INTEGRATED MAINTENANCE PLAN [PDF]

ENGINES. • Commercially. Supported Platforms. Maintenance. Specification. Development. RCM. ANALYSIS. OPNAV/. Fleet. A

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Idea Transcript


INTEGRATED MAINTENANCE PLAN CAPT GORDON COWARD AIR 6.1A CAPT BOB BLAKLEY AIR 3.2A

The Push Behind Going to Fixed PED $ Millions

Increased Operational Commitments (Desert Storm)

Decreased Facilities(BRAC)

SDLM $$ Requirement Bow Wave

ASPA Deferrals FY Funding

Years Pre IMC/P: SDLM / PED Adjusted by ASPA to fit Op Tempo & Budget Constraints • Unpredictable Depot level maintenance budget • A/C material condition declining • Multitude of ISR/PE repairs

Post IMC/P: Fixed PED w/Integrated Maintenance • • • •

Improved Material Condition Based on Reliability Centered Maintenance Analysis Integrated Maintenance Levels (where appropriate) Budget Predictability

CNO DIRECTION ESTABLISH ESTABLISH A A PLAN PLAN TO TO TRANSITION TRANSITION TO TO FIXED FIXED OPERATIONAL OPERATIONAL SERVICE SERVICE PERIODS PERIODS THROUGH THROUGH THE THE IMPLEMENTATION IMPLEMENTATION OF OF RCM-BASED, RCM-BASED, SUSTAINED SUSTAINED MAINTENANCE MAINTENANCE PLAN. PLAN.

TOTAL SOLUTION ALL PARTS MUST RECEIVE EQUAL CONSIDERATON

Integrated Maintenance Concept/Plan

OPERATIONAL SOLUTION

ENGINEERING SOLUTION

BUSINESS SOLUTION

-Fleet buy-in -Executability by O and D level -Supportability

-RCM Analysis -Task Packaging -Structural integrity

-Improved readiness -Depot concerns -Cost

Integrated Maintenance Concept/Plan IMPLEMENTATION

• S-3B • F/A-18 A-D • AH-1W • E-2C

IMC/P LIFE CYCLE RCM ANALYSIS

Maintenance Specification Development

• H-60B, F, H PROTOTYPE

! UH-1N • H-53E

Age Exploration & Sustainment

Supportability Analysis & BCA

• H-46E • C-2A • C-130 F/R, T • EA-6B

Implement/ Monitor

• F-14 A-D

Baseline/ Transition Execution Planning

DEVELOPMENT

• AV-8B FUTURE EMPHASIS

OPNAV/ Fleet Approval

• ENGINES • Commercially Supported Platforms

DEVELOPMENT SUSTAINING

FLEET BENEFITS • Improved Aircraft material condition • Reduced Depot Out of Service Time, increased Aircraft Availability • Scheduled maintenance tasks are performed at the right interval, by the appropriate skill level unconstrained by traditional locations. • Reduced O-level down time and maintenance req’ts • Reduced In-service Repairs. • Integration between Sailors and Depot Artisans.

H-60 IMC PROGRAM BRIEF ASPA1

7Days

7Days

7Days

1 Year

4 Years

18-24 MOS

7Days

ASPA5+

7Days

SDLM

11- 12 YEARS SINCE LAST DEPOT INDUCTION Fixed Period End Date

2 Years

2 Years

2 Years

PMI 1

POI 618 Days

2 Years

Total Operational and Maintenance Service Period

Fixed Service Period (FSP)

45 Days

POI 685 Days

PMI 4 112 Days

FI D

FI D

POI 660 Days

PMI 3 45 Days

POI 685 Days

PMI 2 70 Days

FI D

PMI 1 45 Days

FI D

Repeat PMI Cycle

POI 685 Days

2 Years

LOCATIONS WHIDBEY WHIDBEY ISL ISL EA-6B EA-6B

NASLemoore Lemoore NAS F-18 F-18

Norfolk/Oceana Norfolk/Oceana NavalBase Base Naval F-18 F-18 E-2 E-2 F-14 F-14

CampPendleton Pendleton Camp H-1 H-1

NASNorth NorthIsland Island NAS H-60,F-18,E-2/C-2, F-18,E-2/C-2, H-60, S-3 S-3 MCASMiramar Miramar MCAS F-18 F-18

CherryPoint Point Cherry H-1,H-53, H-53,H-46, H-46, H-1, AV-8B,EA-6B, F-18 AV-8B,EA-6B, F-18 NSMayport Mayport NS H-60 H-60 CCAD CCAD H-1,H-60 H-60 H-1,

MCASKaneohe KaneoheBay, Bay,HI HI MCAS

NAFAtsugi, Atsugi,Japan Japan NAF E-2 E-2 F-18 F-18 H-60 H-60 H-1 H-1 H-53 H-53

MCASBeaufort Beaufort MCAS F-18 F-18

NASJacksonville Jacksonville NAS EA-6B EA-6B P-3 P-3 H-60 H-60 S-3 S-3

Field Site Depot Site

EXAMPLES OF BENEFITS SEEN BY THE FLEET S-3B: • Reduced O-level down time by 25 days per year • Eliminated 19K maintenance man-hours per year • Elimination of Calendar day inspections beyond the 56 day (benefit underway) AH-1W: • “SDLM” Cost Avoidance of $830K per A/C inducted • Reduced Phase Maintenance tasks 50% (from 100hr intervals to 200 hr interval) • Reduced OTS by 126 days (SDLM 310 days, IMC 184 days over full cycle) EA-6B: • Out of service time due to scheduled inspection decreased by 67% (28, 56 and 224 day inspections rolled to the 364 day) • Post Cruise Inspections revealed that aircraft that have been through a PMI event had a better material condition and less corrosion than was historically noted

SCOTT NAST BRIEF

Integrated Maintenance Data Collection • Work Deck (similar to maintenance requirement cards) – Maintenance Guide • provides standard guide through each maintenance event • supports similar rapid maturation of process at all sites

– Data collection template • is the template for written feedback from all sites • data collection parameters are identical for all sites

– data transfer • data entry from work deck into data base

Work Deck card - front example CARD 99

NAVAIR 01-H1AAC-IMC-SPEC DATE 9 August 2001 REVISION DTD TRADE

WORK ZONE / TASK NO.

NAVAIR 01-H1AAC-IMC-WD DATE 9 August 2001 REVISION 3 DTD 24 May 2002 BUNO

BASELINE INSP/TEST/REPAIR

STRUCTURE

TAILBOOM COLDWORKING

ELEC PWR

NA

HYD PWR

NA

COND AIR

NA

NOTE: Ensure all IMC disassembly and inspections have been completed prior to tailboom removal should the tailboom have to be removed. 8 – 2UY0004

1. Ensure that LES CP 80-50-EE-9238 with Amendment 1 has been complied with. This is a onetime rework of specific areas on the tailboom.

End of Card TASK NUMBER

START DATE

FINISH DATE

MMHRS TOTAL

STAMP

2UY0004

Form SOP H1-001-A

Rev 3 Rev Date: 24 May 2002

Work Deck card - back example CARD 99A

NAVAIR 01-H1AAC-IMC-SPEC DATE 9 August 2001 REVISION DTD

NAVAIR 01-H1AAC-IMC-WD DATE 9 August 2001 REVISION 3 DTD 24 May 2002

BASELINE

TRADE STRUCTURE

BUNO

TAILBOOM COLDWORKING TASK NO.

MAL CODE

Form SOP H1-001-A

LENGTH /WIDTH/ DEPTH

WATERLINE /BUTTLINE/ STATION

L W

FS BL

D

WL

L

FS

W

BL

D

WL

L

FS

W

BL

D

WL

L

FS

W

BL

D

WL

L

FS

W

BL

D

WL

L

FS

W

BL

D

WL

CRIT CODE

TYPE DEFECT NBNC ETC

WUC

EST RPR TIME

DESCRIPTIVE DEFECT/DESCRIPTIVE REWORK

MMHRS TO REPAIR

DISCR P/N

QA STAMP

Rev 3 Rev Date: 24 May 2002

Data Access and Presentation • IMC Web Site – common portal for: • data entry – example page

• reports – examples » standardized reports » discrepancies discovered on airframe model » mal code frequency » mal code frequency times cost in man-hours

• RCM data entry and analysis • messages search

Website Browser Page

The blue buttons allow the user to browse through the website. The grey bar on the left is for administration. It is not shown on the regular web page. The next page shows the data entry from remote sites page, and is accessed through the admin area.

Data Entry Form

“Reports”

3D Viewer

3D Viewer Search Engine

3D Viewer Populated

“Reports”

MAL CODES AVG RPR TIME X AVG MALCODE TRUNCATED 500

450

AVG RPR TIME X AVG MALCODE HITS

400

350

300

250

200

150

100

50

0 190

105

170

020

070

246

800

093

804

846

MALCODE

160

935

135

780

350

117

302

127

429

087

MAL CODES AVERAGE MALCODE COUNT ALL SITES TRUNCATED 400

350

AVERAGE COUNT

300

250

200

150

100

50

0 105 170 070

020 246 190

093 800

160 804 350

117 935 302

846 429 135

MALCODE

780 801 425

440 022

381 766 306

114 074 710

BACKUP SLIDES

AIRCRAFT AVERAGE AGE (YEARS)

Background Aircraft Age & Inventory AVERAGE AIRCRAFT AGE

25 24 23 22 21 20 19 18 17 16 15 14 13 12

HELICOPTER

ACTIVE INVENTORY FY1997 AVERAGES: FY1997 AVERAGES: 16.7 YRS 16.7 YRS 14.7 YRS 14.7 YRS 13.6 YRS 13.6 YRS

COMBINED

–HELICOPTER –HELICOPTER –COMBINED –COMBINED –FIXED WING –FIXED WING

FIXED WING

89

90

91

92

93

94

95

96

FISCAL YEAR

98

99

00

01

"

ACTIVE INVENTORY

Life Cycle Support Costs ratio has increased

5,500

5,605

5,487

5,497

5,250

5,000 4,925

4,500

4,514 4,228

4,169

4,406

4,000

4,167

4,079

3,500 3,000

89

90

91

92

93

94

95

FISCAL YEAR

96

97

SOURCE: ACTIVE AIRCRAFT INVENTORY FY89-99 BASED ON FY89-96, A-II INV DATABASE, AND A-II JUL 97 REPORT

98

Naval Aviation TOA

6,500 6,000

02

• DoN in a Shrinking Budget Environment

NUMBER OF AIRCRAFT 7,000

97

Life Cycle Support Costs

99

Years

03

Reliability Centered Maintenance What is RCM? A life cycle process that: •



Establishes and adjusts preventive maintenance (PM) requirements for all maintenance levels. Bases PM on the failure characteristics of the equipment Allows equipment to realize its inherent reliability at lowest cost

RCM LIFE CYCLE Develop RCM Plan *

Failure mode analysis

Data collection

Task Evaluation & Selection

Fleet Benefits • Improved ACFT material condition • Increased ACFT Availability • PM tasks completed at the right interval, by the appropriate skill level unconstrained by traditional locations • Reduced O-level down time and maintenance requirements • Reduced ISR cost • Integration between O/I/D as appropriate

• Savings generated by RCM is across the Fleet Implement, Monitor & Trend Top Degraders

Package O/I/D Maintenance Tasks

Requires PRL funding

* RCM plans is approved by NAVAIR

! P-3 Flap Actuator $6 Million over 5 years ! EA-6B Landing Gear $7 Million Dollars over 5 years ! T-45 84 day Corrosion Inspection Large Reduction in Labor man-hours and airplane down time ! E-6 Aft Engine Mounts $1.5 Million over life of A/C ! AH-1 Change to IMC 30% reduction labor man-hours 50% reduction in Depot turnaround time

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