Download - Aviation Depot 101 - SAE International
UNCLASSIFED
Naval Aviation Depot Maintenance
November 15, 2011
Aviation Depot Maintenance
• Invests today,
• For service life used yesterday,
• In order to provide readiness tomorrow
UNCLASSIFED
Pratt & Whitney, Bridgeport, WV Engine: JT15D-5C (UC-35C); PT6A25 (T-34C)
PT6A34 (T-44); PT6A41/42 (C-12) PT6A68 (T6); PWC535A (UC-35D)
Public / Private Aviation Depot Sites
ORGANIC INTERSERVICE COMMERCIAL
Rolls Royce, Oakland, CA Engine: T56-A-14/16/425/427
(P-3,C-130, C-2A, E-2C); AE1107C (V-22); AE2100D3 (C-130J)
OC-ALC Tinker AFB, OK Acft: E-6B
Engine:CFM56-2A (E-6B) CFM56-7B (C-40), F135(JSF)
CCAD Corpus Christi, TX Engine: T700 (H-60, AH-1W/Z)
FRC SOUTHEAST Acft: P-3, EA-6B, E-2, C-2, EP-3, F-18, H-60
Engine: J52(EA-6B), F414(F/A-18E/F), F135(JSF)
FRC EAST Acft: AH-1W/Z, AV-8B, F-35, H-46, H-53, H-1, EA-6B, V-22 Engine: T58(H-46), T400(UH-1N), F402(AV-8B), T64(H-53)
Acrohelopro, Richmond, BC Engine: 250C20 (TH-57)
FRC SOUTHWEST Acft: AH-1W/Z, AV-8B, C-2, E-2, F/A-18,
EA-6B, EA-18G, H-1, H-53, H-60 Engine: LM2500 (NAVSEA)
Northrop-Grumman, St Augustine, FL Acft: F-5F/N
OO-ALC Hill AFB, UT Acft: C-130, F-16, F-35
Overseas FRC WestPac-Atsugi
AH-1W/Z, CH-46E, CH-53D/E, E-2C, EA-18G, F/A-18C-F, HH-1N, HH-60H, MH-
60R/S, P-3C, SH-60B/F, UN-1N/Y
Vector Aerospace, Andalusia, AL Acft: TH-57B/C
Helipro, Andalusia, AL Engine: 250-C20J (TH-57)
L-3, Waco TX Acft: P-3C, EP-3E
Dallas Air Motive, Millville, NJ Engine: MK511-8 (C-20D) MK611-8 (C-20G)
Sikorsky, Stratford, CT Acft: VH-3D, VH-60N Exec Helo
Boeing, Seattle, WA Acft: C-40
Sabreliner, Perryville, MO Engine: JT12A8 (CT-39)
J85-21C (F-5E/F)
Boeing, Kent, WA Acft: E-6B
GE Engine Services, Arkansas City, KS Engine: T700 (H-60, AH-1W)
Rolls Royce, Canada Engine: BR710 (C-37)
MK511 (C-20D); MK611 (C-20G)
Allen Aircraft Radio MRO, OK City, OK Acft: C-9
Pratt & Whitney, San Antonio, TX Engine: F100-PW-220 (F-16)
Gulfstream, Savannah, GA Acft: C-20A/D/G
Engine: BR-710 (C-37)
L-3, Richmond, Vancouver Engine: 250C20 (TH-57)
AVMATS, Mascoutah, IL Acft: T-39G/N
Engine: JT12A8 (CT-39)
Aerothrust Corp, Miami, FL Engine: JT8D-9A (C-9)
American Airlines, Tulsa, OK Engine: CFM-56-7B24 (C-40)
Depot Level Maintenance Sites Perform (major repair / overhaul) depot maintenance
Performed at both public and commercial facilities • Fleet Readiness Center (FRC) Sites
• Other Service Sites (Interservice / Intraservice)
• Commercial Sites
L-3, Greenville, TX Acft: P-3C, EP-3E
FRC MID-ATLANTIC Acft: C-2, E-2C, F/A-18, H-60
FRC NORTHWEST Acft: EA-6B, EA-18G,
P-3, EP-3
FRC WEST Acft: F/A-18
Columbus AFB, MS Acft: T-38C
Engine: J85-GE-5
Canada Rolls Royce (Engines)
AE2100D3 (C-130J), MK 511-8 (C-20D), MK 611-8 (C-20G)
Orenda (Engines)
J85-GE-4A/5/5M/21C (T-2, F-5)
Standard Aero (Engines)
PT6A-25 (T-34C), PT6A-34 (T-44)
Hawker Beech, Wichita, KS Acft: TC-12B, UC-12B/F/M/W
Jetworks Air, Denton, TX Acft: U/C-35C/D
Lockheed Martin, Greenville, SC Acft: EP-3C, P-3C
Stevens Aviation, Greenville, SC Acft: T-34C, T-44A/C
Hamilton Sundstrand, Windsor Locks, CT Engine: T62T-11/27/46-2
Honeywell Aerospace, Phoenix, AZ Engine: TPE331-2 (C-26D)
Allen Aircraft Radio MRO, Indianapolis, IN
Acft: C-9
Delta, Atlanta,, GA Acft: C-40
Engine: CFM-56 (C-40)
UNCLASSIFED
Resourcing Overview • Aviation Depot Maintenance (ADM)
• Operations and Maintenance Navy (O&M,N/NR) funded
• Funds all Naval Aircraft and Engine Organic, Intra-Service
and Commercial depot workload
•Also fund directly some unique weapon system components
• 58 Unique Type/Model/Series (TMS) Aircraft
•~3900 aircraft in the Navy inventory
•Generate ~750 Airframe and ~2600 Engine/Module
maintenance events per year
•$1.1B Baseline budget / $1.3B w/OCO in PB12
•Engine repairs/overhauls driven by reliability and hours
operated
•Distributed airframe maintenance uses Planned Maintenance
Intervals based on Fixed Inductions Dates (FID)
•~40% of Airframe events performed in/near flight line by
depot field teams
3
UNCLASSIFED 4
29%
20% 23%
9%
7%
12%
Airframes USN
Airframes USMC
Engines USN
Engines USMC
Other USN
Other USMC
Aviation Depot Maintenance ($1.6B FY11)
FY11
1A5A AF/EN/OT O&MN / O&MN,R
UNCLASSIFED
Issues
• Forecasted budget constraints across the FYDP risk
unfunded aircraft maintenance (backlog)
• Aviation Depot Maintenance has relied on Overseas
Contingency Funding to execute full requirement
• Current modeling approaches have focused on risk
as a function of depot recovery • Maximum one year recoverable backlog of 100 Airframes / 340 Engines
• Difficult to map backlog impact to future readiness
• Configuration details within a TMS not currently tracked
for PPBE purposes
• Developing impact of specific aircraft inventories against
future schedule demands to show impact
5
UNCLASSIFED
INTEGRATED MAINTENANCE PROGRAM Notional
PMI 1 180 Days PMI 2 56 Days 4 Years Operational
Fixed
Scheduled Induction
Date
4 Years Operational
Fixed
End Date
Repeat Cycle
• Fundamental shift by the Navy
• Moved away from conditional inspections (ASPA) and
SDLM for all major TMS
• Maintains more consistent level of material condition
• Improved ability to forecast future workload and stabilize
requirements within the PPBE process
Heavy Industrial
Induction Field Event
Requirement
Review
Process
Primary Aircraft
Authorization
(PAA)
Aircraft Inventory
Integrated Maintenance
Work Load Standards
AIR 6.0
Minimize
Inventory Risk
With Available
Funding
Funded
/Backlog
Maintenance
Forecasted
Workload
w/Unit Cost
by Depot
Depot Core
Minimums
Source of Requirement
ADM Pricing
Model
Title 10 CNO
Fleet SYSCOM
Flight Line
Entitlement
Requirements Collections and Modeling Process
TMS PMI
Schedules/Engine
Demands
Wide Variance in Unit Cost
Slide 8
$0
$1,000,000
$2,000,000
$3,000,000
$4,000,000
$5,000,000
$6,000,000
$7,000,000
$8,000,000
$9,000,000
$10,000,000
0
2,500
5,000
7,500
10,000
12,500
15,000
17,500
20,000
22,500
25,000
27,500
30,000
EA-6
B PM
I 2 (
3)
EA-6
B PM
I 3 (
6)
EA-6
B PM
I 4 (
13)
C-2
A PM
I 1 (
4)
C-2
A PM
I 2 (
4)
FA-1
8C PM
I 2 (
37)
FA-1
8F PM
I 2 (
1)
FA-1
8A PM
I 2 (
6)
FA-1
8D
PM
I 2 (
14)
MV-2
2B PM
I 1 (
7)
MV-2
2B PM
I 2M
( 2
)
E-2
C P
MI 1 (
5)
AV-8
B PM
I 3 (
6)
AV-8
B PM
I 2 (
11)
MV-2
2B PM
I 2 (
8)
AH
-1W
PM
I 1N
( 2
0)
AH
-1W
PM
I 2N
( 1
0)
UH
-1Y
PM
I 1 (
8)
MH
-60S PM
I 1N
( 2
4)
UH
-1N
PM
I 1N
( 8
)
MH
-60R PM
I 1N
( 1
)
UH
-1N
PM
I 2N
( 1
)
MH
-60S PM
I 2N
( 1
1)
MH
-60R PM
I 2N
( 2
)
FA-1
8D
PM
I 2M
( 2
)
FA-1
8C PM
I 2M
( 3
)
SH
-60B PM
I 1N
( 7
)
SH
-60B PM
I 2N
( 3
)
FA-1
8D
PM
I 1 (
3)
FA-1
8A PM
I 1 (
4)
FA-1
8C PM
I 1 (
12)
AV-8
B PM
I 1 (
6)
FA-1
8D
PM
I 1M
( 7
)
FA-1
8C PM
I 1M
( 1
0)
CH
-53E PM
I D
( 2
5)
MH
-53E
PM
I D
( 5
)
E-2
C PM
I 2 (
2)
E-2
C P
MI 2H
( 2
)
P-3
C PM
I 1 (
4)
C-2
A PM
I 3 (
4)
P-3
C
PM
I 2 (
2)
EA-6
B PM
I 1 (
2)
FRC-CHP/JAX/NIS Airframe Events by Workload Standard
$.108M avg
1,322 avg mhrs
$.278M avg
3,688 avg mhrs
$.50M avg
5,703 avg mhrs
$1.33M avg
9,002 avg mhrs
$1.44M avg
11,092 avg mhrs
$1.22M avg
13,717 avg mhrs
$6.4M avg
19,554 avg mhrs
$3.1M avg
21,821 avg mhrs
$4.2M avg
27,652 avg mhrs
Work
load S
tandard
-
H
ours
Unit
Cost
per
Event
Determining which TMS
can take risk may cause
large shifts in
cost or backlog
DLHs
Cost
UNCLASSIFED
Understanding Funding Shortfall Impact?
• Developing new thinking on how to take and reflect
risk when funding is constrained
• Currently report unfunded depot workload as a function of number of
airframes and engines not funded (backlog)
• Backlog is an easier understood metric for those outside the
maintenance community
• A Direct Labor Hours (DLHs) metric would be more reflective of depot
production risk but not tied to readiness impact
• New modeling efforts are being developed to better link
aircraft production to readiness demand • Will link necessary production to future inventory demands necessary to
meet readiness goals
• Will emphasize meeting Flight Line Entitlement required for tiered
readiness
9
UNCLASSIFED
Conclusions
• Requirements process is well defined and uses
accredited pricing models to balance funding risk
• Planned Maintenance Intervals with Fixed Period End
Dates has been an effective tool to establish and
manage depot requirements
• Next evolution of modeling fidelity will add stronger
tie to future demand to show impact if funding is
constrained
10
UNCLASSIFED
Questions?
11
UNCLASSIFED
Backup Slides
12
Backlog – 500K DLH Combinations
| Brief Title Slide 13
0
20
40
60
80
100
120
140
160
180
200
1.3K 3.7K 5.7K 9.0K 11.0K 13.7K 20K
Manhours
(K
)
ManHours per Unit
500K Manhours Lines
55 19
12
8 7
5
3
150
units
2
33
4
2 1
1
69
110
30
16
7
4
83
25
13 22
18
4
6
4
33 Units *3.7K manhours/unit
Example
150 @ 1.3K = 195K
33 @ 3.7K = 122K
16 @ 5.7K = 91K
4 @9.0K = 36K
2 @11.0K = 22K
1 @13.7K = 14K
1 @20.0K = 20K
= ~500K manhours
Flightline Entitlement Aircraft for a
representative 12 aircraft squadron
32 month Deployment Cycle
Maintenance Basic Intermediate Sustain Deploy Sustain
R+1 R+2 R+3 R+4 R+5 R+6 R+7 R+8 R+9 R+10 R+11 R+12 R+13 R+14 R+15 POM PDL R+24 R+25 R+26 R+27 D+1 D+2 D+3 D+4 D+5 D+6
Navy Flight Line Entitlement Total FLETMS = Navy Tac Air by FRTP Phase+ Training and Support PAA
3 2 1
Basic Integrated Deployment Sustain Sustain Maintenance
CDR Pete Morrison, OPNAV N32 FHP RO