I n t e g r i t y  ­  S e r v i c e  ­  E x c e l l e n c e

Headquarters U.S. Air Force

Repair Network Integration (RNI):The First Step to True Enterprise Repair

Col Matt Sanford (AFMC/A4L)12 Oct 16

What is RNI

Repair Network Integration provides enterprise visibility into like-repair capabilities and constraints for a central point of contact to facilitate improved

repair throughput

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3

• RNI created after CORONA (Fall ‘08) CSAF tasking to AFMC/CC

• Remains 1 of 7 Enterprise Logistics Governance (ELG) initiatives

• The RNI Project Management Office (PMO) team physically resides at AFMC/A4 and co-manages this Air Force level program

Background and Direction

Background:• Repair is the largest source of supply to meet

Mission Generation needs– Comprised of $14B budget, 46K Maintainers, 3 levels of Mx– No single process owner to manage the enterprise

• Air Force repair needs to be more agile and responsive to the warfighter

Direction:

$3.000; 74%

$1.029; 26%

Annual Sustainment Support for DLRs

Buy

Repair

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Mission Generation Concept

Mission Generation

Network

Flightline Mx

Repair Network

BackshopMx CRFs Depot

On and off-equipment maintenance supporting

flightline operations

Supports Mission Generation by providing maintenance required to fulfill operational needs outside the

capability and/or capacity of Mission Generation Network activities

Maximize Throughput

End-State – Integrated Repair Networks effectively

& efficiently supporting Mission Generation

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Global Repair Networks enable enterprise visibility and collaboration to remove constraints using available Capability & Capacity

ARCARC

ALCALCContractor

Repair

ContractorRepair

Wing/Base

Wing/BaseWing/

Base

Wing/Base

Wing/Base

Wing/Base

Wing/Base

Wing/Base

Wing/Base

Wing/Base

Wing/Base

Wing/Base

Wing/Base

Wing/Base

Wing/Base

Wing/Base

CRFCRF

CRFCRF

CRFCRF

CRFCRF

CRFCRF

ALCALC

ALCALC

ARCARC

CRFCRF

MissionGeneration

Network

Phase II – Integrating OCONUS and CONUS Repair

Networks; Expand collaboration to ALCs

Networks Created

Phase I – Networking by MAJCOM and Weapon System

ARCARC

ALCALCContractor

Repair

ContractorRepair

Wing/Base

Wing/BaseWing/

Base

Wing/Base

Wing/Base

Wing/Base

Wing/Base

Wing/Base

Wing/Base

Wing/Base

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Wing/Base

Wing/Base

Wing/Base

Wing/Base

Wing/Base

CRFCRF

CRFCRF

CRFCRF

CRFCRF

CRFCRF

ALCALC

ALCALC

ARCARC

CRFCRF

MissionGeneration

Network

End-State – Integrated Repair Network

effectively & efficiently supporting Mission

Generation

Integrated Supply Chain Management

(SCM)End-State Repair

Structure

ANG

6

(AFSC (ALCs), AFLCMC)

Phased Approach

7Royalty free production music by JewelBeat

Repair Network Manager

Node Mgr

NodeMgr

NodeMgr

NodeMgr

NodeMgr

Node Mgr

Node Mgr Node

Mgr

Node Mgr

NodeMgr

NodeMgr

NodeMgr

Pre-Network Post Network

Collaboration between nodes is informal, inconsistent, and

personality driven

Collaboration is formal, enterprise-wide, and integrated with the

supply chain

RNM Role

The RNM is the node’s one direct connection to the supply chain to resolve constraints via collaboration

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Collaboration

Node Manager / RNM Relationship

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“If our shop or another shop within our network needs help meeting repairs, it is communicated to the RNM, and they can bring the right parties together to determine the best solution.”

“Prior to RNI, if we had a constraint here at the shop, there was no standard way to resolve the issue. With the RNM, we have one direct connection to help us resolve a variety of constraints, from broken test stands to repairs awaiting parts.”

TSgt Andrew Preston, Node ManagerLuke AFB – Hydraulics CRFFighter Network

Collaboration Process

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RNM, Node Manager, or stakeholder

identifies potential repair constraint

Team collaborates for enterprise solutions

Nodes execute decision

Enterprise Mission Generation

priorities are met

Mission Generation

Nodes

Inp

ut

Ou

tpu

t

RNM

Constraint

De

cis

ion

MAJCOMs

Supply

RNM

Depot

Solution

Backshop

CRF

• Collaboration is ongoing and can solve issues proactively and reactively

• Policy grants the RNM Direct Liaison Authority to communicate with the NM, but the Chain of Command does NOT change

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Scope Prepare Certify Mature Optimization Process

Recommend Quick Wins

RNI Approach

Shape & Size Organize into Networks Mature Optimize/Shape & Size

Original: Prior to January 2014 LB

Hydraulics PRG (Jan’14): Based on Mx Manpower reductions and LB direction

• Directive recommended to consolidate repair nodes to offset manpower cuts• Organize into networks by weapons system and MAJCOM• Mature as functioning networks – integrate repair and supply• Recommend optimization opportunities

• Establish and define networks via a 7-step certification process • Integrate repair into the end-to-end supply chain• Post-networking, recommend optimization opportunities

Continuously Identify/Recommend Quick Wins

E&E & Avionics: (Mar ’16): Analyses identified minimal manpower savings

Scope Organize into Networks Mature Optimize

• Complete analysis to determine scope• Organize into networks by weapons system and MAJCOM• Mature as functioning networks – integrate repair with supply• Recommend optimization opportunities

Continuously Identify/Recommend Quick Wins

Additional PRGs

PropulsionPMEL

AvionicsE&E

7 Networks9 MAJCOMs

130+ Nodes

NetworksBomber

Fighter

ISR & Tanker

SOF

Strategic Airlift

Tactical Airlift

Trainer

Centralized Repair Facility (CRF)

Hydro Update

12~500 NSNs

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Hydraulic PRG Metrics

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• Measuring key supply chain metrics before and after IOC for Hydro demonstrates continued supply support

No Degradation in support to warfighter and accomplishing

the same or more with less resources

Increased IE: More parts on hand to make repairs when they are needed

Trend line

IOC

2014 Q3 2016 Q12015 Q32015 Q1

30%

60%

90%

Avg

IE

%

2016 Q3

Average Issue Effectiveness (IE) for PRG

100K

200K

Reduced MICAP hours

2014 Q3 2016 Q12015 Q32015 Q1 2016 Q3

IOC

0K

Do

c T

ota

l H

rsReduced MICAP Hours for CRF

Supported Bases

So What?

Results:• Established collaborative

process to approach repair constraints

• Codified Processes– AFI 20-117– AFMAN 20-118

• Metrics for first six months within standard deviation

• Harnessed power of the Total Force

• Established support structure enabling enterprise view

What’s Left to be Done:• Optimize PRG

– Develop and analyze operational metrics

– ID and execute opportunities for network improvement

• Continue to gather lessons learned and refine policy

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Seymour Johnson Hydro CRF

E&E and Avionics Update

• Both PRGs recommended network stand-up without consolidation– E&E Business Case Analysis (BCA) indicated manpower bill and

negative impact to mission generation– Avionics analysis indicated limited efficiencies and significant spares

investment

• Overall scope and assumptions:

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– CONUS & OCONUS– Includes AD and ARC nodes– Contract repair is excluded

E&E – TF Network Details

Number of Nodes 152

Number of Networks 7

Number of NSNs 970+

Avionics – TF Network Details

Number of Nodes 63

Number of Networks 4

Number of NSNs 500+

Other Success Stories

Propulsion PRG

• F-100/220 network shifted Nellis workload during test stand down-time Jan-Mar 16, maintained 127% WRE

• T-56 BUP repair actions increase of 30% in FY16

Cost Savings / Cost Avoidance

• 10% reduction in annual PMEL operating costs equating to $16.8M in annual savings expected by end of FY18

• $7.5M cost avoidance via centralized PMEL test equipment in FY15

Propulsion PRG

• F-100/220 network shifted Nellis workload during test stand down-time Jan-Mar 16, maintained 127% WRE

• T-56 BUP repair actions increase of 30% in FY16

Cost Savings / Cost Avoidance

• 10% reduction in annual PMEL operating costs equating to $16.8M in annual savings expected by end of FY18

• $7.5M cost avoidance via centralized PMEL test equipment in FY15

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Enterprise Repair Constraint Resolution

Enterprise Repair Constraint Resolution (ERCR) is an effort to expand RN collaboration to the ALCs• Goal: Increase communication and collaboration

across field and depot maintenance• No change to Depot Source of Repair

ERCR Working Group met Aug ‘16 with the objectives to• ID ways for both ALCs and Field to better leverage the RN for

constraint resolution• ID high level plan to initiate agreed upon working group actions

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CAP2NRTS Codes:

Potential Benefits• Leverage enterprise CAP2• Reduce repair cost• Reduce MICAPs• Reduce repair cycle time• Prevent unnecessary

movement / save SDT $

Opportunity (Depot): Revalidate F-condition I-level reparables in DLA Warehouse prior to induction for repair at another Node

NRTS Codes:

Potential Criteria for removing from DLA warehouse:

• I-level• RO fill rates below 60%• MICAPs• NRTS Codes

CC F

Opportunity (Field): Validate NRTS code usage, utilize RNM NRTS2-7

RNM

Opportunities to Leverage the Repair Network:

ERCR Working Group

Working Group Activities Progress

NRTS Analysis: Analyze NRTS codes to look for trends & recommend actions to enhance usage of Repair Network CAP2

Analyzing 48 NSNs representing 87% of actions taken (RTS & NRTS,12 months)

Financial Map: Map financial transactions associated w/ moving I-Level, F-cond. reparables from DLA warehouse to field

Map complete

Process Map: Develop criteria, repeatable process to move I-Level, F-cond. reparables from DLA warehouse to field to leverage Repair Network

In work

RNM: Explore ways to include RNMs in NRTS decision process to reduce repair cycle time and SDT cost

Awaiting NRTS Analysis

Working Group Participants:

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Way Forward

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What’s Next

PRGs

• Mature Networks PMEL and Propulsion • Hydro FOC – 1 Oct 16• Stand up Electrical & Environmental (E&E) and Avionics

Repair Networks

Institutionalize RNI Management

Processes

• Update Policy• Define field and depot constraint resolution process• ADLS training in development

‒ Published: Node Manager, LIMS-EV/RNV‒ In Work: RNI 101, Repair Network Manager

• Mx and Logistics Formal Training: PMO has provided content for incorporation into the following courses: ‒ AMOC, LROC, MOIC, MCOC, Mission Gen road course‒ AMMOS courses‒ MXG/CC course‒ MAF Mx Superintendent/Production course and Mx

Officer course

Repair Network Integration: Creates a Global Repair Network support structure Enables enterprise visibility and collaboration Resolves constraints using available capability &

capacity Provides agile support to Mission Generation

Key Takeaways

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Discussion/Questions

Video Back-up Slides

RNI: A Strategic View

- Lt Gen John B. Cooper Deputy Chief of Staff for Logistics, Engineering and Force Protection, Headquarters U.S. Air Force

“RNI is going to take that global view and make sure that we have an efficient and effective organizational construct that can supply parts the most effective way by the most efficient means.”

Node

NetworkRepair Network Manager (RNM)

Node Manager (NM)

NM

NM

NMNode

Node

Node

Product Repair Manager (PRM)

Product Repair Group

A Node is an individual organizational uniti.e. Seymour Johnson Engine Shop

(105 Nodes in Props PRG)

A Node Manager (NM) manages shop activities and collaborates with the Repair Network Manager to meet Mission Generation needsi.e. the Propulsion Shop Chief

A Product Repair Group (PRG) is a collection of Networks required to support specific groups of weapons systems, engines, commodities, and other major end items.i.e. the Propulsion PRG

A Network is a collection of Nodes within a Product Repair Group that support the repair enterprisei.e. F100-PW-220 Network (12 Networks

in Props PRG

A Repair Network Manager (RNM) facilitates optimal use of Capability & Capacity for a specific Network via collaboration i.e. the T-56 RNM

Collaboration SuccessHydraulics PRG

Constraint identified within the Network

Enterprise could not complete repairs on Pitch Roll Channel

Assembly (PRCAs) due to Test Stand and SRU constraints.

RNM Stakeholders

Collaboration

RNM facilitates collaboration with stakeholders

RNM looked across enterprise to see what Nodes had the capacity to take on repairs.

Team determined Mt Home AFB and Kingsley ANGB could take on the repairs.

DEPOTW.H.

Unserviceable PRCAs

Node

Node

Serviceable PRCAs

Mission Gen

Nodes execute decisionCondition Code F PRCAs in the

DLA warehouse were validated for I-level repair and 20 were sent out

to the bases. Both bases were able to source parts from the

PRCAs received and turn serviceable assets back into

supply.