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