Depot Contributions to Weapon Systems Readiness

DOD MAINTENANCE SYMPOSIUM | 26-OCT-06 | RENO, NEVADA

Depot Contributions to Weapon Systems ReadinessRDML Michael HardeeUSN, Commander, Air Depots, Naval Air Systems Command

26 OCT 2006 | NAVAIR Depot Contributions to Weapon Systems Readiness Slide 2

Outline

Naval Air Depot Overview– Production

– In Theater

Challenges & Metrics

Transformation Strategies

Summary


10,000 Skilled Personnel Focused on Providing the Warfighter What They Need, When They Need It, at the Right Cost

Depot Ops & IMC Dets: North Island

West Coast TACAIR

JacksonvilleEast Coast TACAIR

Cherry PointMarine Aviation

OCONUS Repair:NAPRA

Pacific/IO OIF/OEF

Worldwide Support Equip Repair

Annual Naval Aviation Industrial Support To The Fleet

CalibrationIn Service RepairFleet Support Teams

$2.0B

700 Aircraft

1500 Engines & Modules

70,000 Components

Mai

nten

ance

&

Mod

ific

atio

ns

Support Equipment


OIF/OEF Support-Global War on Terror-

Deployed: – Over 100 personnel in support of expeditionary maintenance

– 1335 in-service repair field teams

– Mod teams to incorporate missile warning mods on CH-46E’s

– Permanent detachment at Al Assad to perform in-service repair/inspection

Performed: – 100,000 hrs of expeditionary maintenance

– 50,000 hrs of in-service inspections

– 200,000 hrs of in-service repairs

– 30,000 ‘stop-gap’ manufacturing of ‘out-of-production’ parts

– 1400 tech assistance responses

Provided: – 150 emergency/expedited shipments of 5000+ parts

– Over 300 ‘improved reliability’ engines for deployed H-46s

– 200 H-53 engines with titanium nitride coated blades/vanes to improve durability/reliability

– Expedited engineering development of critical mods to include ASE and armor


Metrics

Production to Plan (A/C, Engines, Components)– TAT (on-time delivery)

– WIP

– Cost/NOR

Quality

Reliability/Time on Wing (TOW)


Challenges

Constrained BudgetsFleet Response Plan (FRP)– Faster Air Wing deployment

turnaround– Quicker readiness refresh after

deployment– Increased requirement for “up”

jets on flight line– Higher utilization of aircraft,

engines and components

Material Condition– Aircraft consumption: work

content growth – Increased utilization of aircraft –

GWOT, OIF, OEF– Variability of inducted aircraft

Material Availability– Increasing replacement factors– Variability in material condition of

inducted retrogrades– Difficulty in forecasting quantity &

type of component workload – Long lead time for procurement – Parts obsolescence – Cost growth

Manpower– Aircraft consumption requiring

increased skills i.e. sheet metal – Market constraint for qualified

artisans


Transformation Strategies

Accelerated retirement of oldest, higher cost airframes

Improving reliability of components

AIRSpeed

Integrated Maintenance Concept (IMC)

Fleet Readiness Centers


AIRSpeed Value DeliveredJacksonville Cherry Point North Island

P-3Reduced TAT by 24 days (225 days to 201days)Improved Stability / Reduced Variability by over 40 Days (79 Std Dev to 69 Std Dev)Sold 22 Aircraft vs. 19 Aircraft in FY04Reduced WIP by 5 Aircraft (from 17 to 12)

EA-6BReduced WIP from 17 Aircraft to 9 WIP reduction returned 2 Squadrons to the FleetAircraft Returned to the Fleet Faster (FY04 vice FY05)Reduced Cycle Time from 463 Days to 380 DaysIncreased On-time Deliveries from 31 percent to 83 percent

H-46Reduced TAT by 35 daysGained 3719 WLS HoursWIP reductions resulted in 11 more assets to the fleet

H-53Reduced TAT by 145 daysGained 1200 WLS HoursWIP reductions resulted in 16 more assets to the fleet

F/A-18 PMI 1Reduced TAT by 50 days (from 190 days to 140 days)Reduced WIP by 12 aircraftResults achieved despite work content growth from 6453 hours to 8335 hours

E-2PMI 2 TAT reduced from 225 days to 180 daysPMI 1 TAT reduced from 100 days to 35 days

Cost-wise readiness & dominant maritime

combat power to make a great

Navy/Marine Corps team better!

• Lean, Six Sigma Tools• Focused on reduction

in cost, TAT, and WIP• Enterprise Application• TOC

AIRSpeed


IMC LocationsShifted from on-condition to calendar-based aircraft maintenanceTaking Depot Maintenance to the Fleet Full time depot maintenance at every major Navy & Marine Corp Air Station worldwide

NAF Atsugi, Japan /NAPRA Det OkinawaE-2, F/A-18, H-60, H-46H-1, H-53, EA-6B

NAF Atsugi, Japan /NAF Atsugi, Japan /NAPRA Det OkinawaNAPRA Det OkinawaE-2, F/A-18, H-60, H-46H-1, H-53, EA-6B

Field Site

Depot Site

NAS Jacksonville/Cecil FieldEA-6B, P-3, H-60 S-3, F/A-18

NAS Jacksonville/Cecil FieldNAS Jacksonville/Cecil FieldEA-6B, P-3, H-60 S-3, F/A-18

NS MayportH-60

NS MayportNS MayportH-60

Whidbey ISL EA-6B

Whidbey ISL Whidbey ISL EA-6B

Camp PendletonH-1

Camp PendletonCamp PendletonH-1 Cherry Point

H-1, H-53, H-46, AV-8B,EA-6B

Cherry PointH-1, H-53, H-46, AV-8B,EA-6B

MCAS BeaufortF/A-18

MCAS BeaufortMCAS BeaufortF/A-18MCAS Kaneohe Bay, HI

H-60MCAS Kaneohe Bay, HIMCAS Kaneohe Bay, HIH-60

NAS LemooreF/A-18

NAS LemooreNAS LemooreF/A-18

Norfolk/Oceana Naval BaseF/A-18, E-2, F-14, H-60

Norfolk/Oceana Naval BaseNorfolk/Oceana Naval BaseF/A-18, E-2, F-14, H-60

St. Augustine EA-6B

St. Augustine St. Augustine EA-6B

Paxtuent River, MD F/A-18, H-60

Paxtuent River, MD Paxtuent River, MD F/A-18, H-60

NAS Fallon NV H-60

NAS Fallon NV NAS Fallon NV H-60

Andersen AFB, Guam H-60

Andersen AFB, Andersen AFB, Guam Guam H-60

MCAS MiramarF/A-18

MCAS MiramarMCAS MiramarF/A-18

STAE SingaporeC-130

STAE SingaporeSTAE SingaporeC-130

NAPRA S. KoreaH-53

NAPRA S. KoreaNAPRA S. KoreaH-53

MCAS Yuma, AZAV-8B

MCAS Yuma, AZMCAS Yuma, AZAV-8B

Hill AFB, UTC-130

Hill AFB, UTHill AFB, UTC-130

NAS North IslandH-60, F/A-18 ,E-2, C-2, H-53

NAS North IslandNAS North IslandH-60, F/A-18 ,E-2, C-2, H-53

Point Mugu, CAE-2

Point Mugu, CAPoint Mugu, CAE-2


FRC & BRAC Law –What Does it Mean?-

Disestablish / Reestablish (I-Levels and Depots into FRCs)– Moves Hours

– Moves People

– Moves Facilities

Mandates Savings


Fleet Readiness CentersIntegration of Intermediate and Depot Organic Maintenance

6,000 + Sailors and Marines ashore

3,900 Sailors shipboard

20 Aircraft Intermediate Maintenance Departments and 11 Marine Aviation Logistics Squadrons

6,000 Engine/Module Accessory Repairs

580,000 Component Repairs

$2.0 Billion Operation

• 10,000 Civilians

• 3 NAVAIR Organic Depots

• 70,000 Depot-level Component Repairs

• 700 Depot-level Aircraft Repairs

• 1,500 Depot-level Engineering and Module Repairs

• $2.0 Billion Operation

INTERMEDIATE DEPOT


Fleet Readiness Center Locations

FRC NORTHWESTAIMD Whidbey Island

FRC NORTHWESTAIMD Whidbey Island

FRC SOUTHWESTAIMD North IslandNADEP North IslandNADEP NI Det NI

Site MiramarMALS-11 & 16 MiramarNADEP NI Det Miramar

Site Point MuguSite Pendleton

MALS-39 PendletonNADEP NI Det Pendleton

Site YumaMALS-13 YumaNADEP NI Det Yuma

FRC SOUTHWESTAIMD North IslandNADEP North IslandNADEP NI Det NI

Site MiramarMALS-11 & 16 MiramarNADEP NI Det Miramar

Site Point MuguSite Pendleton

MALS-39 PendletonNADEP NI Det Pendleton

Site YumaMALS-13 YumaNADEP NI Det Yuma

FRC EASTNADEP Cherry Point MALS-14 Cherry PointAIMD Willow Grove

Site New RiverMALS-26 & 29 New RiverNADEP CP Det New River

Site BeaufortMALS-31 Beaufort NADEP JAX Det Beaufort

FRC East ‘Affiliation’HMX-1 Quantico

Site Robbins AFBMALS-42 AIMD Atlanta

FRC EASTNADEP Cherry Point MALS-14 Cherry PointAIMD Willow Grove

Site New RiverMALS-26 & 29 New RiverNADEP CP Det New River

Site BeaufortMALS-31 Beaufort NADEP JAX Det Beaufort

FRC East ‘Affiliation’HMX-1 Quantico

Site Robbins AFBMALS-42 AIMD Atlanta

FRC MID-ATLANTIC AIMD OceanaAIMD NorfolkAIMD NAS Corpus ChristiNADEP CP Det OceanaNADEP JAX Det NorfolkNADEP JAX Det OceanaNAWCAD LKE Det Norfolk

Site Pax RiverSite New Orleans

AIMD Atlanta (E-2C support)NAS JRB New Orleans

Site NAF Washington

FRC MID-ATLANTIC AIMD OceanaAIMD NorfolkAIMD NAS Corpus ChristiNADEP CP Det OceanaNADEP JAX Det NorfolkNADEP JAX Det OceanaNAWCAD LKE Det Norfolk

Site Pax RiverSite New Orleans

AIMD Atlanta (E-2C support)NAS JRB New Orleans

Site NAF Washington

FRC SOUTHEAST NADEP JAXNADEP JAX Det Cecil FieldAIMD JAXAIMD Brunswick

Site MayportAIMD MayportNADEP JAX Det MayportNAWCAD LKE Det Mayport

Site Key West

FRC SOUTHEAST NADEP JAXNADEP JAX Det Cecil FieldAIMD JAXAIMD Brunswick

Site MayportAIMD MayportNADEP JAX Det MayportNAWCAD LKE Det Mayport

Site Key West

FRC WESTAIMD LemooreNADEP NI Det Lemoore

Site FallonNADEP NI Det Fallon

Site Fort WorthAIMD Atlanta (FA-18 support) NAS JRB Fort Worth

FRC WESTAIMD LemooreNADEP NI Det Lemoore

Site FallonNADEP NI Det Fallon

Site Fort WorthAIMD Atlanta (FA-18 support) NAS JRB Fort Worth


Primary Function Statement & FRC Fundamental Design Tenets

Primary FunctionFRCs provide relevant quality airframes, engines, components, and services to meet the NAE’s aircraft Ready for Tasking (RFT) entitlements at improved efficiency and reduced cost.

In order to perform to entitlement requirements, FRCs provide seamless integrated off-flightline repair, in-service industrial scheduled inspections/mods, and deployable Sea Operational Detachments.

Fundamental Design Tenets– Seamless integration of I/D Level maintenance to create optimized two-

activity-level (on-flightline and off-flightline) maintenance

– TMS focus for maintenance planning, budgeting & execution

– Metrics driven operation

– Enterprise Cost reduction achieved through workforce reshaping and reduced material requirements

Requires Process,

Organization, & Culture

Change


FLEETBad Parts

Good PartsGood Parts

FRC

TO BE

Inventory

FLEET Bad Parts I

Good Parts

Good Parts

Good Parts Inventory

AS IS D

Reduced CostDecreased Turn-Around Time

Bad Parts

Bad Parts

Good Parts

I

Artisans

LESS

MORE

D

Component Repair


FRC’s Creating Value -Expected Enterprise Benefits-

Improved readiness through:– Reduced turn-around times

– Less WIP

– Improved reliability/increased time on wing

– Increased Type/Model/Series focus and visibility

Lower enterprise cost through: – Focused D at I that maximizes readiness at reduced cost

– Reduction of duplicate/repeated maintenance activity

– Reduced manpower requirement

– Reduced materiel cost

– Potentially fewer repair sites


LeadershipBe Visibly Committed & Engaged

Establish “Burning Platform”

Advanced Leadership, not management– Change management vs. change leadership

– Manage within resources or go to the next level

– Path of discovery

Refresh education, engage and train leaders & influencers first

Work Top Down

Include the customers & suppliers

Coach, Cheer, Celebrate

Implementation progress will be measured– Can’t just talk the talk

“Of course it’s hard!

It’s the hard that

makes the game

great!”


FROZEN MIDDLE

How do you become a partof the CHOCOLATE?

Senior Leadership

Civilian Artisans & Uniformed Technicians


Status

Basic organization and operation fixed

Funding alignment fixed

HQ and Area Commands standing up provisionally in Oct

Staffing of key HQ and Area Command positions in process

“Fleet Implementation Team” deployed to:– Introduce concepts to Area Commands and Subordinate Sites

– Facilitate workload movement from Depot to IMA

Functional IT requirements in development

MOA’s with Fleet leaders (Commodores) in work


Lessons Learned

Senior leadership must be aligned with basic intent and organization

Beware of Miracles

Move fast

Establish basic governance structure early

Chapter 3 of “Good to Great” is critical

CONOPS must flow:– Intent and operational objectives

– Structured application of design criteria

– Stakeholder involvement and buy-in

Communication is never what you think it is

BRAC is a good foundation, but not sufficient– Navy: Readiness and Cost

– Congress: Jobs, Oversight, and Control


Take Aways

Depot and Intermediate operations provide strong legacy of excellenceNaval Aviation Maintenance is transforming with FRC– Depot capability “placed” forward– BRAC driven– Cost-wise readiness focused

This transformation is highly complex– Synchronization required across the enterprise– Savings and readiness are dependent variables

We are moving fast– Initial Operating Capability Oct06 – Full Operating Capability Oct08– CONOPS and Organizational definition by Aug06

Documents

Depot Contributions to Weapon Systems Readiness