1 Ageing Aircraft Thoughts on a Path Forward Robert Ernst Head, Aging Aircraft IPT Chairman, Joint...

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Ageing Aircraft

Thoughts on a Path Forward

Robert Ernst

Head, Aging Aircraft IPT

Chairman, Joint Council On Aging Aircraft

20 June 2006

Or… Getting Industry to help us advance the issue with aircraft aging

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Aging Aircraft IPT

Avionics Team

Training

Parts

Commonality

Air Vehic le Team

Avionics Team

Wiring & Power Team

Obsolescence Team

Touch-Up Paint Process

Approx 80 Fleet and Depot Personnel Trained on AWA

Equip

Data from F/A-18 to improve H-60 Hydraulic Seals

Analysis

TransparenciesWash Cycles: Reduced MMH

(est. 20,000)

Logistics

DiagnosticsAWA

4-6 Parts Inquiry77% of Investigation Resolved236 DMSMS Cases Reviewed

YTD

Lead Free Solder

Tools: $3.3M in Cost Avoidance (V-22)

Training

ADEC

JCOMMS (All Platforms)

Semi-Conductor Device Wear-out

AFCB Core Logistics

Fleet IntroductionFleet Survey’s (Wiring &

Corrosion) = Approx 1,000Updated & Released 01-

1A-509 Vol 1 thru -4

Batteries: $3.2M MMH & Maint Savings

CYCLE TIME RELIABILITY INVENTORY TOTAL OWNERSHIP

COSTMULTIPLE

“Improving the fleet’s readiness and reducing life cycle cost by aggressively attacking and countering the effects of aging aircraft.”

Focusing Efforts across platforms and PMA’s

Improve aging systems availability while reducing total ownership cost through reductions in cycle time, Man-hours, inventory, and operating costs in various functional areas.

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Who is the JCAA?Who is the JCAA? Jointly Identify, Investigate, and Implement Programs that will Field Products to Improve the Availability and Affordability of all the Services’ and Agencies’ Aging Aeronautical Systems.

Through the use of Integrated Roadmaps, Shared Data and Analyses, the JCAA will:

– Identify Process Recommendations & Improvements

– Advocate/Enable Promising Technology

– Facilitate Transition of Technology/Program Opportunities

– Promote Knowledge Management on Aging Aircraft

– Coordinate Funding for Promising Areas

VisionVision

ProcessProcess

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National Strategy ProgressNational Strategy Progress

JCAA Focus

• Maintenance Training• Analytical Methods/Cost of Aging• Corrosion Prevention• Transition of Commercial Products • Diagnostics/Health Monitoring Systems• Wiring Failure Detection• Arc Fault Circuit Interrupt Equipment • Structural Modeling and Analysis • Maintenance Manual Currency• Obsolescence Management• Avionics Modernization • Component Improvement

NASA

FAAAir

Force

Navy

DLA

Army

Considering Resources,

Overall Progress

OK

CoastGuard

USMC

NDIA

AIA

5 Process Issues

7 Product Focus Areas

Five “Greens” – Four “Yellows” – Three “Reds”Five “Greens” – Four “Yellows” – Three “Reds”

5

0

5

10

15

20

FY04 FY05 FY06 FY07 FY08 FY09 FY10 FY11 FY12 FY13 FY14 FY15 FY16 FY17 FY18 FY19 FY20

VH-XX

CH-53E

AH-1Y/AH-1Z

MH-60S

MH-60R

T-45

JPATS

KC-130J

T-39

C-37

UC-35

C-40

MMA

MV-22

UAV (BAMS, UCAV-N)

AEA (EA-18G)

E-2

F/A-18E/F

JSF(NAVY)

JSF(USMC)

Control

Procurement Bow Wave PR05

AEA

MMAMV-22

F/A-18E/FJSF CVTOL

JSF STOVL

$TYB

E-2C

CH-53E

BAMS/UCAV-N

100 Aircraft

200 Aircraft

300 Aircraft

MH-60R/S

Flatten the FY08-11 Bow WaveFlatten the FY08-11 Bow Wave

PR05:FY04 $11BFY09 $20B

PR05:FY04 $11BFY09 $20B

Need to reduce operating costs to free up money for

procurement

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Aging Aircraft – Steps to Aging Aircraft – Steps to SuccessSuccess

1. Start with good data and understand what is driving the behavior.

• Share data among many sources• Allies with smaller fleets may be able to see

small changes before larger fleets

• Look at Commercial Applications???

Obstacle: We need to share information and send the same Message to “Leadership”Challenge: Nobody wants to fund “data”

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Data• Target studies (what do we care about?)

– Collect Baseline costs– % Reduction (task analysis)– Post Implementation Analysis

Naval Aviation Flying Hour Program CostsReported by CAVTS for All Aircraft Except CNET

0

500

1000

1500

2000

2500

3000

3500

4000

4500

FY

1991

FY

1992

FY

1993

FY

1994

FY

1995

FY

1996

FY

1997

FY

1998

FY

1999

FY

2000

FY

2001

FY

2002

FY

2003

FY

2004

FY

2004

Co

st p

er F

ligh

t H

ou

r

0

200,000

400,000

600,000

800,000

1,000,000

1,200,000

1,400,000

1,600,000

1,800,000

Flig

ht

Ho

urs

Exe

cute

d

Fuel

Maint Cons

AVDLR

Flight Hours

How can we divide up the pie?

All Aircraft (All but CNET) (All Program Elements) (All Schedules)

$0.0

$0.5

$1.0

$1.5

$2.0

$2.5

$3.0

$3.5

$4.0

$4.5

$5.0

1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009

Total FHP Cost per FH (TY$)

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Cost of Aging WorkshopCost of Aging Workshop• As part of the overall Cost of Aging

Study, JCAA Chaired a meeting with industry cost experts to evaluate:

– Cost Elements, Age Related Factors, Analysis Best Practices, And Using CoA Information

• Workshop Recommendations:– Establish Joint CoA Board– Establish CoA Community Of Practice– Develop CoA Analysis Guidebook/Handbook – Work With DAU To Develop CoA Curriculum– Review How Modifications Are Treated In

CoA Analyses

Are we sharing Information and Training the next Generation?Are we sharing Information and Training the next Generation?

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• Share data among many sources

• Allies with smaller fleets may be able to see small

changes before larger fleets

2. Its an international world whether you like it or not

Question: What’s the most cost effective approach

A) Dispatch a USAF C-17 from Dover to Indonesia with support or

B) Have the RAAF dispatch aircraft from Perth?

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Boxing Day Tsunami

Support not limited to $$$

December, 26, 2004 Earthquake hit, 220,000 dead or missingInternational Relief Effort$7 Billion Pledged from Many (50?) countries

Country Financial Military

Australia 7644 helicopters, Ship, & personnel

UK 464 4 planesChina 83Denmark 75 shipSpain 68France 66Germany 647 2 helicoptersNetherlands 259Qatar 25Russia 10South Korea 63Japan 500

US 65014 cargo + 90 helicoptersWhat Barriers Exist?

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Steps to Success - InternationalSteps to Success - International

1. Use of our Collation Allies reduces the burden on the American taxpayer in support of GWOT

2. US has a $40 Billion trade Surplus in aerospace

3. Cost of Consumable Parts is rising by 12% per year impacting our Services Readiness• Obsolescence/ Manufacturing Sources largest single issue

4. FMS Military sales and Commercial Sales Impacted by overly restrictive export Control Laws

Solution?A) Expand JCAA to Include Foreign AlliesB) Two Year waiver on Post MS C Airframe PartsC) FastTrack ITAR Process for Allies

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• Allies with smaller fleets may be able to

see small changes before larger fleets


3. Its not just technology, but think technology with your logistics

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Smart Tech Insertion for Legacy Systems• Automatic Data Collection Coupled with Technology• Evaluating Commercial Sources (Push/Pull)• Re-Establish Joint

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Tech Refresh – Tech Refresh – Key to Cost Wise ReadinessKey to Cost Wise Readiness

Problem: Current aircraft batteriesProblem: Current aircraft batteries• have to be inspected every 28 days (56,000 Man Hours)have to be inspected every 28 days (56,000 Man Hours)• 80% have to be replaced within a year80% have to be replaced within a year

MOAFeasibility

Evaluate COTS SolutionsEvaluate COTS Solutions

Operational Test

Qual Test

Spec Sheet Coordinate Funding for TestingCoordinate Funding for Testing

ECP

DCN’s

Procurement

Transition Logistics to Transition Logistics to Program TeamProgram Team

Providing the mechanism to transition better technologyProviding the mechanism to transition better technologyWhat’s the next successful program?What’s the next successful program?

NSTCNSTC

JCAAJCAA

JALCJALC

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NSTC Example : PD- 680• Problem:

– Not environmentally friendly,– being phased out, – will require multiple replacements –– yet to be identified, evaluated, accepted.

• Phase I:– Screen Tech Manuals referencing PD-680 to assess

requirements for replacements– Query other services– Map applications & status of potential substitutes

• Phase II:– Develop RFI to query industry– Evaluate non-aqueous cleaners against spec– Validate performance

• Phase III– Update Source Data (publications)

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• Allies with smaller fleets may be able to see small changes before larger fleets


3. Its not just technology, but think technology with your logistics

4. We need to fix the gaps. • Champion promising technology• Take risks; bring it to the market place

PM Dilemma – Successful Tech InsertionPM Dilemma – Successful Tech InsertionDevelopment Transition Acquisition Sustainment

The Frogger Affect

PM Dilemma – Successful Tech InsertionPM Dilemma – Successful Tech InsertionDevelopment Transition Acquisition Sustainment

The Frogger Affect

Government Oversight and Regulation

Performance Based Logistics (without

data)

Misguidedmicro-management

Irresponsibleignorance

Too costly Too riskyWe cannot expect

industry to develop technology without

government sharing the risk

• Identify the top concerns• National Strategy

• Work With Industry• Defense Sustainment Consortium• AADI/DSTO

• Fund the Gaps• Work the Transition• Work as a Team

Contracts Planning ScheduleMAR 30 Update

FEB MAR APR MAY JUN JUL AUG SEP

3rd Qtr Incremental

Funding

FastTrack Source Selection

DSC

FastTrack Award

AAIPT Omnibus (Option #1)

Business Clearance & CAP

Draft RFP Released Proposals

Source Selection

AAIPT Omnibus (Option #2?)

Airweighs

RFP ProposalsAirweighs Contract

Source Selection

AWA

Negotiations

RFI

Sources Sought

Business Clearance & CAP

Execution & Task Order Awards

FY06 Congressional Add

FY06 Option Award

4th Qtr Incremental

Funding

3rd Qtr Supplemental

Funding

Industry Day

Final RFP Released

PPC

PPC

Award Fee Determination

Multiple SAP Awards

Multiple SAP Awards

Industry Day

Specs & Standards

????? ?????

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Available Workforce

-2.004.006.008.00

10.0012.0014.0016.0018.0020.0022.00

Feb-06 Mar-06 Apr-06 May-06 Jun-06 Jul-06 Aug-06 Sep-06

Wo

rk-y

ea

rs

Program Management Contracts Engineering Cost Financial

Contracts and Acquisition Workload

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Smart Push - PullSmart Push - Pull

1. Program Teams are Overwhelmed• Need Smart Contracting• Work “Smarter” not “Harder”

2. OEM’s getting a large portion of “bundled” requirements

NAVAIR Small Business efforts decreasing

3. Promising Technology not being transitioned

• Small Businesses being hurt

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• Share data among many sources• Allies with smaller fleets may be able to see small

changes before larger fleets 2. Its an international world whether you like it or not3. Its not just technology, but think technology with

your logistics4. We need to fix the gaps. • Champion promising technology• Take risks; bring it to the market place

5. Steal the good ideas

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NAVAIRNAVAIR

Defense SustainmentConsortium

Executive Director

Defense SustainmentConsortium

Executive Director

National Sustainment Technology Center (NSTC)

Director and Staff San Antonio

National Sustainment Technology Center (NSTC)

Director and Staff San Antonio

DSC ConsortiumMembers

DSC ConsortiumMembers Tactical Board

Members

Tactical BoardMembers

Fulltime DSCMembers

IndustryGovernment

MilitaryAcademia

Fulltime DSCMembers

IndustryGovernment

MilitaryAcademia

Associate Memberwith tasking

Task and Project-Oriented Member

Associate Memberwith tasking

Task and Project-Oriented Member

Advisory BoardAdvisory Board

OEMsGovernment

Stakeholders (DLA)Prime Integrators

Rotating SmallBusiness

Representative

OEMsGovernment

Stakeholders (DLA)Prime Integrators

Rotating SmallBusiness

Representative

JointAeronautical

Commander’s Group (JACG)

JCAA

NationalStrategy

Maintenance Training

Analytical Methods/Cost of Aging

Corrosion

Transition of Commercial Products

Diagnostics/HealthMonitoringSystems

Wiring Failure

Arc Fault Circuit

Structural Modeling and

Analysis

Maintenance Manual Currency

ObsolescenceManagement

AvionicsModernization

ComponentImprovement

ProvideConcurrence

Match Required Taskswith Resource Members

Provide Task OrderExecutive Management

Provide Strategy andRecommend Priorities

DefenseTechnology

Cluster(DTC)

DefenseTechnology

Cluster(DTC)

San Antonio Region Capability Identification

San Antonio Region Capability Identification

Defense Transformation

Institute (DTI)

Defense Transformation

Institute (DTI)

SATAISATAI

North Chamber

North Chamber

San Anto

nio

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Aging Aircraft – SummaryAging Aircraft – Summary

1. How can we Integrate the OEM’s effectively?

• Share data among many sources• “Phantom Works” tech insertion

2. Support Common Policy• ITARS Relief• Obsolescence Policy (AQEC)

3. What Promising Technology do we want to target?

• Address National Strategy• Push from Small Businesses

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Questions?

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Small Business SuccessesAging Aircraft Omnibus Contract ($40M+ over 5 years)• Goal: 30% Small Business Participation

• 26 Small businesses have received tasking to date (~$5M)

• 3rd Year begins 03 Aug 2006

FastTrack ( $450M over 7 Years )•Soon to be awarded

•Goal: 40% Small business participation

Intermediate/Depot Level Wiring Diagnostics ($12.4M)•Final year of multiyear contract with Eclypse

Organizational Level Wiring Diagnostics ($900K)•Joint NAVAIR/NUWC effort contracted with CM Technologies

Multiple Stand-alone Simplified Acquisition Contracts $95K

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Sharing the Technology Risk

Government Oversight and Regulation

Performance Based Logistics (without

data)

Misguidedmicro-management

Irresponsibleignorance

Too costly Too risky

We cannot expect industry to develop technology without government sharing the risk

• Identify the top concerns• National Strategy

• Work With Industry• Defense Sustainment Consortium• AATD/DSTO

• Fund the Gaps• Work the Transition• Work as a Team

Good technology that could Improve Readiness and Reduce Costs will not get into use unless we change the way we develop, test, acquire and support

Bob’s Approach

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– Technology & PolicyA) USAF and USN Policies and Procedures have caused us

to create different certification and training requirements• No apparent reason why these procedures can’t be common• Hugh impact on Publications and training• Gas Free Environment (Fuels), Repair Technology

(Composites)

Potential Exists for Greater Savings if these Policies are Standardized (Outside scope?)

B) Services utilize different technologies• Requires sharing of qualification data• Corrosion Efforts a Good Example of single qualification applied

to all services• Model will be applied to De-Ice, Composite Repair

Commonality has atrophied – will require funding and support to make additional gains

1 Ageing Aircraft Thoughts on a Path Forward Robert Ernst Head, Aging Aircraft IPT Chairman, Joint...

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