DAU Acquisition Conference (Nenninger) – 01/20/2009 U.S. Army Aviation & Missile Life Cycle Management Command DAU-South Acquisition Conference AMCOM Update

DAU Acquisition Conference (Nenninger) – 01/20/2009U.S. Army Aviation & Missile Life Cycle Management Command

AMCOM UpdateDAU-South Acquisition ConferenceDAU-South Acquisition Conference

Gary NenningerG-3 Operations

Aviation & Missile Life Cycle Management Command

18 February 2009

U.S. Army Aviation & Missile Life Cycle Management Command 2DAU Acquisition Conference (Nenninger) – 01/20/2009

Agenda

Support to the Aviation Warfighter

Aviation Field Maintenance Transformation

Reset

Condition Based Maintenance (CBM)


AMCOM Support to the Warfighter

Support To The Warfighter

~ 3000 Aircraft Preset/Reset

Aviation Field Maintenance

Condition Based Maintenance

Supply Support

Provisioning

Worldwide Onsite Technical Assistance (LARs / CFSRs)

Fwd Deployed Repair/ Sustainment Activities: TAMP, TASM

TMDE Calibration and Repair

MWO Applications

Depot Maintenance

Technical Publications

Airworthiness & Safety of Use

389,768 Total Hours:01 Feb 03 – 15 Jan 09

Army Fleet in OEF

AH-64 94,947 HoursMC: 87.0%OPTEMPO: 50.0

AH-64 94,947 HoursMC: 87.0%OPTEMPO: 50.0

CH-47 77,946 HoursMC: 78.0%OPTEMPO: 51.6

CH-47 77,946 HoursMC: 78.0%OPTEMPO: 51.6

UAS 43,496 Hours

Shadow 19,529 hrsHunter 910 hrsSky Warrior 4,953 hrsRaven 18,104 hrs

UAS 43,496 Hours

Shadow 19,529 hrsHunter 910 hrsSky Warrior 4,953 hrsRaven 18,104 hrs

UH-60114,928 Hours

MC: 85.0%OPTEMPO: 42.0

UH-60114,928 Hours


Fixed Wing19,926 Hours




OH-5838,525 Hours


OH-5838,525 Hours


2,456,568 Total Hours:01 Feb 03 – 15 Jan 09

UH-60726,335 Hours


UH-60726,335 Hours






AH-64479,959 HoursMC: 82.0%OPTEMPO: 58.0

AH-64479,959 HoursMC: 82.0%OPTEMPO: 58.0

CH-47123,070 HoursMC: 73.0%OPTEMPO: 44.7

CH-47123,070 HoursMC: 73.0%OPTEMPO: 44.7

OH-58416,903 HoursMC: 84.0%OPTEMPO: 72.2

OH-58416,903 HoursMC: 84.0%OPTEMPO: 72.2

Army Fleet in OIF

UAS569,920 Hours

Shadow 323,342 hrsHunter 38,244 hrsSky Warrior 75,001 hrs

Raven 133,309 hrsgMAV 23 hrs

UAS569,920 Hours

Shadow 323,342 hrsHunter 38,244 hrsSky Warrior 75,001 hrs

Raven 133,309 hrsgMAV 23 hrs

OEF Plus Up


Support to the Warfighter


Reset




What We Did?– Realigned All AMCOM Aviation Field Maintenance

Responsibilities Into One Organization– Established Aviation Field Maintenance Directorate (AFMD)

Why We Did This?– Fragmented Aviation Maintenance Responsibilities

Highlighted in Recent Aviation Maintenance Issues– Mission Explosion for OLRs (Beyond MWO Application)

Required Readjustment of Management Structure

Need to Go Back to the Basics With Aviation Field Maintenance


Aviation Maintenance Hierarchy

Depot•Airframe•Component•Special Projects

Below Depot / Above Unit

•Unit Overflow•Limited Depot Repair•MWO Application•Reset

User•AVUM•AVIM•Scheduled Services & Inspections•Authorized Repairs

AMCOM Managed•Organic•Contracted

Unit Managed•Organic Military•CFT Augmentation

Multiple Managers•AMCOM•NGB•DOL/ALMD

Commander’s Intent:“Establish Unity of Command for

AMCOM Below Depot Aviation Maintenance Activities”

• Consolidate AMCOM Structure• Standardize Processes and

Business Rules• Common Metrics & Oversight

Transform How The Army Operates

SINGLE ARMY AVIATION

MAINTENANCE MANAGER




Reset



The Reset Process

Reset Is NOT:– Routine Scheduled Maintenance– Depot Overhaul

Reset IS:– 100% Disassembly of the Aircraft and Dynamic Components

(Engines, Rotor Systems, Drive Trains, Flight Control Systems)– 100% Cleaning of All Airframe and Component Elements– 100% Serviceability Inspection of All Airframe and Component Elements– Application of DA Directed Modifications– 100% Review and Correction of Historical Records– Refurbishment and Replacement of All Components to Serviceability

Standards– Correction of Outstanding Deferred Maintenance Actions

Returns An Immediately Deployable Aircraft To The Unit With Significantly Improved Operational Availability

And Safety Characteristics


Reset Sites AFMD/ALMD*

Drum (DOL)UH-60

Ft Campbell

UH-60, CH-47, AH-64

GermanyGermany

Ft Lewis

UH-60 and CH47

HawaiiHawaii

USAREUR

(Non-Enduring)

Hawaii(Non-Enduring)

Ft Hood

UH-60, AH-64, OH-58

Ft Bragg

UH-60 and OH-58

Ft Stewart

UH-60 and CH-47

Ft Drum

UH-60

Installations with AFMD and ALMD Activities

Installations with ALMD Only

Installations with AFMD Only

* Aviation Field Maintenance Directorate / Aviation Logistics Management Division


Aviation Reset Status

Reset Summary Status

Data as of 13 Jan 09

Completed 2,906 Aircraft (Includes SOA – 353 A/C)– OIF1 – 923 (Includes 75 SOA)– OIF2 – 426 (Includes 62 SOA)– OIF 04-06 – 561 (Includes 53 SOA)– OIF 05-07 – 446 (Includes 74 SOA)– OIF 06-08 – 452 (Includes 73 SOA)– OIF 07-09 – 98 (Includes 16 SOA)

Aircraft In Reset Or Scheduled For Induction– OIF 06-08 – 10 In Reset; 0 Scheduled– OIF 07-09 – 112 In Reset; 228 Scheduled

Deployment Critical TimelineVarious Stakeholders

0-10

POE

InTransit

-35

POD

-45

Load

TransitTo

POD

-55

ALDHome

-85

Pre-deploy Staging

Leave time

-120

LADRESET MREs

Offload RSOI

BOG

+30

To Include Mods-ARFORGEN--ARFORGEN-




Reset




Reactive Maintenance

Time Based Inspection/Overhaul

Digital Source Collector Installation Knowledge Development Fault Diagnosis Remaining Useful Life Calculation Inspection Targeting

Digital Source Collector Installation Knowledge Development Fault Diagnosis Remaining Useful Life Calculation Inspection Targeting

Proactive Maintenance

‘On Condition’ Inspection/Overhaul

CBM Program Objectives:

Decrease Maintenance Burden on the Soldier

Increase Platform Availability and Readiness

Enhance Safety

Reduce Operations & Support (O&S) Costs

Key CBM Enablers• Digital Source Collectors• Flight Line Diagnostics• Data Fusion/Analysis Currently Monitored by Vibration

Structural Part, Possible Addition for Monitoring

Main Rotor HubMain Rotor ShaftBifilarsSwashplate ASSYSwashplate GuideSwashplate Bearing**PC Links

M/R SpindleSpherical BearingM/R Spindle Tie RodControl HornM/R Shaft ExtenderM/R Damper

T/R BladeT/R Pitch Change HornPC Links

Main Transmission ModuleAccessory ModuleGenerators (2)Hydraulic Pumps (2)Planetary Carrier

Engine (No. 1 & 2)Driveshafts (2)**Input Modules (2)

Tail Rotor GB**Retention Plates (2)Gearshaft

Viscous Bearings (4)**

M/R BladeM/R Blade Tip CapM/R Blade Expandable PinM/R Blade Cuff

Oil Cooler Axial FanOil Cooler Fan Bearing**APU

T/R Pitch Change ShaftT/R Pitch Change Bearing

Intermediate GB**

T/R Driveshafts (7)**

VibrationAbsorbers (2)

Monitored Master Parts List – UH-60A/L (56 Parts)


Digital Source Collector FieldingsThrough Jan 09

* Includes Active, Reserve, and National Guard Units

Aircraft Type Total # of Aircraft DSC Equipped Percent Complete

AH-64A690

0333 48%

AH-64D 333

CH-47D

513

61

71 14%CH-47F 0

MH-47E/G 10

UH-60A

1732

105

364 21%UH-60L 180

UH-60M 79

MH-60K/L 0

MH-6 51 16 31%

OH-58D 339 9

TOTAL 3325 793 24%


CBM Demonstrated Benefits

Increased Readiness

Decreased Mission Aborts4-101 Avn Flew 26,000 Hours on 38 UH-60 During 12 Month OIF Deployment With 87% FMC

• 57 Hrs/Acft/Month = 3.8 Times Peacetime OPTEMPO

• 7,260 Launches With No Missions Dropped for Maintenance

• 3,417 Hours in Highest Month (~110 Hours/Day With 20-25 Aircraft)

Impact of Equipping Deployed UH-60s Battalions With DSCs

03-04 OIF Rotation (30 Aircraft )

Non-equipped (Bn 1)

Non-equipped (Bn 2)

FMC* 65% 77%

Total Flt Hours 10,331 11,844

OPTEMPO (Hours/Year/Aircraft)

334 395

Both Units Completed Reset05-06 OIF Rotation (30

Aircraft)DSC Equipped

(Bn 1)Non-equipped

(Bn 2)

FMC 87% 82%

Total Flt Hours 21,819 20,388

OPTEMPO (Hours/Year/Aircraft)

727 680

Expect Increased Readiness in Deployed. Real Comparison Is Deployed

CBM vs Non-CBM Deployed Aircraft

CBM Will Enhance Pilot Training by Providing Insight Not Previously Available (e.g., Fatigue

Damage Due to Maneuver Severity)

CBM Already Changing the Way Aviation Operations Are

Planned & Conducted

CBM = Increased Warfighting Capability


CBM Benefits to Army AviationIncreased Readiness/Reduced O&S Costs/Reduced Soldier

Burden

2007/2008 AH-64 UH-60 CH-47

# of Aircraft 319 319 71

MMH Avoided 16,369 7,274 2,957

Hrs Reduction in MTF hours 2,005 722 166

Impact of Equipping Aircraft With DSCs

Cost Savings/Avoidance of ~$112M (26 Month Period) Due to CBM

(Accidents Avoided, Components Not Replaced Unnecessarily, MTF Hours Saved,… )

Reduced NMC Due to Maintenance

Cost Savings/Avoidance

$24M: 51 T700 Engines not Replaced on UH-60/AH-64 for Overspeed/Overtorque

~$30M: Additional AH-64/UH-60 Flight Hours Available Due to Increased Readiness/Availability + MTF Hours Saved

~$49M: Three Class A Accidents Avoided

~$6.6M: Components not Replaced, Returned to Service, and Overhaul Savings Due to Early Failure Detection

~ $2.8M: AH-64 Tail Gearbox Scheduled Maintenance

~$112.4M


Hellfire II (AGM-114K) Guidance Section

Methodology – Automatically Measure and Record– Captive Carry Hours / Number of Cycles– Temperature Exposure – Battery Life – Data Histogram– Drop Shock/Humidity

Payoff– Reduced Maintenance Burden– Increased Reliability and Enhanced Safety– Positive Impact to Stockpile Readiness and Shelf Life

HELLFIRECaptive Carry Health Monitor

CCHM

Captive Carry Exposure Data Will Optimize Reset Maintenance,

Improve Reliability, and Reduce Reset Costs


Challenges

Reset– Funding

– ARFORGEN Synchronization

Increased OEF Support

OIF Retrograde


We Are Here…We Are Here…

BECAUSE THEY ARE THERE !!!BECAUSE THEY ARE THERE !!!

Our CustomersOur Customers

Documents

DAU Acquisition Conference (Nenninger) – 01/20/2009 U.S. Army Aviation & Missile Life Cycle Management Command DAU-South Acquisition Conference AMCOM Update