dod maintenance maintenance symposium symposium … · 2008. 10. 27. · cnc mitsui seiki jig bore....

CENTERSOUTHEAST

FLE

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INE

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Fleet Readiness Center Southeast

Captain Timothy S. Matthews – Commanding Officer

DoD Maintenance SymposiumManufacturing Panel

27 October 2008

DoD Maintenance SymposiumManufacturing Panel

27 October 2008

Fleet Readiness Center, Southeast

We fix it right, so they’re ready to fight!

Mission:Mission: We provide aviation maintenance solutions that satisfy Navy Warfighters’ demands.


DEMOGRAPHICS

Largest Tenant Command on Naval Air Station Jacksonville

Largest Industrial Employer in Northeast Florida / Southeast Georgia

70 Buildings on 127 AcresApproximately 45,000 Pieces of Plant Equipment

Total Replacement Value in Excess of $720 Million

2,910 Civilians and 1,016 Military Augmented by over 600 Contractors

Average Civilian Age 51

Approximately 120 Occupations

One of every 10 manufacturing jobs in Jacksonville is at FRCSE

Site Key West


Site Jax

Site Mayport

Presenter

Presentation Notes

Demographics for Sites Mayport – 2 Buildings on 2.01 Acres 7 HVAC systems and 1 heating system, comprised of 5 handlers, 2 boilers, and 2 chillers – Total replacement cost $1.75M Key West – 9 Buildings on 17 Acres 183 Pieces of plant equipment – Total replacement value >$24M Jax – 6 Buildings on 5.96 Acres


WHY WE EXISTFRC’s are Key to Readiness

Ready, Controlled Source of Depot Maintenance

Minimize Equipment Out-of-Service Time

Assure Steady Flow of Engines and Components

In-Service and Emergency Repair On-site

Quick Response Manufacturing Capabilities

Capability to Repair Close to 7,000 Different Components

• Routinely work less than 1/3 of these Components each year.

We are there for the Fleet, when the Fleet needs us


BUSINESS-LIKE…BUT NOT A BUSINESS

A Business FrameworkA Business Framework

Revenues Cover CostsRevenues Cover Costs

A Business PerspectiveA Business Perspective

Focus on Quality, Costs, and Focus on Quality, Costs, and Financial ResultsFinancial Results

A Business CultureA Business Culture

CompetitivenessCompetitiveness

““Best ValueBest Value””

But . . . A Military MissionBut . . . A Military Mission

Motivated by Customer Motivated by Customer RequirementsRequirements

Fleet readiness, not profit!

INDUSTRIAL MANAGEMENT LEADERSHIPUse of State-of-the-Art Business Management Tools

Critical Path Modeling

Project Management Methodology

MRP II in a Remanufacturing Environment

Lean Manufacturing

ISO 9001:2000 Standard Certification

AS9100:2004 – Revision “A”Certification

Aerospace Version

ISO 14001:2004 – Environmental Management System


PARTNERSHIPS…WHAT ARE THEY?Agreement Between Public and Private Sector

FRCSE Provides Articles and / or Services to Industry

FRCSE Serves As:Subcontractor to

• Prime Contractor / Original Equipment Manufacturer (OEM) on Existing Agreement

• OEM in Support of Basic Ordering Agreement (BOA)

Partner With Private Industry

• Provide Goods, Services or Facilities, Not Subject to Contract

Presenter

Presentation Notes


AN/ALQ-126B Electronic Countermeasures85% Guaranteed Availability

ALQ-142 Electronic Countermeasures 85% Guaranteed Availability

F/A-18 Cockpit Displays, HUD, DDI 85% Guaranteed Availability

F404 Engine Components85% Guaranteed Availability

AAS-44 Forward Looking Infra-Red (FLIR) 90% Guaranteed Availability

F/A-18 E/F Unique ComponentsGuaranteed Fill Rate

EA-6B Hydraulic Components 100% Guaranteed Availability

Performance Driven – Delivering Measurable Results

F414 Engine Components85% Guaranteed Availability

• SECDEF PBL AWARD WINNERS

PBL PARTNERSHIPSAvailability & Reliability

F404 Engine Main Fuel Control90% Guaranteed Availability

Presenter

Presentation Notes

Value indicates total dollar value of the contract over the various contract performance period for each contract. Usually five years with a five-year option. ~ General Electric Aircraft Engines, Lynn, MA: - F404 Repairable Engine Components - $513M ~ AAI Services Corporation, Choctaw, MS - EA-6B/F14 Hydraulic Components - $120M ~ Kaiser Electronics a Rockwell Collins Company, San Jose, CA - F/A-18 Cockpit Displays - $393M ~ Raytheon, McKinney, TX – - AN/AAS-44, H-60 Forward Looking Infra-Red (FLIR) - $123M ~ Honeywell - F404 Fuel Controls - $47M ~ Pratt Whitney - J52 - $24M ~ Boeing FIRST - F/A-18 E/F - $750M ~ Lockheed-Martin - H-60 Tip to Tail - $417M Future Growth with industry: MOOG ………………….F/A-18 Leading Edge Flap Actuators Parker Hannifin…………F/A-18 Trailing Edge Flap Actuators Raytheon………………..F/A-18 Advanced Targeting Forward Looking Infra-Red / & H-60 Multi-spectral Targeting System


Legislative AuthoritiesAuthority Description

10 U.S.C. 2208(j) Depot Sales of Articles or Services outside DoD if the purchaser is fulfilling a DoD contract.

10 U.S.C. 2474 CITE Designations and Public-Private Partnerships

10 U.S.C. 2539b Sale of Services for testing of materials, equipment, models, computer software, etc.

10 U.S.C. 2563 Sale of Articles or Services outside of DoD (specific conditions).(Formerly 10 U.S.C. 2553)

22 U.S.C. 2770 Allows sales of articles and services to a U.S. company for incorporation into end items to be sold to a friendly country.

FAR, Subpart 45.3 Permits provision of government-furnished equipment, material and facilities to contractors.

FAR, Subpart 45.4 Provides for contractor use and rental of government property.

Presenter

Presentation Notes

10 U.S.C. 2208(j)Permits depot financed through working capital funds to sell articles or services outside the DoD if the purchaser is fulfilling a DoD contract and the contract is awarded pursuant to a public-private competition. 10 U.S.C. 2474Requires the Military Departments to designate depot maintenance activities as Centers of Industrial and Technical Excellence (CITEs), authorizes and encourages public-private partnerships, permits performance of work related to core competencies, permits use of facilities and equipment and permits sale proceeds from public-private partnerships to be credited to depot accounts. 10 U.S.C. 2539bAuthorizes the sale of services for testing of materials, equipment, models, computer software, and other items. 10 U.S.C. 2563 (Formerly 10 U.S.C. 2553) Authorizes sale of articles or services outside the DoD (excluding those authorized 10 U.S.C. 4543), under specified conditions. 10 U.S.C. 2667Allows leasing of non-excess equipment and facilities. 10 U.S.C. 4543Authorizes Army industrial facilities that manufacture cannons, gun mounts, etc., to sell articles or services outside the DoD under specified conditions. 10 U.S.C. 7300Authorizes Naval shipyard sale of articles or services to private shipyards for fulfillment of contracts for nuclear ships. 22 U.S.C. 2754Allows sale or lease of articles and services to friendly countries and with certain conditions. 22 U.S.C. 2770Allows sales of articles and services to a U.S. company for incorporation into end items to be sold to a friendly country or international organization under specific conditions. FAR, Subpart 45.3Permits provision of government-furnished equipment, material and facilities to contractors. FAR, Subpart 45.4Provides for contractor use and rental of government property


Sales of Articles and Services 10 USC 2563: Articles and services of industrial

facilities: sale to persons outside the Department of Defense

Sale of articles & services by working capital fund industrial facilities not commercially availableNot commercially available = unavailable in required– Quantity,– Quality, or– Time

The articles or services can be substantially manufactured or performed by the industrial facility concerned with only incidental subcontracting The sale of the goods and services is made on the basis that it will not interfere with performance of work by the industrial facility concerned for the Department of Defense


10 USC 2563: (cont)

Methods of sales– Advanced incremental funding allowable

– Payments before the commencement of work or the incurring of costs in connection with the manufacture of the articles or the performance of the services

– Full cost, either reimbursable or fixed price

Fleet Readiness Center, SoutheastManufacturing

The manufacturing facilities at FRCSE Jacksonville utilize state of

the art equipment and techniques for producing precision parts and

assemblies. Components are made to precise standards to meet the

most demanding requirements. The wide range of processes

provides customers with unique capabilities not typically found at

one facility. The scope of our operations includes a variety of

advanced methods, with exceptional process controls and

production oversight.

FRCSE Jacksonville is ISO 9000/AS9100 certified and has fully

embraced and implemented Lean Process Improvement principles.

FRCSE MANUFACTURING CAPABILITIES

Fleet Readiness Center, SoutheastManufacturing

Sheet Metal Fabrication

* CNC Laser/Punch Press capability * Fluid Cell Press forming * Large capacity stretch forming * Large capacity flat pattern digital scanning * Large 8-axis CNC brake * Plastic forming and injection

Machine Tool Manufacturing

* Climate controlled CNC machine shop * Six new 5-axis machine centers, (four large capacity) * High speed machining technology * Thirty-three foot 5-axis gantry mill capability (end of FY ’09) * New large capacity (up to 30,000#) horizontal boring mill capacity * Advanced CNC turning and grinding capability up to 60-inch diameter * CMM measuring/inspection * Dedicated NC programmers

Surface Treatments

* Large Electroplating and Corrosion Control facility * Large environmentally compliant component and aircraft painting facilities * Manual and CNC shotpeening * Robotic and manual powdered metal spraying processes (Plasma, HVOF and Thermal) * Two large cleaning facilities with chemical & mechanical cleaning processes

Additional Processes

* Metal heat treat facilities (very large aluminum capability) * State of the art Non Destructive Inspection capability * Tool & Die, Pattern and Mold making facilities * In house Material Laboratory support Established “Critical Safety Item” process* In house FST Engineering for F/A-18, EA-6B, P-3, E- 6 and H-60. Utilize sister FRCs engineering staff on other platforms.* Qualified staff, process and facilities to perform First Article Testing (FAT).* Process engineering support staff


CPI Projects:– Manufacturing Equipment Modernization (FY03-08) - $21.0M

• Installed six new CNC 5-Axis Machining Center• Installed new CNC Horizontal Boring Mill• Installed new Hydro Form Fluid Cell Press• Installed new Stretch Wrap Press• Rebuilt two W&S Lathes• Procuring new Spar Mill• Procuring new CMM• Procuring new CNC Lathe

– Heat Treat Equipment Modernization (FY07-09) - $3.5M• Installed new small vacuum furnace• Procuring new aluminum processing furnace (salt bath) • Procuring new medium vacuum furnace• Procuring new pit, melting pot, and tempering furnaces

Industrial Manufacturing CPI

Manufacturing

Fleet Readiness Center, SoutheastSheetmetal Fabrication

CNC Strippit Laser/Punch Press Fluid Cell Metal Forming Press

Stretch Wrap Press CNC Strippit 8-Axis Press Brake


CNC Monarch Spinner Lathes CNC Hermle 5-Axis Machine Center

CNC G&L Horizontal Boring Mill CNC Mitsui Seiki Jig Bore

Machining


CNC 5-Axis Mitsui Seiki Machining Center

CNC Hauser Jig Grinders

Coordinate Measurement Machine (CMM)

Machining

Presenter

Presentation Notes

Why PBLs work: Improved Parts Support … Material availability increases + Logistics Response Time (LRT) decreases resulting in Improved Readiness Depot Efficiency … Repair Turn Around Time (RTAT), Awaiting Parts (AWP), & Work in Process (WIP) decrease Reliability Investment … Mean Time Between Failures (MTBF) improves Diagnostic Process Upgrades … inductions and frequency of repairs decrease Long-Term Contracts … enabler for above … firm fixed price for level of performance … long-term commitment allows contractor to amortize investment over greater length of time … structured to incentivize contractor to reduce demands and introduce efficiencies PBL’s are….. A Proven approach to cost wise readiness by industry assuming larger active role in system support PBL’s are.….The Solution to today’s challenges, Industry manages and controls what it does best PBL’s are…..The enabler for future savings for the NAVY and future Earnings for Industry

Fleet Readiness Center, SoutheastNon‐Destructive Inspection & Plating

Eddy Current Tester Ultrasonic Tester

Ion Vapor Deposit (IVD) Electroplating Shop

Fleet Readiness Center, SoutheastHeat Treating

Heat Treat Furnaces


Variety of Customers

17 orders for DLA in 2008 for $1.3 mil

Manufacturing MOA signed with Boeing– Obtaining NADCAP Certification

Manufactured EA-6B Canopy Side Beams for Northrop Grumman

Multiple FMS customers

Manufacture for other Navy Depots

Support Airforce workload

Manufacturing Workload for 2008 - 154K hrs


MANUFACTURING SUCCESS STORIES

Critical Workload Completed or In Process– F/A-18

• Y395 Former• Engine Mounts (L & R) • Nacelle Parts• Inner Wing Spar Segments

– EA-6B• NLG Swivel Pins• ICAP-III Fixtures• Antenna Base Plates

– P-3• AFB 394 Plank

Components

• Center Wing Plank Components

– H-60• Tail Bumpers

• RAST Fitting

– H-53• Skins (for FRCE &

FRCSW)


F-18 L/H ENGINE MOUNT

Presenter

Presentation Notes

FA-18C/D Right hand engine mount failure caused several aircraft to be grounded Aircraft inspection bulletin issued for inspection of all aircraft Inspection revealed that problem was widespread and had potential to ground more aircraft NAVICP had contracted a vendor to supply spares 1 year prior to this major failure Vendor had not produced a part that would pass First Article Inspection FRCSE took action to procure raw stock, develop N/C Program, and machine a complete mount assembly in 45 days. The first part produced passed First Article Testing Follow-on orders from NAVICP to produce 5 Assemblies per week to fill backlog Current production rate of 10 per month to support fleet Total order quantity 90 each


F/A-18 Y395 Former

Presenter

Presentation Notes

R/H formerNI cost 29,172FRCSE manufacturing cost 15,000 L/H formerNI cost 52,172FRCSE manufacturing cost 15,000 These fuselage Y395 former "dog bone" pockets collect moisture over time and cause the aluminum material within the pocket to corrode. The corrosion is visible after nacelle removal, but the nacelle is only removed during in-depth aircraft disassembly, such as the CBR+ program. This corrosion prone area had gone undetected for many years. This problem quickly became the biggest problem on the CBR+ line when it was found that one third of all aircraft undergoing CBR+ had dog bone pockets that could not be repaired and would require a Y395 former replacement. The FRCSE manufacturing team developed a timeline to execute the manufacturing of the replacement Y395 former and installation fittings/plates. In less than forty-five calendar days process planning, material procurement, tooling fabrication, machine tool programming, program prove-out, production and certification was executed on Critical Safety Item (CSI) parts


EA-6B SWIVEL PIN

Presenter

Presentation Notes

MLG Swivel Pin is the main pin that goes thru the drag brace and secures landing gear to aircraft. Prowler line was pulling this pin from SARDIP/Stricken assets to use them for RED gear. They decided to have these pins NDI'd before using them. That's when they found them cracked. Subsequent investigation initiated by engineering after they were notified of this condition revealed a large number of these pins exhibited the same cracking. This generated a fleet wide bulletin, but before the bulletin could be released it had to be logistically supportable. There was only one pin in the supply system. FRCSE manufacturing group was tasked to manufacture the pin. It is a complex, tapered pin approximately 2 1/2 to 3 inches in diameter. They have recently completed the first lot of pins and DLA has requested they continue to manufacture and provide in lots of 10. The good news story here is that FRCSE is able to react to emergent needs of legacy aircraft.


Contact Information

Mr. Tony Davis


Industrial Business Office

(904) 542-4170, Extension 104


BACKUP SLIDES


What Allows Us to Partner 10 USC 2464: Core Logistics Capabilities

It is essential for the national defense that the Department of Defense maintain a core logistics capability that is Government-owned and Government-operated (including Government personnel and Government-owned and Government-operated equipment and facilities) to ensure a ready and controlled source of technical competence and resources necessary to ensure effective and timely response to amobilization, national defense contingency situations, and otheremergency requirements.

The Secretary of Defense shall require the performance of core logistics workloads necessary to maintain the core logistics capabilities and shall assign such facilities sufficient workload to ensure cost efficiency and technical competence in peacetime while preserving the surge capacity and reconstitution capabilities necessary to support fully the strategic and contingency plans.


What Allows Us to Partner 10 USC 2474: CITE & Partnerships

Service Secretaries required to designate Centers of Industrial & Technical Excellence (CITE)The Secretary designating a Center of Industrial and Technical Excellence may authorize and encourage the head of the Center toenter into public-private cooperative arrangements (“public-private partnership”) to provide Private sector use of excess capacityMaximize the utilization of the capacity of a Center of Industrial and Technical Excellence


What Allows Us to Partner 10 USC 2474: CITE & Partnerships (cont)

To reduce the cost of products of the Department of Defense produced or maintained at a Center To leverage private sector investment in—– (i) such efforts as plant and equipment recapitalization for a Center; and – (ii) the promotion of the undertaking of commercial business ventures at a Center

Any facilities or equipment of a Center of Industrial and Technical Excellence made available to private industry may be used to perform maintenance or to produce goods in order to make more efficient and economical use of Government-owned industrial plants and encourage the creation and preservation of jobs to ensure the availability of a workforce with the necessary manufacturing andmaintenance skills to meet the needs of the armed forces To foster cooperation between the armed forces and private industry Head of CITE has authority to enter into partnerships

dod maintenance maintenance symposium symposium … · 2008. 10. 27. · cnc mitsui seiki jig bore....

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