Air Force Materiel Command
WR-ALC
Maintaining the
Fleet
Maj Gen Polly Peyer
HQ WR-ALC/CC
26 Aug 2010
Integrity  Service  Excellence
Why Team for the Future?
Due to the rapid pace of technology, the
maintenance of an aging fleet requires teaming with
other organizations within the Government, Industry
and Academia
New technologies are needed to provide additional
capabilities and ensure the warfighter has the means
to defend against challenges from potential
adversaries
Challenges
 Increased Aircraft Availability
 Reduced costs
 Enhanced competitiveness
 Improved systems / processes
 Added core competencies
 Added partnerships
 Constrained budgets
 Increased Effectiveness
 Increased reliability
 Reduced maintenance
 Improved safety
 Enhanced suitability
Facing the Challenges
 High Velocity Maintenance (HVM)
 C-5 Avionics Modernization Program (AMP)
Systems Integrated Lab Integrated Aircraft
Test Environment
 Corrosion Program
 F-15 Rewire Program
 Versatile Depot Automatic Test System
(VDATS)
High Velocity Maintenance (HVM)
Project Description
Why HVM?
 An AFMC-wide initiative to dramatically transform production
operations in support of increasing aircraft availability, seeking
to better emulate industry’s high daily rate of touch-labor
maintenance
 HVM examines all processes which impact aircraft
programmed depot maintenance across the enterprise,
including not only product flow, but also funding,
requirements, infrastructure, materiel support, and
information technology
 Pilot Platform: AFSOC C-130 Fleet
 Program Manager: Mr. Jerry Mobley
Velocity
(hrs/day)
1000
ISO
Stakeholders & Teaming Partners
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MAJCOM Customers (AFSOC, AMC, AETC, AFRC, ANG)
AFMC (A4, C-130 SPO, 402 MXW, OC-ALC/HVM, OO-ALC/HVM)
AFGLSC
DLA
Flight Test Squadron
AFRL
Intergraph/AACL (Std Visual Work / PIIs)
Boeing (IETMs)
M1/DERCO (Supply Integrator / Task Kitting)
Robins-Gioia (PDMSS Support)
MERC (Industrial Engineering / Shadow Tools / Simulations)
ICF (Supply Chain Management Services)
Georgia Tech (Transition Planning & CAVE Development)
Simpler (Lean Sensei Support)
HSC ISO
•0
 Aircraft Availability
 GWOT, Aging Fleets, $ Constraints
 Scheduled Maintenance Impacts Aircraft Availability
 Inefficient Depot Maintenance Processes
 Low velocity compared to Industry
 Airline burn rate 500-900 hours/day
Industry
 ALC PDM 145-220 hours/day
Velocity
 Field and Depot not synchronized
 Function as two independent sys
 A/C condition not well known
PDM
USAF
Depot
Velocity Mx
Cycle
ISO
Benefits
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Increased Aircraft Availability to the Warfighter
Reduced Depot Possessed Time
Dramatically Increased Burn-Rates (Touch Labor Time)
Synchronized Field Inspection & Depot Maintenance Programs
Mechanic-Centric Focus Yielding Greater Production Efficiency
Advance Condition Knowledge Greatly Improving Accuracy in
Supply Forecasting & Lead-Time Availability
 Point-of-Use Task Kitting Supporting Mechanics based on
Known Requirements
 Integrated Planning, Scheduling, Analysis, & Data Collection
Processes – Result: Actual Requirements Drive Choreographed
Execution of Scheduled Maintenance Tasks
Examples of HVM Technology
Insertion
Mechanic Centric Focus - Redesigned
C-130 maintenance stands
Pre-Planned Work – Task kits
Adherence to Standard Work – Andon system
Aircraft Condition – Pre-induction inspections utilizing borescopes
Automated Access to Tech Orders -Toughbooks for mechanics
Production Control Boards – Touch screen monitors
Fleet Mgt Tool – Eagle Modification Action Plan (EMAP)
C-5 AMP Systems Integrated Lab Integrated
Aircraft Test Environment
C-5 #840059 crash near
Dover AFB on 3 April 2006
402 SMXG participated in
post crash recovery efforts
C-5 AMP flight deck arrives at
Robins on 23 August 2006
Minor construction project
addition to Software
Support Facility Jan 2010
C-5 AMP Systems Integrated Lab Integrated
Aircraft Test Environment (Cont.)
Benefitss:
 Establishes an organic independent verification and
validation capability at WR-ALC
 Hardware in the loop aircraft test environment improves
fidelity of test
 Reduction of in ground and flight testing; therefore
increasing aircraft availability
 Improves Core compliance and 50/50
 Commercial off the shelf solution
AF Corrosion Prevention and Control Office
Lavatory Assessment
Project Description
Assess the overall impact of corrosion
caused by aircraft lavatory/crew relief
systems
Develop recommendations, and aid
AFMC/CC directed lavatory IPT in
implementing optimal solutions.
Stakeholders & Teaming Partners
Platforms: B-1, B-2, B-52, C-5, C-17, C-130,
E-3, E-8, KC-10, KC-135, RC-135
Partnership: Industry, ALCs, and DoD
Contractors
Way Forward
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Ensure lavatory refurbishment is mandated in all
PDM work packages
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Recommend immediate action on issues facing
C-5, KC-10, and B-52
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Encourage SPOs to actively engage w/field units
and hold annual CPABs
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Include lessons learned and AFCPCO early in
future new acquisition process – KC-X
Benefits
Reduce corrosion damage and
repair/replace areas in and around
aircraft lavatory/crew relief systems.
Lavatory Corrosion and
Solutions
B-52 skin repair due to extensive corrosion in lavatory area
Lavatory Corrosion and
Solutions (cont)
Above and below: Typical
cannon plug corrosion under
lavatory
Above: Condemned toilet - Bad field
repair
Above: Possible replacement
for B-52s: C-130J type
Above: Leaking toilet on other A/C set
aside to be reinstalled without repair.
F-15 Rewire (Eagle Division)
Project Description
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Replacement of 1970’s-era Kapton wire with new composite
wire in 176 long term F-15C/D aircraft
Estimated cost of program is $683M (engineering, val/ver
kits (3ea), production kits, labor, Wire Integrity Tester (WIT))
Landing gear, wings, some radar cables not included.
Estimated 5,000 man-hour PDM effort
Program Manager: Mr. Reggie Jenkins (WR-ALC/GRMAB)
Engineer: Mr. Alan Byrd (WR-ALC/GRMEA)
Stakeholders & Teaming Partners
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MAJCOM Customers (ACC, USAFE, PACAF, AFMC, ANG)
DLA (kits)
Boeing (Engineering, kits)
InterConnect, Inc/Israel Aerospace Industries (IAI) (kits)
Korean Airlines (KAL) (PDM installs )
CK Technologies, Inc. (diagnostic tester)
Status
 Three ( 3) validation/verification aircraft completed in CY08-09
of 3 distinct aircraft configurations, CV1, CV2, DV1. Aircraft
have returned to home stations.
 Production installs began Oct 09 (FY10), end in FY15.
 TCTO 1F-15-1551
 7 complete @ WR-ALC, 5 complete @ KAL
 5 in work @ WR-ALC, 6 in work @ KAL
 Boeing, St Louis on contract for initial 99 shipsets.
 Interconnect/IAI on contract for remaining 74 shipsets.
Benefits
 Eliminates 30-60 down days per year, per aircraft , for wiring
related maintenance .
 Eliminates funding associated with Depot teams required to
replace multiple harnesses/wires as a result of large-scale
burns.
 Eliminates 143,520 man-hours of wiring related maintenance
annually.
 Eliminates $44M in Line Replaceable Unit (LRU) exchange fees
annually due to false LRU removal.
F-15 Rewire (cont.)
Bay 5 Old Wiring
Bay 5 New Wiring
F-15 Rewire (cont.)
ECS Bay Old Wiring
ECS Bay New Wiring
Versatile Depot Automatic
Test System (VDATS)
VDATS is the standard family of tester
for the Air Force
Currently three different configurations:
DA-1, DA-2, and RF-1
Government owned
Supported Platforms
WR, OO, OC-ALC
B-2
F-15 IFF
F-16 IFF
Global Hawk
LAIRCM
MILSTAR
JSTARS
Space Crypto
CARA
AN/APX-119
Kadena Mini-Depot
VDATS POCs
Name
Joe Eckersley – Section Chief
Matt Mosely-PM
Jonathan Hill-PM
Jeff Burrows-ES
Larry Adams-Eng
Bob Pennington-SIL FLT Chief
Phone #
472-0255
472-0298
472-0308
472-0301
472-0295
468-1307
VDATS Benefits
Test Program Set standardization
Significant reduction in Automatic Test Equipment
(ATE) footprint
24 scheduled ATE replacements
From This…
To This!
Decreasing footprint, Combating obsolescence, and Reducing cost!
Teaming for the Future
• Benefits
– Reduced development and operations costs for the
Government
– Improved technology and capability for Government
– Improved responsiveness to the warfighter
• WR-ALC partnership efforts
– Use government sponsored development efforts
– Increase maintenance partnerships
– Foster performance based logistics solutions
Always seeking Opportunities
What is in the future?
 More Joint Efforts
 Continuous Condition Monitoring
 Integrated systems health monitoring
 Aircraft subsystem diagnostics
 Prognostics based on existing data
 Maintenance Acceleration/Increased Density
 Cost reduction
 Crack and corrosion detection and prevention
 Reduce coating removal time
 Bonded repair technology
 Depot and maintenance shop improvement
 Supply chain enhancements