1 ageing aircraft thoughts on a path forward robert ernst head, aging aircraft ipt chairman, joint...
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Ageing Aircraft
Thoughts on a Path Forward
Robert Ernst
Head, Aging Aircraft IPT
Chairman, Joint Council On Aging Aircraft
20 June 2006
Or… Getting Industry to help us advance the issue with aircraft aging
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Aging Aircraft IPT
Avionics Team
Training
Parts
Commonality
Air Vehic le Team
Avionics Team
Wiring & Power Team
Obsolescence Team
Touch-Up Paint Process
Approx 80 Fleet and Depot Personnel Trained on AWA
Equip
Data from F/A-18 to improve H-60 Hydraulic Seals
Analysis
TransparenciesWash Cycles: Reduced MMH
(est. 20,000)
Logistics
DiagnosticsAWA
4-6 Parts Inquiry77% of Investigation Resolved236 DMSMS Cases Reviewed
YTD
Lead Free Solder
Tools: $3.3M in Cost Avoidance (V-22)
Training
ADEC
JCOMMS (All Platforms)
Semi-Conductor Device Wear-out
AFCB Core Logistics
Fleet IntroductionFleet Survey’s (Wiring &
Corrosion) = Approx 1,000Updated & Released 01-
1A-509 Vol 1 thru -4
Batteries: $3.2M MMH & Maint Savings
CYCLE TIME RELIABILITY INVENTORY TOTAL OWNERSHIP
COSTMULTIPLE
“Improving the fleet’s readiness and reducing life cycle cost by aggressively attacking and countering the effects of aging aircraft.”
Focusing Efforts across platforms and PMA’s
Improve aging systems availability while reducing total ownership cost through reductions in cycle time, Man-hours, inventory, and operating costs in various functional areas.
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Who is the JCAA?Who is the JCAA? Jointly Identify, Investigate, and Implement Programs that will Field Products to Improve the Availability and Affordability of all the Services’ and Agencies’ Aging Aeronautical Systems.
Through the use of Integrated Roadmaps, Shared Data and Analyses, the JCAA will:
– Identify Process Recommendations & Improvements
– Advocate/Enable Promising Technology
– Facilitate Transition of Technology/Program Opportunities
– Promote Knowledge Management on Aging Aircraft
– Coordinate Funding for Promising Areas
VisionVision
ProcessProcess
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National Strategy ProgressNational Strategy Progress
JCAA Focus
• Maintenance Training• Analytical Methods/Cost of Aging• Corrosion Prevention• Transition of Commercial Products • Diagnostics/Health Monitoring Systems• Wiring Failure Detection• Arc Fault Circuit Interrupt Equipment • Structural Modeling and Analysis • Maintenance Manual Currency• Obsolescence Management• Avionics Modernization • Component Improvement
NASA
FAAAir
Force
Navy
DLA
Army
Considering Resources,
Overall Progress
OK
CoastGuard
USMC
NDIA
AIA
5 Process Issues
7 Product Focus Areas
Five “Greens” – Four “Yellows” – Three “Reds”Five “Greens” – Four “Yellows” – Three “Reds”
5
0
5
10
15
20
FY04 FY05 FY06 FY07 FY08 FY09 FY10 FY11 FY12 FY13 FY14 FY15 FY16 FY17 FY18 FY19 FY20
VH-XX
CH-53E
AH-1Y/AH-1Z
MH-60S
MH-60R
T-45
JPATS
KC-130J
T-39
C-37
UC-35
C-40
MMA
MV-22
UAV (BAMS, UCAV-N)
AEA (EA-18G)
E-2
F/A-18E/F
JSF(NAVY)
JSF(USMC)
Control
Procurement Bow Wave PR05
AEA
MMAMV-22
F/A-18E/FJSF CVTOL
JSF STOVL
$TYB
E-2C
CH-53E
BAMS/UCAV-N
100 Aircraft
200 Aircraft
300 Aircraft
MH-60R/S
Flatten the FY08-11 Bow WaveFlatten the FY08-11 Bow Wave
PR05:FY04 $11BFY09 $20B
PR05:FY04 $11BFY09 $20B
Need to reduce operating costs to free up money for
procurement
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Aging Aircraft – Steps to Aging Aircraft – Steps to SuccessSuccess
1. Start with good data and understand what is driving the behavior.
• Share data among many sources• Allies with smaller fleets may be able to see
small changes before larger fleets
• Look at Commercial Applications???
Obstacle: We need to share information and send the same Message to “Leadership”Challenge: Nobody wants to fund “data”
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Data• Target studies (what do we care about?)
– Collect Baseline costs– % Reduction (task analysis)– Post Implementation Analysis
Naval Aviation Flying Hour Program CostsReported by CAVTS for All Aircraft Except CNET
0
500
1000
1500
2000
2500
3000
3500
4000
4500
FY
1991
FY
1992
FY
1993
FY
1994
FY
1995
FY
1996
FY
1997
FY
1998
FY
1999
FY
2000
FY
2001
FY
2002
FY
2003
FY
2004
FY
2004
Co
st p
er F
ligh
t H
ou
r
0
200,000
400,000
600,000
800,000
1,000,000
1,200,000
1,400,000
1,600,000
1,800,000
Flig
ht
Ho
urs
Exe
cute
d
Fuel
Maint Cons
AVDLR
Flight Hours
How can we divide up the pie?
All Aircraft (All but CNET) (All Program Elements) (All Schedules)
$0.0
$0.5
$1.0
$1.5
$2.0
$2.5
$3.0
$3.5
$4.0
$4.5
$5.0
1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009
Total FHP Cost per FH (TY$)
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Cost of Aging WorkshopCost of Aging Workshop• As part of the overall Cost of Aging
Study, JCAA Chaired a meeting with industry cost experts to evaluate:
– Cost Elements, Age Related Factors, Analysis Best Practices, And Using CoA Information
• Workshop Recommendations:– Establish Joint CoA Board– Establish CoA Community Of Practice– Develop CoA Analysis Guidebook/Handbook – Work With DAU To Develop CoA Curriculum– Review How Modifications Are Treated In
CoA Analyses
Are we sharing Information and Training the next Generation?Are we sharing Information and Training the next Generation?
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Aging Aircraft – Steps to Aging Aircraft – Steps to SuccessSuccess
1. Start with good data and understand what is driving the behavior.
• Share data among many sources
• Allies with smaller fleets may be able to see small
changes before larger fleets
2. Its an international world whether you like it or not
Question: What’s the most cost effective approach
A) Dispatch a USAF C-17 from Dover to Indonesia with support or
B) Have the RAAF dispatch aircraft from Perth?
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Boxing Day Tsunami
Support not limited to $$$
December, 26, 2004 Earthquake hit, 220,000 dead or missingInternational Relief Effort$7 Billion Pledged from Many (50?) countries
Country Financial Military
Australia 7644 helicopters, Ship, & personnel
UK 464 4 planesChina 83Denmark 75 shipSpain 68France 66Germany 647 2 helicoptersNetherlands 259Qatar 25Russia 10South Korea 63Japan 500
US 65014 cargo + 90 helicoptersWhat Barriers Exist?
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Steps to Success - InternationalSteps to Success - International
1. Use of our Collation Allies reduces the burden on the American taxpayer in support of GWOT
2. US has a $40 Billion trade Surplus in aerospace
3. Cost of Consumable Parts is rising by 12% per year impacting our Services Readiness• Obsolescence/ Manufacturing Sources largest single issue
4. FMS Military sales and Commercial Sales Impacted by overly restrictive export Control Laws
Solution?A) Expand JCAA to Include Foreign AlliesB) Two Year waiver on Post MS C Airframe PartsC) FastTrack ITAR Process for Allies
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Aging Aircraft – Steps to Aging Aircraft – Steps to SuccessSuccess
1. Start with good data and understand what is driving the behavior.
• Share data among many sources
• Allies with smaller fleets may be able to
see small changes before larger fleets
2. Its an international world whether you like it or not
3. Its not just technology, but think technology with your logistics
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Smart Tech Insertion for Legacy Systems• Automatic Data Collection Coupled with Technology• Evaluating Commercial Sources (Push/Pull)• Re-Establish Joint
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Tech Refresh – Tech Refresh – Key to Cost Wise ReadinessKey to Cost Wise Readiness
Problem: Current aircraft batteriesProblem: Current aircraft batteries• have to be inspected every 28 days (56,000 Man Hours)have to be inspected every 28 days (56,000 Man Hours)• 80% have to be replaced within a year80% have to be replaced within a year
MOAFeasibility
Evaluate COTS SolutionsEvaluate COTS Solutions
Operational Test
Qual Test
Spec Sheet Coordinate Funding for TestingCoordinate Funding for Testing
ECP
DCN’s
Procurement
Transition Logistics to Transition Logistics to Program TeamProgram Team
Providing the mechanism to transition better technologyProviding the mechanism to transition better technologyWhat’s the next successful program?What’s the next successful program?
NSTCNSTC
JCAAJCAA
JALCJALC
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NSTC Example : PD- 680• Problem:
– Not environmentally friendly,– being phased out, – will require multiple replacements –– yet to be identified, evaluated, accepted.
• Phase I:– Screen Tech Manuals referencing PD-680 to assess
requirements for replacements– Query other services– Map applications & status of potential substitutes
• Phase II:– Develop RFI to query industry– Evaluate non-aqueous cleaners against spec– Validate performance
• Phase III– Update Source Data (publications)
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Aging Aircraft – Steps to Aging Aircraft – Steps to SuccessSuccess
1. Start with good data and understand what is driving the behavior.
• Share data among many sources
• Allies with smaller fleets may be able to see small changes before larger fleets
2. Its an international world whether you like it or not
3. Its not just technology, but think technology with your logistics
4. We need to fix the gaps. • Champion promising technology• Take risks; bring it to the market place
PM Dilemma – Successful Tech InsertionPM Dilemma – Successful Tech InsertionDevelopment Transition Acquisition Sustainment
The Frogger Affect
PM Dilemma – Successful Tech InsertionPM Dilemma – Successful Tech InsertionDevelopment Transition Acquisition Sustainment
The Frogger Affect
Government Oversight and Regulation
Performance Based Logistics (without
data)
Misguidedmicro-management
Irresponsibleignorance
Too costly Too riskyWe cannot expect
industry to develop technology without
government sharing the risk
• Identify the top concerns• National Strategy
• Work With Industry• Defense Sustainment Consortium• AADI/DSTO
• Fund the Gaps• Work the Transition• Work as a Team
Contracts Planning ScheduleMAR 30 Update
FEB MAR APR MAY JUN JUL AUG SEP
3rd Qtr Incremental
Funding
FastTrack Source Selection
DSC
FastTrack Award
AAIPT Omnibus (Option #1)
Business Clearance & CAP
Draft RFP Released Proposals
Source Selection
AAIPT Omnibus (Option #2?)
Airweighs
RFP ProposalsAirweighs Contract
Source Selection
AWA
Negotiations
RFI
Sources Sought
Business Clearance & CAP
Execution & Task Order Awards
FY06 Congressional Add
FY06 Option Award
4th Qtr Incremental
Funding
3rd Qtr Supplemental
Funding
Industry Day
Final RFP Released
PPC
PPC
Award Fee Determination
Multiple SAP Awards
Multiple SAP Awards
Industry Day
Specs & Standards
????? ?????
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Available Workforce
-2.004.006.008.00
10.0012.0014.0016.0018.0020.0022.00
Feb-06 Mar-06 Apr-06 May-06 Jun-06 Jul-06 Aug-06 Sep-06
Wo
rk-y
ea
rs
Program Management Contracts Engineering Cost Financial
Contracts and Acquisition Workload
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Smart Push - PullSmart Push - Pull
1. Program Teams are Overwhelmed• Need Smart Contracting• Work “Smarter” not “Harder”
2. OEM’s getting a large portion of “bundled” requirements
NAVAIR Small Business efforts decreasing
3. Promising Technology not being transitioned
• Small Businesses being hurt
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Aging Aircraft – Steps to Aging Aircraft – Steps to SuccessSuccess
1. Start with good data and understand what is driving the behavior.
• Share data among many sources• Allies with smaller fleets may be able to see small
changes before larger fleets 2. Its an international world whether you like it or not3. Its not just technology, but think technology with
your logistics4. We need to fix the gaps. • Champion promising technology• Take risks; bring it to the market place
5. Steal the good ideas
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NAVAIRNAVAIR
Defense SustainmentConsortium
Executive Director
Defense SustainmentConsortium
Executive Director
National Sustainment Technology Center (NSTC)
Director and Staff San Antonio
National Sustainment Technology Center (NSTC)
Director and Staff San Antonio
DSC ConsortiumMembers
DSC ConsortiumMembers Tactical Board
Members
Tactical BoardMembers
Fulltime DSCMembers
IndustryGovernment
MilitaryAcademia
Fulltime DSCMembers
IndustryGovernment
MilitaryAcademia
Associate Memberwith tasking
Task and Project-Oriented Member
Associate Memberwith tasking
Task and Project-Oriented Member
Advisory BoardAdvisory Board
OEMsGovernment
Stakeholders (DLA)Prime Integrators
Rotating SmallBusiness
Representative
OEMsGovernment
Stakeholders (DLA)Prime Integrators
Rotating SmallBusiness
Representative
JointAeronautical
Commander’s Group (JACG)
JCAA
NationalStrategy
Maintenance Training
Analytical Methods/Cost of Aging
Corrosion
Transition of Commercial Products
Diagnostics/HealthMonitoringSystems
Wiring Failure
Arc Fault Circuit
Structural Modeling and
Analysis
Maintenance Manual Currency
ObsolescenceManagement
AvionicsModernization
ComponentImprovement
ProvideConcurrence
Match Required Taskswith Resource Members
Provide Task OrderExecutive Management
Provide Strategy andRecommend Priorities
DefenseTechnology
Cluster(DTC)
DefenseTechnology
Cluster(DTC)
San Antonio Region Capability Identification
San Antonio Region Capability Identification
Defense Transformation
Institute (DTI)
Defense Transformation
Institute (DTI)
SATAISATAI
North Chamber
North Chamber
San Anto
nio
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Aging Aircraft – SummaryAging Aircraft – Summary
1. How can we Integrate the OEM’s effectively?
• Share data among many sources• “Phantom Works” tech insertion
2. Support Common Policy• ITARS Relief• Obsolescence Policy (AQEC)
3. What Promising Technology do we want to target?
• Address National Strategy• Push from Small Businesses
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Questions?
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Small Business SuccessesAging Aircraft Omnibus Contract ($40M+ over 5 years)• Goal: 30% Small Business Participation
• 26 Small businesses have received tasking to date (~$5M)
• 3rd Year begins 03 Aug 2006
FastTrack ( $450M over 7 Years )•Soon to be awarded
•Goal: 40% Small business participation
Intermediate/Depot Level Wiring Diagnostics ($12.4M)•Final year of multiyear contract with Eclypse
Organizational Level Wiring Diagnostics ($900K)•Joint NAVAIR/NUWC effort contracted with CM Technologies
Multiple Stand-alone Simplified Acquisition Contracts $95K
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Sharing the Technology Risk
Government Oversight and Regulation
Performance Based Logistics (without
data)
Misguidedmicro-management
Irresponsibleignorance
Too costly Too risky
We cannot expect industry to develop technology without government sharing the risk
• Identify the top concerns• National Strategy
• Work With Industry• Defense Sustainment Consortium• AATD/DSTO
• Fund the Gaps• Work the Transition• Work as a Team
Good technology that could Improve Readiness and Reduce Costs will not get into use unless we change the way we develop, test, acquire and support
Bob’s Approach
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– Technology & PolicyA) USAF and USN Policies and Procedures have caused us
to create different certification and training requirements• No apparent reason why these procedures can’t be common• Hugh impact on Publications and training• Gas Free Environment (Fuels), Repair Technology
(Composites)
Potential Exists for Greater Savings if these Policies are Standardized (Outside scope?)
B) Services utilize different technologies• Requires sharing of qualification data• Corrosion Efforts a Good Example of single qualification applied
to all services• Model will be applied to De-Ice, Composite Repair
Commonality has atrophied – will require funding and support to make additional gains