of Outstanding Deferred Maintenance Actions Returns An Immediately Deployable Aircraft To The Unit With Significantly Improved Operational Availability And Safety Characteristics

  9. Reset Sites AFMD/ALMD*  Ft Drum UH-60 Ft Lewis UH-60 and CH47   Hawaii (Non-Enduring) Ft Bragg UH-60 and OH-58    Hawaii  Ft Stewart UH-60 and CH-47 Drum (DOL) UH-60 USAREUR (Non-Enduring) Ft Hood UH-60, AH-64, OH-58 Ft Campbell UH-60, CH-47, AH-64  Germany Installations with AFMD and ALMD Activities Installations with ALMD Only Installations with AFMD Only * Aviation Field Maintenance Directorate / Aviation Logistics Management Division

  10. Pre-deploy Staging Leave time Transit To POD In Transit Load Offload RSOI MREs RESET BOG Home ALD POE LAD POD -10 -120 -85 -55 -45 -35 0 +30 Aviation Reset Status Various Stakeholders Deployment Critical Timeline To Include Mods -ARFORGEN- Reset Summary Status • Completed 2,906 Aircraft (Includes SOA – 353 A/C) • OIF1 – 923 (Includes 75 SOA) • OIF2 – 426 (Includes 62 SOA) • OIF 04-06 – 561 (Includes 53 SOA) • OIF 05-07 – 446 (Includes 74 SOA) • OIF 06-08 – 452 (Includes 73 SOA) • OIF 07-09 – 98 (Includes 16 SOA) • Aircraft In Reset Or Scheduled For Induction • OIF 06-08 – 10 In Reset; 0 Scheduled • OIF 07-09 – 112 In Reset; 228 Scheduled Data as of 13 Jan 09

  11. Support to the Warfighter • Aviation Field Maintenance Transformation • Reset • Condition Based Maintenance (CBM)

  12. Digital Source Collector Installation • Knowledge Development • Fault Diagnosis • Remaining Useful Life Calculation • Inspection Targeting Condition Based Maintenance (CBM) • Reactive Maintenance • Time Based Inspection/Overhaul • Proactive Maintenance • ‘On Condition’ Inspection/Overhaul Monitored Master Parts List – UH-60A/L (56 Parts) CBM Program Objectives: • Decrease Maintenance Burden on the Soldier • Increase Platform Availability and Readiness • Enhance Safety • Reduce Operations & Support (O&S) Costs T/R Blade T/R Pitch Change Horn PC Links M/R Spindle Spherical Bearing M/R Spindle Tie Rod Control Horn M/R Shaft Extender M/R Damper Main Rotor Hub Main Rotor Shaft Bifilars Swashplate ASSY Swashplate Guide Swashplate Bearing** PC Links T/R Pitch Change Shaft T/R Pitch Change Bearing M/R Blade M/R Blade Tip Cap M/R Blade Expandable Pin M/R Blade Cuff Tail Rotor GB** Retention Plates (2) Gearshaft Viscous Bearings (4)** T/R Driveshafts (7)** Vibration Absorbers (2) Intermediate GB** • Key CBM Enablers • Digital Source Collectors • Flight Line Diagnostics • Data Fusion/Analysis Engine (No. 1 & 2) Driveshafts (2)** Input Modules (2) Main Transmission Module Accessory Module Generators (2) Hydraulic Pumps (2) Planetary Carrier Oil Cooler Axial Fan Oil Cooler Fan Bearing** APU Currently Monitored by Vibration Structural Part, Possible Addition for Monitoring

  13. Digital Source Collector FieldingsThrough Jan 09 * Includes Active, Reserve, and National Guard Units

  14. CBM Demonstrated Benefits • Increased Readiness • Decreased Mission Aborts 4-101 Avn Flew 26,000 Hours on 38 UH-60 During 12 Month OIF Deployment With 87% FMC • 57 Hrs/Acft/Month = 3.8 Times Peacetime OPTEMPO • 7,260 Launches With No Missions Dropped for Maintenance • 3,417 Hours in Highest Month (~110 Hours/Day With 20-25 Aircraft) Impact of Equipping Deployed UH-60s Battalions With DSCs CBM Will Enhance Pilot Training by Providing Insight Not Previously Available (e.g., Fatigue Damage Due to Maneuver Severity) Expect Increased Readiness in Deployed. Real Comparison Is Deployed CBM vs Non-CBM Deployed Aircraft CBM Already Changing the Way Aviation Operations Are Planned & Conducted CBM = Increased Warfighting Capability

  15. CBM Benefits to Army AviationIncreased Readiness/Reduced O&S Costs/Reduced Soldier Burden Impact of Equipping Aircraft With DSCs Cost Savings/Avoidance $24M: 51 T700 Engines not Replaced on UH-60/AH-64 for Overspeed/Overtorque ~$30M: Additional AH-64/UH-60 Flight Hours Available Due to Increased Readiness/Availability + MTF Hours Saved ~$49M: Three Class A Accidents Avoided ~$6.6M: Components not Replaced, Returned to Service, and Overhaul Savings Due to Early Failure Detection ~ $2.8M: AH-64 Tail Gearbox Scheduled Maintenance ~$112.4M Reduced NMC Due to Maintenance Cost Savings/Avoidance of ~$112M (26 Month Period) Due to CBM (Accidents Avoided, Components Not Replaced Unnecessarily, MTF Hours Saved,… )

  16. HELLFIRECaptive Carry Health Monitor • Methodology – Automatically Measure and Record • Captive Carry Hours / Number of Cycles • Temperature Exposure • Battery Life • Data Histogram • Drop Shock/Humidity • Payoff • Reduced Maintenance Burden • Increased Reliability and Enhanced Safety • Positive Impact to Stockpile Readiness and Shelf Life CCHM Captive Carry Exposure Data Will Optimize Reset Maintenance, Improve Reliability, and Reduce Reset Costs Hellfire II (AGM-114K) Guidance Section

  17. Challenges • Reset • Funding • ARFORGEN Synchronization • Increased OEF Support • OIF Retrograde

  18. Our Customers We Are Here… BECAUSE THEY ARE THERE !!!

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