Challenges

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18 Νοε 2013 (πριν από 3 χρόνια και 8 μήνες)

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Integrity


卥牶楣S


䕸捥汬敮捥

WR
-
ALC
Maintaining the
Fleet

Maj

Gen Polly
Peyer

HQ WR
-
ALC/CC

26 Aug 2010

Air 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 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



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


0

Velocity
(hrs/day)


Industry
Velocity

PDM

ISO

ISO

HSC

ISO

Mx

Cycle

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 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)



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 Integrated

Aircraft Test Environment


C
-
5 #840059 crash near
Dover AFB on 3 April 2006

402 SMXG participated in
post crash recovery efforts

Benefits
s
:




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 Integrated

Aircraft 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)


Status

Project 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 POCs

Name




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
-
ALC


B
-
2


F
-
15 IFF


F
-
16 IFF


Global Hawk


LAIRCM


MILSTAR


JSTARS


Space Crypto


CARA


AN/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
Opportunities

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