air force sustainment center -...

Air Force Sustainment Center

Kevin Stamey

AFSC/EN

23 Aug 2017

DISTRIBUTION STATEMENT A. Approved for public release; Unlimited distribution

B r e a k i n g B a r r i e r s … S i n c e 1 9 4 7

LSE2040: Infrastructure Modernization

Vision & Roadmap for the Next 30 years

DISTRIBUTION STATEMENT A. Approved for public release; Unlimited distribution

B r e a k i n g B a r r i e r s … S i n c e 1 9 4 7DISTRIBUTION STATEMENT A. Approved for public release; Unlimited distribution.

“100% Data Availability”

• Optimize repair data collection, archiving and

access to enable accurate forecasting,

process analysis, and repair execution

• Digital Thread, Real Time Display, Digital Twin

• Maintain electronic Technical Orders

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“100% Parts Availability”

• JIT parts – print on

demand parts

• Tracking & delivery

• Counterfeit detection

• Agile manufacturing –

additive manufacturing

• Data-driven models to

predict future demand

• 3-D models for

reprocurement

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“Safe & Environmental

Excellence”

• Move from control & protection to elimination

• Proper hierarchy of controls in all process engineering

• Target cadmium, hexavalent chrome, beryllium, lead, RDX

(explosives) and OSHA “Watch” chemicals

• Execute environmentally compliant processes• Solid waste recycling/recovery

• Hazardous air emission reductions

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“Efficient Depot Operations”

• Delivery is on-time, every time

• Flexible, optimized processes--accurate, actionable metrics

• Wide-spread automation & robotics

• Standard work across the enterprise

• One-pass, whole weapon system assessment

• Scripted networks; condition based PDM

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“Effective Workforce”

• Workforce trained for current & future workloads

• 8 for 8, 8 hour work exp’n, effective/efficient training, hands-free digital info

Tech Super Tech Professional

S&E

• Right people with right skills

Robust K-12 STEM outreachComplexity driving higher skills

Enthusiastic

Engaged

Workforce

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“100% Process Control”

• Controlled, optimized process sequencing

• Process config mgmt - tip-to-tail product traceability

• Rigorous accept/reject criteria

• Process engineering

expertise incorporated

in manufacturing

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“Strategic Sustainment

Management”

• AFSC is the gateway to the Sustainment Enterprise

• Common IT tools across ALCs – interchangeable/optimized

• Agile manufacturing – additive manufacturing/material substitution,

improved local manufacturing velocity

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Shared/Collaborative resourses can create virtual

“manufacturing centers” & “jumpstart” innovation

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http://www.cascom.army.mil/g_staff/g3/SUOS/index.htm


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10.0

20.0

30.0 Millions of Source Lines of Code

“Resilient Mission-Ready

Software Sustainment”

• Characteristic A - Resiliency: Assure resiliency for AFSC

software development environments (SDEs) against

current & future threats

• Characteristic B - Effectiveness: Improve effectiveness of

requirements validation, test and training capabilities of

AFSC software resulting in 100% error free fielded

software

• Characteristic C - Innovation: Employ collaborative tools

& techniques to address increasing AFSC software

complexity where innovation is leading industry

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“Energy Efficacy”

• Industrial Energy Efficiency: Reduce IE consumed 5% Y-O-Y,

achieving NETZERO status by 2035

• Electricity

• Fossil Fuels

• Propane

• Energized Waters

• Gases

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• Ensure mission assurance by providing:

• Installation security

• cybersecurity

• Infrastructure resiliency (facilities, airfields, communications)

• Installation Command and Control (C2)

• Provide world class Installation security by utilizing forward thinking

initiatives such as:

• Drone detection

• Vehicle Taser

• Active shooter surveillance

• Explosive detection equipment

• FOD truck

• Identifying gaps in future security risks

“Host Installation Support”


Resources for

Meeting Sustainment Req’ts

• 100% Data Availability

• 100% Parts Availability

• Safe & Environmental Excellence

• Efficient Depot

• Effective Workforce

• 100% Process Control

• Strategic Sustainment Mgmt

• Software Sustainment

• Energy Efficacy

LSE2040 – Technology Plan

• TDIP – SBIR, RIF, DMT ●AFMC Agile Combat Support CFSP

• WCF CIP ● AFLCMC SPO O&M

• ABW POM’d FSR ● AFRL ManTech

• MILCON ● OSD ESTCP and ECIP

FUNDING – Possible Sources

• AFSC (ALCs, Supply Chain Mgmt, Engineering)

• AFRL

• AFLCMC

• AFNWC

• Industry

• Academia

PEOPLE – Strategic Teamwork

Must Find and Commit Resources


Innovation Center

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Innovation Center Timeline

Development history

Feb 2016: RFI released to gauge community interest

Mar 2016: Hosted symposiums at ALCs

May 2016: RFIs (13) received

Jun 2016: Reviewed RFI responses

Sep 2016: IPT stood up to develop Courses of Action

Sep-Oct 2016: ID’d available resources / avenues to access

Sep-Jan 2017: Developed requirements and models

Dec-Feb 2017: Researched options / site visits / contacts

May 2017: Received AFSC/CC approval to advance Blended solution

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Innovation Ecosystem

Innovation Center solutions

should:

Leverage other

organizations

contributions/capabilities

Optimize available resources

unique to each location

Answer workforce needs

Build relationships across

AFSC, USAF, industry, and

academia

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Innovation

Capacity

AFSC

Existing

Innovation

Centers

Private

Industry

UniversitiesAFRL

AFLCMC/

NWC


AFSC Innovation Center Goals

Enable workforce to generate rapid, innovative solutions

Advance state-of-the-art of agile manufacturing technology

Develop organic agile manufacturing capabilities

Develop organic workforce that thinks agile, and has skills to leverage

agile manufacturing technology

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Innovating with

Mature Technology

Pushing boundaries

of S&T

• Polymer Printers

• Metal Printers (Tooling)

Spectrum of InnovationShort Term Long Term

• Exotic materials

and Processes

• Metal Printers for

A/C worthy Parts

Solution Must Span Spectrum of Innovation

Creating an Innovation Minded Workforce


Capability Requirements(not in Rank Order)

Requirement Description LSE 2040 Attribute

Metal Additive Manufacturing Process Development

Develop the techniques & processes necessary to produce qualified AC parts

• 100% Parts Availability• Agile Manufacturing & Repair Plan

Rapid Tech Data Development ThroughReverse Engineering

Rapid development of Tech Data for acquisition of parts (existing AC parts)

• 100% Parts Availability• Agile Manufacturing & Repair Plan

Rapid Part Development & Re-engineeringa) Plastic b) Metal

Rapid development of AC parts using advanced manufacturing processes(Reliability, DMS, etc.)

• 100% Parts Availability• Efficient Depot• Agile Manufacturing & Repair Plan

PrototypingRapid development of prototypes for form/fit tests (i.e. print plastic part prior to manufacture of metal part

• 100% Parts Availability • Efficient Depot

Rapid Tool Developmenta) Plastic b) Metal

Rapid development of Tooling• Efficient Depot• Agile Manufacturing & Repair Plan

EducationIncrease workforce knowledge, share lessons learned across sites/orgs/academia and develop awareness of state of the art technologies


TrainingTraining on hardware, software (e.g. CAD, modeling/sim tools, etc.)


LRIP Productiona) Plastic b) Metal

On demand ability to produce AC quality parts in low quantities

• 100% Parts Availability

Advanced Manufacturing Process Improvement

Identify/evaluate emerging manufacturing technologies for potential improvements & efficiencies to sustainment center practices. Modeling/Testing/prototyping manufacturing processes

• Efficient Depot

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Four Potential IC Models

AFSC Virtual Innovation Hub

Virtually connect existing organic capabilities across all ALCs

AFSC Innovative Design & Engineering Analysis (IDEA) Lab

Collocate advanced technologies and organic capability within AFSC

Reverse Engineering, Polymer 3D printing, Metal 3D printing

Leverage existing Innovation Centers

Develop blueprint to access existing gov’t/public ICs (e.g. GTMI)

Gains access to existing body of knowledge

External Partnerships

Partner with industry leaders to start new Innovation Centers near ALCs

(e.g. USTAR)

Industry led effort will maximize innovation potential

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Unique Blended Solution

for Each Site

Each site combines models to balance requirements and resources

No single approach balances cost, resources & capability

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2016 2017 2018 2019 2020 2021

Tinker

Robins

Hill

AFSC Virtual IC Hub

AFSC Virtual IC Hub

AFSC Virtual IC Hub

Leverage Existing ICs

External Partnership

Leverage Existing ICs

External Partnership

RFI

Released

AFSC IDEA Lab

IOC


Benefits of Blended Approach

Each ALC will incorporate variations of the models as appropriate

Meets local needs while achieving overall AFSC strategy

Leverages existing organic capabilities

Not all agile technologies need to be organic

Shares cost for new non-organic advanced capabilities

Maximizes flexibility to solve varying degree of complexity problems

Maximizes “innovation” culture and industry collaboration

Workload/projects distributed across all sites based on

capacity/capability

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Tinker AFB: IDEA Facility &

External Partnerships

Both efforts are in planning phase

Goal for on base Innovative Design & Engineering Analysis (IDEA) Lab

Easy access, located near workforce

Organic capability fosters innovative minded workforce

Goal for External Partnerships

Expands capability reach beyond organic assets

Expanded collaboration possibilities with more partners

Address more complex challenges: Multi material parts, complex

internal geometry, avionics, composites etc.

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Vision Includes AFSC and AFLCMC


Strategic Issues

Needing Innovative Solutions

Near Term

Significant challenges

Need more people using more 3D printers to produce more parts

Quantity of AM workforce is still a LIMFAC

Need OEMs to qualify/certify more AM parts

Adds credibility towards achieving Air Worthiness Certification

Medium Term

Design to performance specs vs. material performance spec

Future proof design by allowing for technology advances

Develop an enterprise wide AM process and certification spec

Everyone understands and plays by the same rules

Long Term

Considerations for AM as a single source of supply for certain parts

Will drive supply chain behavior

Need a MMPDS “like” material properties spec for AM

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Agile Contracting

Multi-layer Circuit Boards

Reverse Engineering

Castings (Direct Print, Mold Print)

Die Extraction/Repackaging

DMS Composite Replacement

Technology Insertion/Evaluation


Technology Needs and Challenges

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Logistics Command & Control (Log C2)

Log C2 processes & tools = enabled core capabilities = mission success

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Problem Statement: The Air Force does not have

comprehensive global visibility of logistics resources, or the

structured processes required, to conduct coordinated planning

across multiple theaters and organizations. As a result, contingency

operational planning tends to be theater-centric while planning for

institutional activities tends to be organizationally focused. There is

no capability to identify potential competing resource demands

among these multiple planning efforts. The inability to provide a

global perspective for logistics planning is creating unknown and

unquantifiable risks to multi-theater missions and the forces

conducting those missions. Vision: Globally integrated logistics and optimized allocation of

resources synchronized across all domains conducted in collaboration

with other command and control nodes to achieve effects across all

spectrums of conflict in all environments.


Hazardous Materials Reduction

Technology Needs

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Qualifications of safer, effective non-Hazardous

Materials for paint and depaint processes

Reduce HazMat risks and costs

Effective depaint process for non-Chrome coating system

Alternatives for MeCl and NMP (EPA-proposed ban)

Better engineering controls and more comfortable PPEs

to protect workers during paint/depaint processes

Allow personnel to meet the mission more effectively and

efficiently


Nondestructive Inspection

Challenges AFMC Strategic Goal is to reduce the amount of

time to do NDI by 50%

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AFSC sees four areas of opportunity

Digital data

Broad area

inspections (OML)

Deep structure

Increased probability

of detection


Nondestructive Inspection Challenges

– Digital Data

NDI Inspectors

overburdened with

paperwork

Overly ripe for automation

As much paperwork time as

actual inspecting

Analog results

Needs

Automated defect identification

Digitally recorded inspection

results

Geo-registration

Integrated with weapon system

data

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– Broad Area Inspections (OML)

Large area inspections becoming more common

Some inspections take so much time, cannot fit in the

Inspection Gate

Labor, equipment intensive

Needs

Automated, rapid inspection of large areas

Digitally recorded inspection results

Geo-registration of data

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– Deep Structure

Some inspections take more prep time than

inspection time

For example, 206 hours of MX prep/restore for 5

hours of inspection

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Needs

Technology for deep structure

inspections

Could include robotics

Reduce or eliminate

disassembly

Reduce or eliminate MX

induced damage



– Increased Probability of Detection

Increased probability of detection

(PoD) = increased inspection

intervals = reduced MX

Nearing the limits of physics of

current methods

Needs

Technology advances to increase the

PoD of current inspections

Minimize human factors

Algorithms and analytics

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NDI Opportunities Abound

NDI tools and process are 70-80 era

Significant manual labor

Very little automation or digital tools

Heavily dependent on technician skill and data interpretation;

PoD varies

NDI is a large driver of labor cost and depot flow time

Safety Critical: Must be accurate

Improved PoD variance and crack size detection will lengthen

Mx Intervals

Better tools & techniques to improve coverage

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End to End, Fully Integrated Digital NDI Capability


Technology Needs &

ChallengesCoatings and Masking

Replacement Needs/Challenges Eliminate coatings that contain HazMat

Replacement for Brush Cd Plating

Eliminate manual taping/masking

Currently Masking Parts Prior to

Coating/Plating Mold Formed Rubber Masks

Labor Intensive Tape Masks

Wax Masks

Technology Need - New Method of

Masking Robotic UV Cured Masking

3D Printed Rubber Maskings

Brush Zn-Ni repair/touch up

Re-usable masking

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Technology Needs &

ChallengesCoatings Removal

Current Coating Types Paint/Primer

Cad Plating

Current Removal Methods Chem-Strip

Plastic Media Blast

Water Jet

Grinding

Technology Needs/Challenges Need to Reduce Hazardous Waste Stream

Effective/Efficient Removal Processes

Confined space selective removal

Minimization of Worker Exposure

Zero damage to Aircraft/Part

Waste Treatment

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Technology

Needs/ChallengesElectro-Magnetic Testing (EMP)

Renewed strategic interest in EMP

New Mil-Std-3023 High Altitude EMP

New threats emerging

Technology Need

High Powered (1500 volts), Modular

Amplifier to drive load impedances from

short to open circuits for Direct Drive

testing

Currently no COTS amplifier exists

Previous vacuum tube technology

unsupportable

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Misc Tech Needs

Digital real-time tools (video) for 202 communication

Improve real-time collaboration

Automation of quality checking

Sensing/verification of task completion

Missile Maintenance Technology

Methods to dissect missile motors for obtaining aging fleet

surveillance data

Automated NDI to map wall thickness and corrosion for ICBMs

More efficient test method to identify/quantify levels of residual

hydrogen. Better than current ASTM F519 method in terms of

accuracy, precision and repeatability

NDT to find anomalies on high strength steel (steel and aluminum)

landing gear components without removing existing coatings

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Misc Tech Needs

Tech data automation/visualization

Augmented reality of Tech Data and Aircraft

Projected tech data

Google glass

Video aids

Automation of quality checking

Sensing/verification of task completion

“Big Data” analytics

Detect, identify and isolate incipient failure modes

Estimate the remaining useful time of failing components

Demonstrate the efficacy of improved data mining and

prognostic technologies

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