integrated maintenance plan - sae international · note: ensure all imc disassembly and inspections...
TRANSCRIPT
CAPT GORDON COWARD AIR 6.1ACAPT BOB BLAKLEY AIR 3.2A
INTEGRATED MAINTENANCE PLAN
Decreased Facilities(BRAC)
SDLM $$ Requirement
Bow WaveIncreased Operational Commitments (Desert Storm)
ASPA Deferrals
FY Funding
$ Millions
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
The Push Behind Going to Fixed PED
CNO DIRECTION
ESTABLISH A PLAN TO
TRANSITION TO FIXED
OPERATIONAL SERVICE
PERIODS THROUGH THE
IMPLEMENTATION OF
RCM-BASED, SUSTAINED
MAINTENANCE PLAN.
ESTABLISH A PLAN TO
TRANSITION TO FIXED
OPERATIONAL SERVICE
PERIODS THROUGH THE
IMPLEMENTATION OF
RCM-BASED, SUSTAINED
MAINTENANCE PLAN.
Integrated Maintenance Concept/Plan
ENGINEERINGSOLUTION
-RCM Analysis-Task Packaging-Structural integrity
OPERATIONALSOLUTION
-Fleet buy-in-Executabilityby O and D level-Supportability
BUSINESSSOLUTION
-Improved readiness-Depot concerns-Cost
TOTAL SOLUTIONALL PARTS MUST RECEIVE EQUAL CONSIDERATON
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.
Integrated Maintenance Concept/PlanIMPLEMENTATION
• S-3B• F/A-18 A-D• AH-1W• E-2C • H-60B, F, HPROTOTYPE
! UH-1N• H-53E• H-46E• C-2A• C-130 F/R, T• EA-6B• F-14 A-DDEVELOPMENT
• AV-8BFUTURE EMPHASIS• ENGINES• Commercially Supported Platforms
MaintenanceSpecificationDevelopment
RCMANALYSIS
OPNAV/Fleet
Approval
Implement/Monitor
Age Exploration & Sustainment
IMC/P LIFE CYCLE
DEVELOPMENT
SUSTAINING
Supportability Analysis
& BCA
Baseline/Transition ExecutionPlanning
11- 12 YEARS SINCE LAST DEPOT INDUCTION
SDLMASPA1
4 Years 1 Year
H-60 IMC PROGRAM BRIEF
Fixed Period
End Date
Total Operational and Maintenance Service PeriodFixed Service Period (FSP)
PMI 1
45 D
ays
PMI 2
70 D
ays
PMI 3
POI 660 Days
POI 685 Days
2 Years
FID
FID
FID
45 D
ays
POI 685 Days
112
Day
s
PMI 4
FID
POI 618 Days
2 Years 2 Years 2 Years
Repeat PMI
Cycle
7Day
s
7Day
s
7Day
s
7Day
s
ASPA5+
7Day
s
18-24 MOS
45 D
ays
PMI 1
POI 685 Days
2 Years
LOCATIONS
NAF Atsugi, JapanE-2F-18H-60H-1H-53
NAF Atsugi, JapanNAF Atsugi, JapanE-2F-18H-60H-1H-53
Field Site
Depot Site
NAS JacksonvilleEA-6BP-3H-60S-3
NAS JacksonvilleNAS JacksonvilleEA-6BP-3H-60S-3
NS MayportH-60
NS NS MayportMayportH-60
WHIDBEY ISL EA-6B
WHIDBEY WHIDBEY ISL ISL EA-6B
Camp PendletonH-1
Camp PendletonCamp PendletonH-1
NAS LemooreF-18
NAS LemooreNAS LemooreF-18
Norfolk/OceanaNaval Base
F-18E-2F-14
Norfolk/OceanaNorfolk/OceanaNaval BaseNaval Base
F-18E-2F-14
CCADH-1, H-60
CCADCCADH-1, H-60
NAS North IslandH-60, F-18,E-2/C-2,S-3
NAS North IslandNAS North IslandH-60, F-18,E-2/C-2,S-3 MCAS Miramar
F-18MCAS MiramarMCAS MiramarF-18
Cherry PointH-1, H-53, H-46, AV-8B,EA-6B, F-18
Cherry PointH-1, H-53, H-46, AV-8B,EA-6B, F-18
MCAS BeaufortF-18
MCAS BeaufortMCAS BeaufortF-18MCAS Kaneohe Bay, HIMCAS Kaneohe Bay, HIMCAS Kaneohe Bay, HI
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
ELEC PWR NACARD
99
NAVAIR 01-H1AAC-IMC-SPECDATE 9 August 2001REVISION DTD
NAVAIR 01-H1AAC-IMC-WDDATE 9 August 2001REVISION 3 DTD 24 May 2002
BASELINE
HYD PWR NAWORK ZONE/ TASK NO.
TRADE
STRUCTURE
BUNO INSP/TEST/REPAIR
TAILBOOM COLDWORKING COND AIR NA
8 – 2UY0004
NOTE: Ensure all IMC disassembly and inspections have been completed prior to tailboom removal should the tailboom have to be removed.
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 thetailboom.
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 - front example
CARD
99A
NAVAIR 01-H1AAC-IMC-SPECDATE 9 August 2001REVISION DTD
NAVAIR 01-H1AAC-IMC-WDDATE 9 August 2001REVISION 3 DTD 24 May 2002
BASELINE TRADESTRUCTURE
BUNO
TAILBOOM COLDWORKING
TASKNO.
MALCODE
LENGTH/WIDTH/DEPTH
WATERLINE/BUTTLINE/
STATIONCRIT
CODE
TYPEDEFECT
NBNCETC
WUCESTRPRTIME
DESCRIPTIVE DEFECT/DESCRIPTIVE REWORKMMHRS
TOREPAIR
DISCRP/N
QASTAMP
L FSW 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 BLD WL
Form SOP H1-001-A Rev 3 Rev Date: 24 May 2002
Work Deck card - back example
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
0
50
100
150
200
250
300
350
400
450
500
190 105 170 020 070 246 800 093 804 846 160 935 135 780 350 117 302 127 429 087
MALCODE
AVG
RPR
TIM
E X
AVG
MAL
CODE
HIT
S
MAL CODES AVERAGE MALCODE COUNT ALL SITES
TRUNCATED
0
50
100
150
200
250
300
350
400
105 170 070 020 246 190 093 800 160 804 350 117 935 302 846 429 135 780 801 425 440 022 381 766 306 114 074 710
MALCODE
AVER
AGE
COUN
T
BACKUP SLIDES
BackgroundAircraft Age & Inventory
FISCAL YEAR
4,079
4,169
4,167
4,2284,406
4,5144,925
5,2505,4875,605
5,497
3,000
3,500
4,000
4,500
5,000
5,500
6,000
6,500
7,000
89 90 91 92 93 94 95 96 97 98 99FISCAL YEAR
SOURCE: ACTIVE AIRCRAFT INVENTORY FY89-99 BASED ON FY89-96, A-II INV DATABASE, AND A-II JUL 97 REPORT
NUMBER OF AIRCRAFTACTIVE INVENTORY
1213141516171819202122232425
89 90 91 92 93 94 95 96 97 98 99 00 01 02 03
FY1997 AVERAGES:16.7 YRS –HELICOPTER14.7 YRS –COMBINED13.6 YRS –FIXED WING
FY1997 AVERAGES:16.7 YRS –HELICOPTER14.7 YRS –COMBINED13.6 YRS –FIXED WING
AIR
CR
AFT
AVE
RA
GE
AG
E (Y
EAR
S) AVERAGE AIRCRAFT AGEACTIVE INVENTORY
FIXED WING
COMBINED
HELICOPTER
Nav
al A
viat
ion
TO
A
Years
• DoN in a Shrinking Budget Environment" Life Cycle Support Costs ratio has increased
Life Cycle Support CostsLife Cycle Support Costs
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
! 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
Reliability Centered MaintenanceWhat 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
Failure mode analysis DevelopRCM Plan *
RCM LIFE CYCLE
Task Evaluation &
Selection
PackageO/I/D
Maintenance Tasks
Implement,Monitor & Trend
Top Degraders
Data collection
* RCM plans is approved by NAVAIR
Requires PRL funding