Viewing Depot Operations: Building Blocks for the Future
Transcript of Viewing Depot Operations: Building Blocks for the Future
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Viewing Depot Operations:
Building Blocks for the Future
Greg Kilchenstein
OSD(Maintenance)
16 Nov 2011
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Viewing Depots Through Two Lenses
• Efficient Business Operations
– CPI / Lean / TOC
– CBM+
– Total Asset Visibility…IUID/SIM
– Net-Centric Data…ERP/PLM
• Tomorrow’s Industrial Operations
– Improve Current Infrastructure
– Invest in People & Training
– Expeditionary Capabilities
– Improved Supply Support
– Inspect, Test & Measure
– Strip & Coat…Low Observables
- Composites
- Electronics
- Software
- Environmental
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1st Lens: Efficient Business Operations
– Continuous Process Improvement (CPI):
Maximize Readiness / Minimize Costs
– Lean: Dynamic, knowledge-driven, customer-
focused process to continuously eliminate waste
and expense, maximize resources and streamline
operations.
– Theories of Constraint (TOC):
Alleviating process bottlenecks
How Can I Improve?
What We Do Today Will Shape What We Are Tomorrow
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Condition Based Maintenance Plus (CBM+)
• Maintenance performed on evidence of need provided by analysis,
processes & technology
• Enables analysis to forecast sustainment workload and parts required
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– Item Unique Identification (IUID) / Serialized
Item Management (SIM)
• Improved insight into cause-and-effect
relationship between resources & readiness
• Weapon system support decisions will be more
informed and take less time
• Data-driven continuous process improvement
Total Asset Visibility…
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Depot SIM Process Map
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– Enterprise Resource Planning (ERP) / Product Lifecycle Management (PLM)
• Integration of ERP and PLM allows direct
sharing of engineering and manufacturing
data through an automated process
• Creates modernized Net-Centric Operations
Net-Centric Data
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2nd Lens: Tomorrow’s Industrial Operations
Improve Current Infrastructure
Invest in People & Training
Joint/Expeditionary Capabilities
Improve Supply Support
Strip & Coat…Low Observables
Inspect, Test & Measure
Increased Use of
Composites
Electronics
Software Maintenance
Environmental Impacts
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Improve Current Infrastructure
• Remain Relevant to Today’s Systems
• Incrementally Improve Capabilities
• Efficiency and effectiveness must
improve
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SMART Machines (USA, USN, USAF)
• Issue: Aging fixed assets with archaic controls
• Solution: equip installed machinery with the capability to
automatically gather and report performance in a consistent fashion.
This performance data enables the ability to understand trends,
predict potential delays, and allow shop operations to visibly improve
their equipment and/or process utilization.
• Benefits
>40% productivity improvements
demonstrated.
Increased shop efficiency reduces
non productive time and its cost.
Schedule preventive maintenance
reduces cost.
Improved asset utilization results in
greater throughput and reduced cycle times
Improve Current Infrastructure
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Centralized Fleet Automated Management System (CFAMS)
►Issue: Due to lack of visibility of assets, industrial fleet vehicles are in motion
only 30% of their key/seat time, vehicle fleet size at any given site tends to be
15-25% higher, and are potentially available to unlicensed and/or untrained
operators attributing to lost work time accidents.
►Solution: A COTS wireless fleet management hardware and software solution
that utilizes RF technology.
► Benefits
Increased vehicle readiness and 10%
reduction in fleet size.
Maintenance cost reduction (both labor
and material) by 50% .
Damage to vehicles, cargo and facility
reduced by 25% .
Increase in vehicle uptime.
Operator productivity increased by 10% .
Prevents use of unsafe equipment –
accidents significantly reduced.
Improve Current Infrastructure
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Volumetric Accuracy for Large Machine Tools (VALMT)
►Issue: Large monolithic parts are integral within today’s weapons systems
whether they be submarine propellers, aircraft skins, airframe structures, or
armored vehicle hulls. Fabrication of very large metal parts presents difficult
problems of machine tool accuracy and repeatability, often requiring extensive
re-work and the inability to interchange parts in the maintenance process.
►Solution: Implement a quick metrology method providing compensated
volumetric accuracy of 0.005” or less to the machine tool.
►Benefits
Reduced rework for Navy propellers by 30% resulting
in a reduction of 20 days in the overall cycle time.
Commercial aircraft have realized reduced rework
resulting in $1M savings peraircraft. Military aircraft
could expect similar savings.
Reduced scrap, rework, and hand fit assembly,
decreasing both production costs and “flow days”.
Improve Current Infrastructure
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Invest in People & Training
– Train workforce on new tools and
processes using modern methods
– Apprentice Programs
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Virtual Workplace Simulator
►Issue: Ineffective training methods.
►Solution: The Virtual Workplace Simulator (VWS)
Stresses the most important purpose of any enterprise;
stabilizing, improving and sustaining improvements
that will create value for the customer. The session
provides the students with explicit knowledge, along
with implicit and tacit knowledge critical to delivering results.
►Benefits
Without knowing how to implement learning, nothing significant will
happen, yet most training stops short of this important step.
Think of the System and their role in the System, as well as recognize
the unintended consequences of their actions.
Work as a team to achieve the overall goals of the organization
Move from “Fire Fighting” to “Preparing” and eventually to “Preventing”
problems that occur.
Invest in People & Training
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Training through Gaming
►Issue: Ineffective training methods.
►Solution: Using games methods for training reduces costs and increases
efficiency. Additionally, employees retain training through interactive means
more than they would through lectures or training videos
►Benefits
Consistent training across the
organization
Reduction in training costs
More efficient and faster training
with better retention
Invest in People & Training
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Joint/Expeditionary Capabilities
• Increase efficiencies by bringing the
capability to where its needed
• Seek and develop mobile technology that
supports forward operations
• Improve Joint &
coalition Mx
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Enabling Interoperability in Maintenance and Repair
Activities (USMC)
► Issue: Significant redundancy of parts stocks, consumable inventory, and maintenance capability, commonly referred to as the “Iron Mountain”
► Solution: Expand interoperability of maintenance and Serialized Item Management (SIM) data into United States COTS and potentially GOTS applications including the ability to communicate maintenance data in an inter-service and coalition environment.
►Benefits Improved weapons system readiness
and availability with Class IX Inventory reductions
Improved global part/LRU visibility and readiness.
Consistent with Joint Staff doctrine, providing a developed tool to support the Joint Logistics Enterprise
Joint/Expeditionary Capabilities
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Fast Field Fluid Assessment Tools (3FAST) ► Issue: The current practice of manually sampling oil from vehicles at time or
service-based intervals, sending the samples to the laboratory, and reporting the
results back to fleet maintainers is an onerous process.
► Solution: Portable, hand-held analytical tools providing a lab-quality assessment
suitable for real-time in-field use. The device gives a soldier or mechanic the ability
to determine oil quality on a real-time basis before or during a mission without
messy and time-consuming sampling.
► Benefits
$828M in increased asset availability
$15M/year in
maintenance/shipping/disposal cost
avoidance
Significantly reduced cycle time and greatly
improved soldier safety
Joint/Expeditionary Capabilities
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Improved Supply Support
• Increase efficiencies by reducing inventory
and improving asset visibility and supply
chain operations
• Parts will be re-used…rebuilt, overhauled
• Rapid Manufacturing capabilities
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Rapid Manufacturing and Repair (USA, USAF, USN, NASA, DoE)
• Issue: Lack of availability or long-lead times for legacy parts needed for repair.
• Solution: Additive Manufacturing allows for economical, low-volume
manufacturing of hard-to-replace legacy parts vital to weapon systems
readiness
• Benefits
50 to 70% cycle-time reductions for part
repair and replacement.
Part availability weeks vs. months or
years quoted by bidders
Parts made by the NCMS ADF-RP program
in 78 Case Studies to date saved 344 weeks
or 80% delivery time. Castings can be turned
around in 20% of traditional supply time.
50-75% raw material and labor cost avoidance.
Cost avoidance annually from the NCMS ADF
-RP program of $4.2M/year to date.
Cost avoidance up to 90% per part
Improved Supply Support
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Laser Engineered Net Shaping (LENS®) ► Issue: Lack of availability or long-lead times for legacy parts needed for repair.
► Solution: LENS® enables the low-volume production of metallic components as
well as repair of legacy parts.
► Benefits
The technology has been used to
repair six engine component parts
at ANAD. The unit was in service
for five years realizing a savings in
excess of $30M.
Torpedo aft fuel tanks – Repair of
corroded surfaces saves$500K/year
Submarine connector rods –
rebuilding up connector rod surfaces saves $110K/year
Compressor crankshafts – Building up crankshaft surfaces saves
$150K/year.
Improved Supply Support
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OptiCam Reverse Engineering ► Issue: Diminishing manufacturing resources and obsolete parts.
► Solution: Development of rapid reverse engineering methods with automated
3D data collection, high data integrity, and translation into manufactured parts.
Improved Supply Support
► Benefits
25% faster 3D data capture than conventional
methods
20% faster 3D data capture than laser
scanning
25% decrease in total modeling time
25% decrease in reengineering labor cost
Annual cost savings of $1.05M/year
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Inspect, Test & Measure
– Inspection and test initiate maintenance
– Streamlined, standard inspection and data
collection is essential
– Test sets must be modernized and
“footprint” greatly reduced
– Modern accurate laser and optical
measurement capabilities improve quality
and reduce RTAT
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Automated Process & Inspection Guide ► Issue: Overhaul and repair inspections are paper based, conducted
over three shifts, not co-located, and are performed by multiple individuals. This leads to no standardization of data capture and inspection processes.
► Solution: Replace inefficient paper-based processes with mobile data capture devices combined with COTS software to guide inspectors.
► Benefits
$8.55M/year for inspections, training,
cycle time and paperwork reduction
Reduced repair cycle time: 2 Flow days
saved per aircraft; 5 hours per HMMWV
Increased industrial capacity with
enhanced failure and trend analysis.
Inspect, Test & Measure
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Synthetic Instrumentation ► Issue: Avionics test stations typically remain in service beyond 20
years, and are specialized to particular weapon systems, are often slow and require a large logistical footprint.
► Solution: Develop and deploy COTS equipment that synthesizes the capability of multiple instruments and leveraging common core functions frequently replicated across a test system.
Inspect, Test & Measure
► Benefits
Reduction in the quantity of instruments needed for testing avionics.
Reduction in storage, documentation, logistical footprint, and personnel training
Performance characteristics that previously could only be achieved with dedicated instruments, such as digital multimeters, oscilloscopes, counters, spectrum analyzers, etc.
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Laser Paint Stripping of Helicopter Blades ► Issue: Manual methods are time consuming and highly variable, with
damage oftentimes induced during the stripping process
► Solution: Develop and implement an automated stripping system that
can consistently and quickly remove the coatings from helicopter
blades with no scrap.
► Benefits
Per unit repair cost reduced from
$1,188.14 per blade to $222.53
per blade
Environmental costs substantially
alleviated
Enhanced work environment
Minimal operator intervention
required.
Stripping and Coating
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Robotic Automated Coating Removal System ► Issue: Coating removal for V-22 repair costly and adds substantially
to the repair turnaround time.
► Solution: Develop and implement an automated stripping system that
can consistently and quickly remove the coatings from an entire V-22
aircraft.
Stripping and Coating
► Benefits
Reduce stripping time for V-22
from current 372 hrs to ~35 hrs.
Unit can be configured to remove
coatings from other components
and fuselages.
Reduce damage resulting from
manual operations.
Reduced environmental waste.
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Automated Processing of Composite Shelters
► Issue: The refurbishment of composite shelters is a highly manual
process and oftentimes shelters are scrapped late in the repair
process because of unforeseen damage. ► Solution: Develop and implement an automated robotic system that
can consistently inspect, remove coatings, repair and repaint a shelter
in a fraction of the time currently needed.
Stripping and Coating
► Benefits
Reduced repair cycle time for
composite shelters by 70%
Labor savings over 90%
Reduce scrap rates by 20%
Improved and consistent
inspection procedures.
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Kinetic Spray Coating ► Issue: Corrosion protection is minimally a $10B problem/year for
DoD.
► Solution: Develop a portable and fieldable system to apply corrosion
protective coatings and as a quick repair technology for metallic
surfaces.
Stripping and Coating
► Benefits
$80K/year cost savings of H-53
Helicopter gearbox repair restoration
(average four/year)
$100K/year cost savings for corrosion
protection of just one 1010 steel
component of LAV fleet on Okinawa
Applicable to a wide range of
corrosive structures with large
potential cost savings.
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Electronics Troubleshooting and Repair
– Systems increasingly electronics intensive
– Remote operation adds to complexity
– Automated troubleshooting replacing
manual methods
– Intermittent fault detection and isolation
– Reduced use of lead solder
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Enhanced Wiring Integrity System (EWIS/AWTS)
►Issue: Wiring has emerged as a critical system due to its complexity,
inaccessibility, high-density, and communications interface. Wiring faults
are an increasing factor in reducing weapon system readiness and
performance.
►Solution: Portable, small footprint COTS technology which can reduce
troubleshooting time by quickly identifying the location of wiring failures
within six inches.
Electronics Troubleshooting and Repair
►Benefits
Increased vehicle readiness by 10%
F-15 wiring faults--$49M/yr cost avoidance
and 120 lost a/c days recouped
Improved reliability of the wiring and
electrical system and the increased
mission availability of the platform.
Reduction in man-hours required when
troubleshooting and repairing platform-
wiring discrepancies.
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Intermittent Fault Detection
►Issue: A major cost driver is the maintenance of electronics and
electrical systems that control and operate the wide-ranging
inventory of weapons and weapon systems. One of the highest
contributing causes for these costs is age-related, No Fault Found
(NFF) intermittence.
►Solution: Development of test equipment and test methodology to
detect and isolate intermittent faults.
Electronics Troubleshooting and Repair
►Benefits
Increased weapon system
readiness
Improved reliability of the
wiring and electrical system
and the increased mission
availability of the platform.
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Static Event Detection
►Issue: DoD depots are not able to determine if/when a electrostatic
event has occurred and damaged an electrical system under repair.
►Solution: Develop of a Static Event Detector (SED) Health
Monitoring system that alerts inspectors or equipment operators to
an ESD event that may have inflicted catastrophic damage resulting
in degraded weapon systems performance.
Electronics Troubleshooting and Repair
►Benefits
Reduction in damaged, destroyed or
degraded electronic devices.
Improvement in the handling of ESD
sensitive devices, resulting in
improved readiness in the field.
Improved repair cycle time on field
returns.
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Lead-Free Soldering Materials ►Issue: Lead must be eliminated from soldering materials
►Solution: Demonstrate and validate an alternative material, an Isotropically
Conductive Adhesive (ICA), to the conventional tin-lead solders used on
circuit card assemblies.
Electronics Troubleshooting and Repair
►Benefits
Removal of lead from soldering
materials
Compliance with International
Standards and Use.
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Tomorrow’s Industrial Operations
– New Technology Trends
• Increased Software & Robotics
• Increased Use of Composites
• Environmental Concerns
“Full Spectrum Dominance – Attaining that Goal Requires the
Steady Infusion of New Technology” – Joint Vision 2020
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Enhanced Control Autoclave Processing of Composites
► Issue: Current composite production has not changed sub-
stantially over the past 50 years. Deploying advanced controls
allows optimized curing cycles, higher quality parts, and reduced costs.
► Solution: Optimization of existing hardware through a new approach to
controls and sensing plus a paradigm shift in the approach to the autoclave
curing of composite parts.
Composites
► Benefits
Reduction of the manpower to operate
multiple pieces of process equipment by
a ratio of approximately 8:1
Improvement in cure profiles resulting in
more consistent parts.
Reduction of scrapped materials and
parts.
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Inspection and Repair Preparation Cell (IRPC)
► Issue: Manual repair processes of composite radomes are
inconsistent, resulting in time-consuming, unneeded or missed
repairs.
Composites
► Solution: Development and
implementation of automated
inspection and repair processes, on
the same work cell, for the C-130
radome.
► Benefits
16-30% reduction in day flow
25 – 33% reduction in labor hours
Annual cost savings $2 million
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Environment
►Benefits:
Preliminary 20% improvement
in wearability with commiserate
cost savings.
Elimination of the use of
hexavalent chrome in the
plating process.
Replacement of Toxic Hexavalent Chrome with Non-Hazardous
Trivalent Chrome in Electroplating
►Issue: Chrome plating is unmatched in performance for corrosion protection
and wear surfaces. Current plating processes involve the use of toxic,
hexavalent chrome which is being phased out in use.
►Solution: Replacement of hexavalent chromium in electroplating processes
with non-toxic chromium without sacrificing coating performance.
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Environment
►Benefits: Reduced turnaround time for plating by
40-70% at CCAD and FRCSW (net
savings over $1.6 million)
Eliminates the need for time
consuming masking prior to hard
chrome plating resulting in 45% faster
turnaround time for plating/machining
repair process
Advanced Tooling for Hard Chrome and Nickel Plating
►Issue: Plating shops are environmentally hazardous, produce toxic
waste streams, and are oftentimes bottlenecks in the maintenance
process.
►Solution: Implementation of revolutionary commercial electroplating
methods that resulted in improved product quality and drastically
reduced throughput times
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Environment
►Benefits:
Reduced VOC emissions
Reduced operational costs
compared to current thermal
oxidizing systems.
Reduced maintenance and
replacement costs
Air Pollution Control Systems ► Issue: DoD facilities are under increasing pressure to reduce volatile
organic compounds (VOC) emissions from painting operations.
► Solution: Development and implementation of an air pollution
control system at the USMC Maintenance Center Barstow that
utilizes a biological destruction approach.
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Wrap Up
– The “future” is fast approaching – Depots must
strategically and tactically prepare
– Resources beyond CIP $$ are available
• Aggressively pursue all potential resources
– Remain Customer Focused:
• Quality ,Reliability, and Readiness
• Speed and Value
– Partner with Industry - Remain a relevant “National
Treasure”