Diesel Maintenance Process
Why The Need To Improve
What We Are Doing
Rich Caccese
CNSP N43A23P
2010 Port Engineers Conference
How We Meet the Mission and
Overcome Challenges
Deckplate
Leadership
SWE
Alignment
Training
Manning
Ship
Readiness
Warships Ready for Tasking
2
Background
• In the past three years, 9 CNO avails have
been delayed due to diesel engine work.
• Emergent diesel engine repairs have
significantly impacted ship’s operational
availability.
• Diesel readiness is not what the surface force
desires or expects despite numerous
implemented initiatives.
• Diesel repair work should be accomplished
within the scheduled time and budget!
3
Background
Notional Plan - 6 Months Deployment – 10 Months Operational – 8 Months Maintenance
Deployment
Deployment
CM
quarter
1
1
CNO
quarter
1
1
1
CM
quarter
1
1
1
CM
quarter
1
1
1
CM
quarter
1
1
1
CM
quarter
1
1
1
quarter
1
1
1
quarter
1
1
1
1
LSD 52 - 6 Months Deployment – 5 Months Operational – 13 Months Maintenance
Deployment
Deployment
CM
CM
CNO
CM
CM
Time Now
LSD 45 - 6 Months Deployment – 7 Months Operational – 11 Months Maintenance
Deployment
Deployment
CM
CNO
CM
CM
CM
Time Now
LSD 47 - 6 Months Deployment – 8 Months Operational – 13 Months Maintenance
Dply
Dply
CM
CNO
CM
CM
CM
CM
Time Now
4
Questions from Leadership
• Why do diesel engines require so much
maintenance?
• Why are maintenance requirements so
unpredictable?
• Why does it take so long to accomplish
identified maintenance requirements?
• How do we get away from incremental
discovery?
• How can the diesel engine maintenance
process be improved to produce LSD class
ships ready for tasking?
5
Working Group
• Formed as a result of ships not being able
to meet their operational requirements due
to diesel engine maintenance and repair
requirements.
• The purpose : Determine the optimal
process for planning and execution of
maintenance for LSD class diesel engines
over the FRP cycle.
6
Q: Why Change?
A: Dysfunctional Cycle
Poor CSMP
Poor selfassessment
Poor prediction of
maintenance needs
Wrong
maintenance
package
Increasing
degradation
Shorter
MTBR
More
CASREP’s
Less
operational
experience
Less training
cycle time
More time and resources spent
on crisis maintenance
Less time and fewer
resources spent on
preventative maintenance
Better Maintenance Planning and Execution
Enables Better Prediction of Requirements
7
The “Cycle”
8
Overview of the Basic Depot Level
Maintenance Process
Assess
current
condition
Predict
future
condition
Identify
desired
work scope
Accomplish
advance
planning
Procure LLTM
Authorize
and Fund
Execution
Package
Accomplish
Execution
Planning
Ready
to
execute
Procure
balance of
material
Accomplish Work Package
6
Sources of Trauma in the Current Process
Incomplete or
incorrect
assessment of
current condition
Assess
current
condition
Package built to budget
without ORM analysis
of tasks to be deferred
Predict
future
condition
Identify
desired
work scope
Inaccurate model of MTBF
and periodic maintenance
requirements
LLTM not anticipated
and procured in time
Significant delta
between initial ROM
estimates and actual
proposed cost
Accomplish
advance
planning
Procure
LLTM
Late authorization and port
loading constraints results in
inadequate time to conduct detail
planning
Authorize
and Fund
Execution
Package
Accomplish
Execution
Planning
“Sticker shock” induces
both package cuts
without ORM analysis of
tasks to be deferred and
late funding and
authorization
Ready
to
execute
Procure
balance of
material
Late funding results in additional
material lead time problems
Assessments happen during Execution
causing “Incremental Discovery.” End
result is an availability with an inadequate
work package hastily planned for execution
and severely impacted by material
availability. Consequence is excessive
churn, significant cost growth, schedule
delays, and missed milestones
Accomplish Work Package
Timeline no longer drives the repairs – Repairs drive the Timeline
7
11
Today’s Path
Q: Why Change?
A: Dysfunctional Cycle
Poor CSMP
Poor selfassessment
Poor prediction of
maintenance needs
Wrong
maintenance
package
Increasing
degradation
Shorter
MTBR
More
CASREP’s
Less
operational
experience
Less training
cycle time
More time and resources spent
on crisis maintenance
Less time and fewer
resources spent on
preventative maintenance
Better Maintenance Planning and Execution
Enables Better Prediction of Requirements
12
Bottom Line
• How do we get away from incremental
discovery?
• We need to readjust the assessment,
planning, and execution processes of
maintenance so that the CNO Availabilities
consistently result in diesel engines being
fully functional, reliable, and sustainably
ready to support training and operations
throughout the entire deployment to
deployment cycle.
13
CNSF stands up the Diesel
Solutions Group (DSG)
14
The Diesel Solutions Group (DSG)!
N43
Srv Cnt
LSDRON
FME
Engr
TYCOM
OEM
By May 2010, create a new
diesel repair process that achieves
LSD Class Ships ready for tasking
MSMO
NAVSEA
SURFMEP
Metro
RMC
TW - 05
NASSCO
ISEA
SEA 21
JRMC
SWRMC
W/O
Engr
NSSA
15
The Working Group
Engaged,
Committed,
Empowered!
Assess
current
condition
Predict future
condition
Project
Future Work
Predict Team
Identify
desired
work scope
Accomplish
advance
planning
Authorize
and Fund
Execution
Package
Procure LLTM
Planning Team
Accomplish
Execution
Planning
Procure
balance of
material
Ready
to
execute
Accomplish
Work
Package
Execution Team
Successful Prediction and Advance Planning leads to successful Execution!
12
Main Action Items
1. Integrated Assessment Cycle to include
Formal Periodic Assessments (FPAs)
2. Maintenance Philosophy and Lifecycle
Maintenance (LCM) Plan
3. Restoration Plan and 8 Engine Test Plan
4. Parts & Tools requirements
5. Maintenance Standards
6. Personnel and Resources
17
LSD-41 Class CONUS
Fully Integrated
Diesel Assessment Cycle
NLT
9 Wks
A-240
50% PL
LSD-41 Notional Sched
w/ShipMain Dates
Diesel Assessment Cycle
Supporting Work Package
Ultra E
ICMP/Directed
Maintenance
DRS
TSSRA IV
FPA Focused CMAV
24-27 Month
Anchor
18
LSD-41 Class OCONUS
Fully Integrated
Diesel Assessment Cycle
A-240
DRS
50% PL
LSD-41 Notional Sched
w/ShipMain Dates
Diesel Assessment Cycle
Supporting Work Package
Ultra E
ICMP/Directed
Maintenance
A-170
100% PL w/Reserv
24-27 Month
Anchor
19
Maintenance Philosophy
Paper and Lifecycle
Maintenance Plan
• NAVSEA 05 TWH John Hartranft is
preparing the paper and LCM plan.
– To invoke NAVSEA Maintenance Standards
through ICMP
– “Progressive Overhauls”: 4 cylinders
overhauled at a time instead of entire engine
– LCM Plan establishes a 5 year projection of
work to allow for proper planning and
procurement of parts.
20
Diesel Restoration Plan
and Eight Engine Test
Plan
PCD
Restoration Plan
LOA
2 weeks
2 weeks
Cold Checks
Hot Checks
• MPDE IPPAP
• SSDG PSART
• MPDE IPPAP
• SSDG PSART
Sea
Trial
s
CNO
Avail
Comp
21
Parts and Tools
• Goal: eliminate maintenance delays and
deferrals due to lack of parts or tools and
right size the multiple “gold piles”
• Achievement through:
– Proper planning and ordering of LLTM
– Better use of available parts inventories
– Create inventory of parts and disseminate to
maintenance community
– Ensure each port has a complete set of diesel
22
engine tools
Maintenance
Standards
• Goal: reduce variability in cost, schedule,
and repair results by increasing the
standardization of maintenance.
• MPDE Maintenance Standards are under
review
• SSDG Maintenance Standards are in
development.
• Final Maintenance Standards will become
part of the Master Specification Catalog.
23
Personnel and
Resources
• Roles, Responsibilities, and Expectations
(RRE) document
– Clarity, focus, & awareness to key personnel
– Leads to better efficiency between team
members
– SME, DEI, PE, SBS, PM, QA, ACO, OEM, SF,
ISIC, TYCOM included
24
Diesel Subject Matter
Expert
• Diesel SMEs are a key component of the
process
– Work with MT to provide a systems approach
and oversight
– Collection point for all avail planning data
– This data provided to PE for action
• Data/information feeds into a single
person – a new assistant Port Engineer
– “Consultant” to the Port Engineer
– Similar to Combat Systems Port Engineer
25
Proactive Results
• Comprehensive, rigorous, and disciplined
availability planning and execution process
•Meets the ShipMain milestones
• Limits Incremental discovery on the Diesels AND
the related support systems
• Keeps Ship’s Training Cycle sacrosanct
26
Questions?
27