vsm workshop dod maintenance symposium …subject: dod maintenance symposium panel presentation -...
TRANSCRIPT
19 Aug 2009
VSM WORKSHOPLeadership Outbrief
Presented by: Mr. Garry NewtonDeputy Commander, Fleet Readiness Centers
Presented to: COMFRC LEADERSHIP
27 Oct 2009
DOD MAINTENANCE SYMPOSIUM FRC Transformation Overview
Presented by: Mr. Garry NewtonDirector, Industrial OperationsDeputy Commander, Fleet Readiness Centers
2File: 20091014_FRC transformation overview_V3.pptPresenter: Deputy, COMFRCSubject: DoD Maintenance Symposium Panel Presentation - Transformation
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NAVAL AVIATION MAINTENANCE TRANSFORMATION HISTORY
1995 Established Integrated Maintenance ConceptFirst significant moves of depot capability closer to the flightline
2001 Implemented AIRSpeed throughout NAEImplementation of industry-proven process improvement tools
2005 Established Fleet Readiness CentersReturning ready-for-tasking aircraft back to the Fleet faster by moving maintenance closer to the flightline
3File: 20091014_FRC transformation overview_V3.pptPresenter: Deputy, COMFRCSubject: DoD Maintenance Symposium Panel Presentation - Transformation
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NAVAL AVIATION INTEGRATED MAINTENANCE CONCEPT
OCONUS LOCATIONSMCAS Kaneohe Bay, HI H-60Andersen AFB, Guam H-60STAE Singapore C-130NAF Atsugi Japan / NAPRA Det Okinawa E-2, F/A-18, H-60, H-46, H-1, H-53, EA-6BNAPRA S. Korea H-53
FIELD SITE
DEPOT SITE
FULL-TIME DEPOT MAINTENANCE AT EVERY MAJOR NAVY & MARINE CORPS AIR STATION WORLDWIDE
Shifted from on-condition to
CALENDAR-BASEDaircraft maintenance,
taking Depot Maintenance
to the Fleet
4File: 20091014_FRC transformation overview_V3.pptPresenter: Deputy, COMFRCSubject: DoD Maintenance Symposium Panel Presentation - Transformation
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INDUSTRIAL STRATEGY FOR NAVAL AVIATION
Workforce RevitalizationTransformations that facilitate changes in skills, knowledge,
ability, experience and organizational construct in
concert with changes in weapons, technologies, and supporting
processes.
Optimize the Industrial Base
Develop the industrial capabilities to support future
Naval Aviation requirements that are of the proper size and mix between Organic, Commercial,
and Inter-service.
Logistics TransformationOrganizational realignments, process improvements, and
integration across the value chain to produce aircraft ready for
tasking at the right time, the right place and at the right cost.
Capital InvestmentPrioritization and provisioning of investment dollars in support of the above strategic objectives.
Core-Sustaining CapabilityProvide the most up to date
industrial capability to sustain Naval Aviation’s current readiness
requirements with the right capability for the right cost that
conforms to USC Title 10.
5File: 20091014_FRC transformation overview_V3.pptPresenter: Deputy, COMFRCSubject: DoD Maintenance Symposium Panel Presentation - Transformation
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FRC NORTHWESTWHIDBEY ISLAND
Det Everett
FRC Southwest Det Northwest Whidbey
Island
FRC WESTLEMOOREDet Fallon
Southwest Det West LemooreDet Fort WorthDet China Lake
FRC WEST PACNAF Atsugi, Japan
Det GuamDet Okinawa
Det SingaporeDet Korea
Det IwakuniDet Australia
FRC SOUTHWESTNORTH ISLANDDet Point MuguSite Pendleton
MALS-39NADEP NI Det Pendleton
Site YumaMALS-13
NADEP NI Det YumaDet NAVCAL Lab
FutenmaDet NAVCAL Lab
Iwakuni
FRC SOUTHEASTJACKSONVILLE
Det MayportDet Key West
FRC EASTCHERRY POINT
MALS-14 Cherry PointSite New River
MALS-26 & 29 New RiverSite Beaufort
MALS-31 BeaufortNADEP JAX Det Beaufort
Site QuanticoHMX-1 Quantico
Site Robins AFBMALS-42 AIMD AtlantaSite McGuire AFBAIMD Willow Grove
Site Stewart ANGBMALS-49
FRC MID-ATLANTICOCEANA
Det NorfolkDet Pax River
Det New OrleansDet NAF Washington
Det AtlantaFRCSE Det MA
OceanaDet Beaufort
FRC SEFACSOLOMON’S ISLAND
*Dets in red indicate closing activities
D-LEVELI-LEVEL• 6,000+ SAILORS &
MARINES
• 20 IMAS
• 6,000 ENGINE/ MODULE/ ACCESSORY REPAIRS
• 580,000 COMPONENT REPAIRS
• $2.0 BILLION OPERATIONMISSION FUNDED
• 10,000 CIVILIANS
• 3 DEPOTS
• 1,500 ENGINE/ MODULE REPAIRS
• 70,000 COMPONENT REPAIRS
• 700 AIRCRAFT REPAIRS
• $2.0 BILLION OPERATIONNWCF FUNDED
OPTIMIZING THE INDUSTRIAL BASEINTEGRATE AND OPTIMIZE
6File: 20091014_FRC transformation overview_V3.pptPresenter: Deputy, COMFRCSubject: DoD Maintenance Symposium Panel Presentation - Transformation
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LOGISTICS TRANSFORMATION PILLARS
• Distribute
– Moving Depot Capability Forward
– Establishing High Velocity Repair Loops with Brokered R/R
• Consolidate
– BRAC-Related Closures
– Consolidating Repair Sites and Creating Centers of Excellence
• Optimize
– AIRSpeed Saturation
– Supply/ Maintenance Consolidation of Connectivity
CHOOSING THE RIGHT APPROACH BASED ON THE SITUATION
7File: 20091014_FRC transformation overview_V3.pptPresenter: Deputy, COMFRCSubject: DoD Maintenance Symposium Panel Presentation - Transformation
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DISTRIBUTED DEPOT MAINTENANCE
• EXAMPLE OF IMPROVEMENTS– F/A – 18 A-D Hydraulic Drive Unit (HDU) Repairs
• 44 HDUs Interdicted• $1.15M in AVDLR Cost-avoidance
– F/A – 18 A-D Horizontal Stabilizer Actuator Repair• $3.31M in AVDLR Cost-avoidance to date
– H-53 Main rotor Blade Repairs• 27 Rotor Blades Interdicted• $2.05M in AVDLR Cost-avoidance to date
Disassemble Inspect
I- Repair
Re-AssembleNot Repairable
Disassemble Inspect
Assemble
Transport D-Repair Assemble
I-Repair
Disassemble Inspect
Assemble
D-Repair Assemble
Distributed Maintenance Example
Non-Distributed Maintenance Example
8File: 20091014_FRC transformation overview_V3.pptPresenter: Deputy, COMFRCSubject: DoD Maintenance Symposium Panel Presentation - Transformation
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NAS Brunswick, MEP-3,C-130 Prop / -14 Level 1
NAS Pax River, MDP-3, C-130, E-2,C-2 Prop / -14 Level 1
Stuart ANGB, NY (MALS-49)C-130 Prop / -16 Level 2
MCAS Futenma, OkinawaC-130, P-3 Prop / -16 Level 1
NAS JRB Willow Grove, PAP-3, C-130 Prop / -14/ -16 Level 2
NAS New OrleansP-3, C-130 Prop / -14/-16 Level 1
NAS Whidbey Island, WAP-3 Prop / -14 Level 1
MCAS Kaneohe Bay, HIP-3, C-130 Prop / -14 Level 1
NAS Misawa, JAP-3 Prop / -14 Level 1
NAS Jacksonville, FL
NAS Sigonella, ItalyP-3, C-130 E-2, C-2 Prop
NAS Pt. Mugu, CAP-3, C-130, E-2, C-2 Prop-14 / -427 Level 2-425 Level 1
CONSOLIDATION EXAMPLE(AIMD / MALS / Depot / Commercial)
P-3 / C-130 / E-2 / C-2 Propellers and Engines
MCAS Miramar, CA
NAS JRB Fort Worth, TXC-130 Prop / -16 Level 2
C-130 Prop / -16 Level 2
NS Bahrain
MCAS Cherry Point, NCC-130 prop / -16 Level 1(NADEP CP Propeller CFA)
NAS Norfolk, VAE-2/C-2 Prop / -425/-427 Level 2
NAS Atlanta, GAE-2/C-2 Prop
-425 Pres / Depres
-14 / -425 Level 1-16 Level 3-427 Level 2
Rolls Royce -427 Depot
Standard Aero-14/16/425 Depot
NADEP CPP-3/E-2/C-2 Props
PPIP-3 Props
NAF Washington-16 Pres / Depres
P-3 prop / -14 Level 1(NADEP Jax Engine CFA)
NAF Atsugi, JapanE-2/C-2 Prop / -425/-427Pres / Depres Only
Closed Sites
NS Rota
NAS Keflavikk
NAS Adak
NAS Barbers PT
Closed Sites
NAS Kadena
NS Diego Garcia
NAS Roosevelt Roads
NAS Agana
NAS Moffet Field
Navy ActiveRed MarinesNavy Reserve
Warner RobbinsC-130 Props
P-3 Prop BU / OTW RGB
Infrastructure Adjustments throughClosure vice Optimization
-25 Repair Sites Worldwide- Wide Performance variation- Supporting different operating environments
9File: 20091014_FRC transformation overview_V3.pptPresenter: Deputy, COMFRCSubject: DoD Maintenance Symposium Panel Presentation - Transformation
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Greatest cost savings, C130 Support RiskFY04 Constant Year $ Reg / TMS1 INVESTMENTMILCON $0SE $0CONTAINERS $0INITIAL SPARES $0PCS COST $83,322OPERATIONS & SUPPORTMANPOWER -$32,402,654AFM $0AVDLR (Excl CRR) $01A5A (incl. Civ Manpower) $0Commercial I-Level Repairs N/ATRAINING -$3,177,834SPARES $0TRANSPORTATION $3,222,135PERSONNEL SUPPORT -$5,229,847TEST CELL SUPPORT/YEAR $0
INVESTMENT $83,322
OPERATIONS & SUPPORT -$37,588,200Total Cost FYDP Deltas (Negative indicates Savings) -$37,504,878
LOCATION NEC/MOS BA COB POB 5 Reg / TMS1NAS BRUNSWICK ME 6418 41 28 23 25NAS WILLOW GROVE PA 6418 19 19 19 8MALS-49 (Stuart ANG) 6226 4 4 4 10NAF WASHINGTON 6418 0 0 0 0NAS NORFOLK VA 6423 35 17 25 30NAS JACKSONVILLE FL 6418 49 41 45 36MALS-14 (Cherry Point) 6226 10 7 5 0NAS ATLANTA GA 6423 0 0 0 0NAS SIGONELLA IT 6418 47 47 47 4NAS NEW ORLEANS LA 6418 25 18 14 8MALS-41 (Fort Worth) 6418 6 6 6 12MALS-11 (Miramar) 6226 9 9 9 0NAF ATSUGI JA 6423 4 4 3 4NAS MISAWA JA 6418 33 21 33 10NAS PT MUGU CA 6418 10 3 6 3NAS PT MUGU CA 6423 26 21 19 30NAS WHIDBEY ISLAND WA 6418 28 15 17 40MALS-36 (Okinawa) 6226 9 9 9 10NS BAHRAIN 6418 3 2 2 6MALS-24 (Kaneohe Bay) 6418 24 13 16 10
Total 382 284 302 246
T56 / PropI Level Optimization
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NAS Brunsw ick, ME(BRAC)
NAS Pax River, MD
Stuart ANGB, NY (MALS-49)
NAS JRB W illow Grove, PA(BRAC)NAS W hidbey Island, W A
MCAS Kaneohe Bay, HINAS Jacksonville, FL
NAS Sigonella
NAS Norfolk, VA
NAS Atlanta, G A(BRAC)
NAF W ashington
(Brunswick Sqd to Jax)C130 Capability established
NS BahrainProp BU / OTW RGB Only
Legend: Blue I-1Gray I-3
Orange: Min
19 / 8
4 / 10
47 / 4
49 / 61
35 / 30
0 / 0
0 / 0
3 / 6
24 / 10
9 / 0
33 / 10
36 / 33
28 / 40
Region / TMS 1Hybrid Scenario.
Combination o f Capacity driven by region and TMS based (scenarios 1&2)
(w/BRAC and flow)
McGuire AFB (VR-64)Eng Pres-Depres (VR-53 C130Tx4)
(Atlanta Sqd to NO)
(Feed by Jax/ NORVA CNAF dir)
6 / 12
(Feed by Jax/ NORVA CNAF dir)
25 / 8NAS JRB Fort W orth, TX NAS New Orleans
MCAS Futenma, Okinawa
Eng Pres-Depres
NAF Atsugi, Japan4 / 4
NAS Misawa, JA
9/ 10
NAS Pt. Mugu,
MCAS Cherry Point, NC10 / 0
MCAS Miramar, CA
Current Man Tota l: 382Projected Man Tota l:246
Reduction of 136
Note: CNAF / CNAFR direct Module / QECA Movement
CONSOLIDATION EXAMPLE
• RESULTS– OPTIMIZED REPAIR NETWORK– MORE TRANSPORTATION (WITH
CLEAR PROTOCOL)
• OUTCOMES– FASTER REPAIR CYCLES– LESS MANPOWER– LESS EQUIPMENT– LESS OVERALL COST
10File: 20091014_FRC transformation overview_V3.pptPresenter: Deputy, COMFRCSubject: DoD Maintenance Symposium Panel Presentation - Transformation
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OPTIMIZATION (BEST PRACTICE REPLICATION) Optimization Cost Avoidance
EOY Trend ~ $105M
06 RFI % 07 RFI % 08 RFI % 09 RFI %
100%
95%
90%
85%
80%
75%
70%
65%
60%
55%
50%
BRAC APPROVAL TARGETED CPI PROJECT PLANS
RFI TRENDS
COMP PROJ
11File: 20091014_FRC transformation overview_V3.pptPresenter: Deputy, COMFRCSubject: DoD Maintenance Symposium Panel Presentation - Transformation
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FLEET READINESS CENTER TRANSFORMATIONSUMMARY
• ACCOMPLISHMENTS– DELIVERING COST-EFFECTIVE
READINESS TO THE FLEET
– CREATING A CONTINUOUS PROCESS IMPROVEMENT CULTURE
– CONNECTING THE DOTS ACROSS ORGANIZATIONS AND PROCESS
• CHALLENGES– BLENDING ORGANZIATIONAL
CULTURES
– CREATING AN ENVIRONMENT OF SHARED RESPONSIBILITY AND MUTUAL ACCOUNTABILITY
– OVERCOMING POLICY AND PROCESS BARRIERS