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