Transforming Army Aviation to Condition Based Maintenance (CBM)! 1 DSS-0228 – CBM (OSD) – 11/29/2004 CBM Program Update DA & OSD Senior Leaders Robert.

Transforming Army Aviation to Condition Based Maintenance (CBM)! 1

DSS-0228 – CBM (OSD) – 11/29/2004

CBM Program UpdateDA & OSD Senior Leaders

Robert BrownAMCOM Lead - CBMRobert BrownAMCOM Lead - CBM

E-MAIL: [email protected]: (256) 842-8911

Bill BraddyWestar A&DGBill BraddyWestar A&DGE-Mail: [email protected]: (256) 430-1610 x148

OSD Policy and Army Guidance CBM Program Objectives Commander’s Guidance Stakeholders/Enablers Proof of Principle

— Mission— Products — Process— CBM Data Management

CBM Transformation Milestones Summary

Topics for 30 Nov 2004


DSS-0228 – CBM (OSD) – 11/29/2004

OSD Policy and Army Guidance

DOD – Policy Letter for CBM Dtd: 25 Nov 2002— Guidance and Directive to Services to Examine, Evaluate, and Implement CBM

— CBM Shall Be Implemented to Improve Maintenance Agility, Responsiveness, and Increase Readiness With Reduced Life Cycle Ownership Cost

DOD – CBM Memorandum Dtd: 20 Nov 2003— Develop CBM As One of Six Future Logistics Enterprise Initiatives

— Created the Maintenance Technology Senior Steering Group (MTSSG)

Army CBM Plus Plan Dtd: 14 Apr 2004— Shifts From Preventive and Reactive Maintenance to Proactive CBM

— Affirms the Goal of the Common Logistics Operating Environment (CLOE) to Provide Combatant Commanders With Higher Equipment Availability Using Fewer Resources

DA, G4 – Draft Army Aviation White Paper On CBM Plan Dtd: 10 Nov 2004— Stated That Task Force- Aviation Was One of Sixteen Army Focus Areas

— Task Force Aviation Goal Is to Achieve Full CBM Within Aviation By End of FY 2015

— Identifies Responsibilities of Stakeholders Within Aviation Community


DSS-0228 – CBM (OSD) – 11/29/2004

CBM … Turning Data Into Maintenance Action!

Condition Based Maintenance Defined …

OSD/Army: CBM Is a Set of Maintenance Actions Based on Real-time or Near-real Time Assessment of Equipment Condition, Obtained From Embedded Sensors and/or External Measurements or Tests

To the Commander: The Ability to Meet Mission Requirements With Proactively Driven Maintenance; Increasing Operational Availability --CBM Proof of Principle Team

To the Soldier: The Ability to Convert Data on Aircraft Condition and Usage Into Proactive Maintenance Action, Reducing Maintenance Workload -- CBM Proof of Principle Team


DSS-0228 – CBM (OSD) – 11/29/2004

CBM Program Objectives

Use Real-time Assessments of Material Condition Obtained From Embedded Sensors and Other Data Sources to Improve Diagnostics and Prognostics Capabilities

Increase Operational Availability for the Warfighter

Reduce the Maintainers Workload

Convert Unscheduled Maintenance to Planned Maintenance

Achieve IOC By 2011 IAW CSA Intent; FOC 2015


DSS-0228 – CBM (OSD) – 11/29/2004

AMCOM Commander’s Guidance

Guidance:

CG, AMCOM Serve As the Lead to Transform Army Aviation to

CBM

Identify the Stakeholders and Build Consensus

Develop a Long Range Plan

Develop Funding Requirements for FY 06 and FY 07-11

Program Change Proposal

Report Progress Monthly

"This Opportunity, Has the Potential to Significantly Increase the Operational Readiness of Our Aircraft and Reduce "This Opportunity, Has the Potential to Significantly Increase the Operational Readiness of Our Aircraft and Reduce the Maintenance Burden on Our Soldiers. You Are the Team to Make This Happen. I Thank You for Your the Maintenance Burden on Our Soldiers. You Are the Team to Make This Happen. I Thank You for Your Involvement and Dedication." Involvement and Dedication."

MG James H. Pillsbury, Commander, Aviation/Missile Life Cycle Management CommandMG James H. Pillsbury, Commander, Aviation/Missile Life Cycle Management Command


DSS-0228 – CBM (OSD) – 11/29/2004

The Stakeholders …

PM-TMDE

RDECOM - Engr Dir - AED

OtherIndustry

Logistics Transformation

Agency

DA G4

OSD CBM AGHQ AMC

Aviation Task Force

PEO AVN

OEMs

User Reps− USAAVNC− USAALS

IMMC

CDR AMCOM


DSS-0228 – CBM (OSD) – 11/29/2004

CBM Enablers

1. World Class Change Management

2. Digital Source Collectors — Open Architecture— Non Proprietary Data— Efficient Download and Transfer— Reliable, Simple Translation Into Engineering Units (Relational Data)

3. Reliable Data Warehouse— Multiple Sources and Data Types

• DSCs – Vibration and State Data• ELAS – Maintenance Actions• ELAS – Parts Tracking and Usage History

— Multiple Customers• Different Needs for Data Granularity• Different Needs for Information

4. Closed Loop Information System— Data (for Engineers)

• To Information (for Analysts)– To Knowledge (for Planners)

o To Maintenance Action! (for Commander/Soldiers)


DSS-0228 – CBM (OSD) – 11/29/2004

CBM Proof of Principle

Mission:

“In Support of the Transformation of Army Aviation to CBM, Demonstrate

the Feasibility of Converting Condition and Usage Data Into Maintenance

Action”

Products:

Sample Components From Each MDS

Data Sources for Each Component By Aircraft

Analytical Methods

— Collaborated Analytical Methods (With AED)

— Draft Charter in Staffing

— A Proof of Principle Data Warehouse By 31 Jan 05

— Condition / Usage Data Into Maintenance Action By Jul 05


DSS-0228 – CBM (OSD) – 11/29/2004

CBM Proof of Principle Process

Calculate New CIs

Implement Maintenance

Actions

Research Existing Data & Condition Indicators

(CIs)

SelectPart

Collect Data

Accuracy Of

Estimate Sufficient?

Yes

No

Build FailureCurve

Collect Additional Parameters/Data

Condition Based MaintenanceCondition Based Maintenance

Pro

ba

bili

ty o

f F

ailu

re

Maintenance Action

Maintenance Action

“Inspect & Lubricate bearing”

“Replace Bearing”

“Order Part ”

Time in Regime or Planned Usage

Supply Action

A significant volume of collected data over time, will establish the curve.

Tail # specific history and component CI’s tell you where the part lays on the curve

Perform Analysis:Hypothesis: Aircraft vibration & usage has a significant

effect on the failure of a component.Predicted Outcome: Time remaining to component

failure under planned usage.Possible Factors: Vibration, Time in Regime, Gross

Weight, Torque, etc.


DSS-0228 – CBM (OSD) – 11/29/2004

AH-64 Consensus AED PMO CBM Proof ATTC DSC OEM

AH-64 Parts Selected

Vibration Active Monitoring

(Non-vibration)Passive Monitoring

(Inspection, Sampling, Data)

Fatigue Life Limited M/R Swashplate, M/R Pitch Housing

TBOAPU Clutch, Fwd/Aft

Hanger bearing

On Condition Engine Assy, 701CHydraulic Pump

Motor, Hydraulic (Gun)

Status: Finalized

TypeComponent

MonitoringMethod


DSS-0228 – CBM (OSD) – 11/29/2004

Current Preventive Maintenance CBM Potential

Potential CBM BenefitAH-64 Aft Hanger Bearing

Mechanic acknowledges HUMS

directiveMMH=0

Aft Hanger Bearing received

MMH=0

HUMS Monitors Health and Remaining Life of

Aft Hanger Bearing

Task: Remove/Install Aft Haner Bearing per HUMS

DirectiveMMH=5

HUMS alerts Mechanic of Aft Hanger Bearing change in 25 flight hours under current or

projected usage

Wait TimeDays=0

Aircraft Mission Ready

Yes

Yes

NC

R=

0 D

ays

Requisition new BearingMMH=1

Inspect Aft Hanger Bearing every 250

hoursMMH=1

Is Bearing Serviceable

MMH=1

Wait TimeDays=10

New Bearing receivedMMH=1

Complete Inspection MMH=1

Aircraft Mission Ready

Yes

Yes

No

NC

R=10 D

ays

Make CorrectionIs Bearing Serviceable

MMH=4

No

YesCurrent MaintenanceUnscheduled FailureMMH = 18 HrsWait Time = 10 DaysNot Combat Ready = 11 Days

CBM PotentialNo Unscheduled MaintenanceMMH = 5 HrsWait Time = 0 DaysNot Combat Ready = 0 Days

Assumptions:• No Fault Found During 1st Two Inspections• Inspection Interval Is 250 hours• MTB Repair is 537 hrs• Part Time Change is 2500 Hrs• Part Not on Hand

CBM Potential:• 13 Fewer Hours of Maintenance• 11 More Days of Availability

(Reactive) (Proactive)


DSS-0228 – CBM (OSD) – 11/29/2004

AH64 A&D Opportunities

Data Types Today – No Significant In-theater Data Collection Capability

CBM Progress Requires at Least 4 Data Types Vibration – Fault Detection of Monitored Components State and Usage Data – Maneuvers, Stress Accumulation,

Conditions Parts Tracking Info – Part ID and Usage History Maintenance Activity – Details on Component Change Out

Units AH64D Unit Deploys to OIF With Data Collection Capability

AH64A Units With VMEP in SC NG


DSS-0228 – CBM (OSD) – 11/29/2004

UH-60 Parts Selected

Vibration Active Monitoring(Non-vibration)

Passive Monitoring (Inspection, Sampling, Data)

Fatigue Life Limited M/R Blade,

Oil Cooler Bearing

TBO

On Condition Engine Output Drive

ShaftPump Module Assy

Engine Assy 701Damper Assy,

Main Landing Gear Strut

TypeComponent

MonitoringMethod

UH-60 Consensus AED PMO CBM Proof ATTC DSC OEM

Status: Finalized


DSS-0228 – CBM (OSD) – 11/29/2004

UH60 A&L Opportunities

Required Data Types Vibration – Fault Detection of Monitored Components State and Usage Data – Maneuvers, Stress Accumulation,

Conditions Parts Tracking Info – Part ID and Usage History Maintenance Activity – Details on Component Change Out

4th Battalion 101st AASLT Division— UH60Ls Equipped With IMD HUMS

1-52 Aviation, 8th US Army— UH60As With VMEP

SC National Guard, — UH60As With VMEP


DSS-0228 – CBM (OSD) – 11/29/2004

Aft Swashplate AssyHUMS

Fwd Swahsplate AssyHUMS

Power Steering UnitNot Monitored

Pump, Axial PistonHUMS

Engine AssyHUMS

Tie Bar AssyNot Monitored

Hnge Pin AssyNot Monitored

Head Assembly, AftHUMS

Shaft Assembly, Eng DrivenHUMS

Head Assembly, FwdHUMS

Vibration Active Monitoring(Non-vibration)

Passive Monitoring (Inspection, Sampling, Data)

Fatigue Life Limited Shaft Assy, Engine Driven Tie Bar Assy

TBO Fwd/Aft Swashplate Assy, Fwd/Aft Head Assy

Engine Assy Hinge Pin Assy

On Condition Pump Axial Piston Power Steering Unit

TypeComponent

MonitoringMethod

CH-47 Consensus AED PMO CBM Proof ATTC DSC OEM

CH-47 Parts SelectedStatus: Finalized


DSS-0228 – CBM (OSD) – 11/29/2004

CBM Data ManagementCBM Data Management


DSS-0228 – CBM (OSD) – 11/29/2004

AED

IMMC

PEO Aviation

OEMs

PMs TMDE, AGSE, AS, ASE, …

Commander, AMCOM

We Are Vertically Challenged

Apa

che

LUH

CH

47

AR

H

UH

60

How Do We Provide Horizontal Views of Data Stored in Different Places - in Different Formats - Under Different Management ?

Systems of Record

Res

po

nsi

ble

Ag

enci

es

Avi

atio

n D

ata

Sys

tem

s

Ent

erpr

ise

Dat

a S

yste

ms


DSS-0228 – CBM (OSD) – 11/29/2004

AMCOM

CBM Proof of Principle Architecture

IMMC

UniRAM

OSMIS

ELAS – Sgt DaltonLOGSA

PM TMDE

PM Utility

UH HUMS

CH HUMSTBD

OEMs

Cost

Parts

Failure Mode

Condition

State

Usage

Aircraft

Data WarehouseSubject Areas

AH MDR

AH HUMS

IMMC

ELAS

Data Sources Customers

PM Cargo

PM Apache

PEO-AV

Ext

ract

, T

rans

form

, Lo

ad

Met

a D

ata

and

Acc

ess

Laye

r

1. Optimal storage2. Change mgmt

1. User interface2. Efficient Query3. Periodic refresh

1. Loading2. Normalization3. Cleansing

EDRS

AMSAA AED


DSS-0228 – CBM (OSD) – 11/29/2004

Proof of Principle Data Management

ProductionControlSource

ETL Station

Regime Recog

Failure Analysis

Logistics Req’s

Service Life

Database10G w/RAC

CBM Proof of PrincipleInformation System

Reports

GenerateMaintenance

Action

Satellite

Internet

Mail

Plane Side

Analysis


DSS-0228 – CBM (OSD) – 11/29/2004

CBM Milestones

21 Oct – Stakeholders Meeting

26 Oct – NCR Senior Leaders (Ms. Leiby, MG Stevenson)

09 Nov – UH60/Navy IDM HUMS Symposium

17 Nov – CLOE Ground Systems Demo

30 Nov – DA Leadership Visit (Mr. Pybus, MS Plummer, COL Smith)

30 Jan – CBM Strategy/Milestones/PCP


DSS-0228 – CBM (OSD) – 11/29/2004

Summary

On Track …

Moving Forward With Proof of Principle

Long-term Strategy Is Emerging

Positive Support From Stakeholders

Challenges: — CBM Data and Information Management

— Automation Architecture (CLOE, LMP, PLM+, GCSS-A)

— Connectivity

— Long-term Commitment to CBM Transformation


DSS-0228 – CBM (OSD) – 11/29/2004

Back Ups

Transforming Army Aviation to Condition Based Maintenance (CBM)! 1 DSS-0228 – CBM (OSD) – 11/29/2004 CBM Program Update DA & OSD Senior Leaders Robert.

Documents

cbm cbm

maintenance cbm

cbm osd

cbm dtd

proactive cbm

cbm plan dtd

transforming army aviation

maintenance workload