Warner Robins Air Logistics Center
People First…Mission Always
High Velocity Maintenance
Overview
Presented By:Jerry MobleyWR-ALC/HVM
June 2010
Warner Robins Air Logistics Center
People First…Mission Always2
What is High Velocity Maintenance?
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
Warner Robins Air Logistics Center
People First…Mission Always 3
HVM Concept
Refine Scheduled Maintenance– Correct Inefficient Processes
• Low velocity compared to Industry»Airline burn rate 500-900 hours/day»ALC PDM 145-220 hours/day
– Implement Industry Best Practices• Daily Standard Work• Point-of-Use Task Kitting• Mechanic-Centric Focus
– Know tail number condition
Maintain Enterprise Approach• Scalable and Transportable Processes
Single Maintenance Concept
•1000
•500
•0
• Vel
oci
ty
(hrs
/day
)
•Industry Velocity
•PDM•ISO •ISO•HSC •ISO •Maintenance Cycle
•USAF Depot •Velocity
•Create an Ideal Process and Repeat it Every Time
HVM VISION
Increase Aircraft Availability using AFSO21 tools to establish a synchronized, integrated, end-to-end process such that maintenance does not impact mission requirements
Warner Robins Air Logistics Center
People First…Mission Always 4
Current State Limited Knowledge of Aircraft Condition
Two Mx systems; creates knowledge barriers 5+ Year PDM cycle (C-130)
Damage accumulates Promotes a “must fix now” mentality
Job Shop Environment Mechanic gets own tools; searches for parts;
accomplishes own set up Inadequate Planning – req’ts, Mx work, parts,
materiel, equipment Lacks information – complete BOM, planned
work, support Stove-piped Processes and Execution
Unsynchronized, inefficient, encourages work arounds (non-compliance)
Future State Known Aircraft/End Item Condition
Lead Time Ahead of Induction – Parts, Training, Infrastructure, Equipment, Data, etc.
Mechanic-Centric Focus (Surgeon) Parts, Tools, Data, Equipment Pre-Positioned
at Point of Use Maximum Use of Kitting
Expand Standard Work & Processes Choreograph Repair Operations Synchronize work Single Maintenance Concept Integrated Planning, Decision-making, & Data
Collection
Attributes
Warner Robins Air Logistics Center
People First…Mission Always
HVM Future State Process
Potential IFS Interfaces- IMDS/G081 (CAMS)- PDMSS- Concerto- MWR- AIRCAT- PM/CCAT- AFSAS- FEMS- IETMS- JEDMICS- CENTRA- Spreadsheet of Task Kit Configurations- AFMC Form 202 and TO 00-25-107 Engr Dispositions- DFIMS- DMAPS- JOPMS- MFT- MP&E- J025- BQ System (FIRST)- CAFDEx (CAM Process)- CEMS- Digital Data Exchange with DLA- CREPR- EXPRESS- ECSS- AMREP- BOM (G005M)- COLT- COPA
Industrial Engineer Liaison Engineer Planner
Cell HVM Team
Supportability(Task Kitting)
SupervisorScheduler Quality/Safety
Product Support Center Characterizes Issues
PSC Determines Scope of Resolution
Fix with Current PSC Resources
Cell Resolve Issue
YesNo
Pre-Dock Activities * De-Fuel * Inventory * Tailored Disassembly
TailoredEvaluation & Inspection
HVM Wing Cycle
HVM Fuselage Cycle
HVM Paint and Flight Controls
HVM Empennage Cycle
De-paint Remove &
Route Flight Controls
Paint
Ops Checks/FCF
Joint Acceptance/Sell
Paint Touch Ups
Inspect, Repair, Lube, & Dry Rig Flight Controls
Install & Rig Flight Controls
Fuselage structural inspection & repair
Install, rig & ops ck Landing Gear &
Brakes
Remove Gear, Perform wheel
well Refurb
Complete Wing structural inspection
& repair
Fuel System inspection &
repair
Empennage, Ramp, aft door, & 737 bulk head structural
inspection & repair
Remove Engines, inspect and
reinstall
Avionics & Electrical Systems inspection &
repair
Pressurization checks
D+0 Induct AircraftRequirements Review Board
(RRB)
Bill Of Work Process(BOW)
{Contains BOM}
Maintenance Requirements Supportability Review Panel
(MRSRP)
Feed Aircraft & Missiles Requirements
Document(AMRD) Process
Deliver Fully Supportable Standard Daily Work
Package to Production
CAM Office Loads Budget Authority
SPO/PM Initiates Quarterly Proj Order for
each MAJCOM
MXW/OB Accepts Quarterly Project Order
MXW/OB Establishes JON
Number for Tail Nr
MXW/OB Notifies Work Loader that Funds are
Available
MXW/OB Tracks Expenditure by Tail
Number
Budget Close Out
Requirement FeedbackConsumption Feedback
Aircraft Requires Over & Above FundingO/A Funding
Parts (DLA Retail Supply)Consumables and Depot Level Repairables
Gather E&I data for next cycle
Aircraft Maintenance Team (AMT)
UDLM/Mod
Product Team
Financial Team
Materiel Team
Requirements Team
Industrial Engineer Liaison Engineer Planner
Cell HVM Team
Supportability(Task Kitting)
SupervisorScheduler Quality/Safety
Product Support Center Characterizes Issues
PSC Determines Scope of Resolution
Fix with Current PSC Resources
Cell Resolve Issue
YesNo
World WideMaintenance and
OperationsData
Data collection and Analysis
- RCM Analysis (IRCMS)- CBM+ Predictive Tools- Engineers Tool Box (LCSE)- Modeling and Simulation of workflow (DELMIA)- Pre-induction Analysis Tools- Mx and Modification Schedule (IFS)
- IFS- AIRCAT
- Flight Data- Operating Locations- Field Level Engr Requests- ASIP Inspections- Center and Outer Wing Service Life
- Mx Field Data (IMDS)- Foreign Operator Data- PIWG/CPAB Action Items- DRs (G021 and JDRS)- Hazard Tracking DB- AFSAS- PDM Trends (IFS and 202 Data)- Specific Tail Number Mx Requests (AFTO Form 103)- MECSIP Requirements- Prop and Engine Change Reqts (CEMS)
Load Requirement into PDMSS/ECSS
Info/Tech Team
Pass changes in support equipment requirements to
AFFVESA
- CREPR- COLT- COPA
Specific Tail #Mx Request (was
AFTO 103)
Develop Standard Work/Kit
Daily Std Work Package (PDMSS/JST/ECSS)
PDMSS Data Dump to REMIS
·Supporting processes (requirements, budget, etc) optimized & integrated to support Mx activities
For Official Use Only
D+7Exception
ManagementProcess Begins
D+5Assessment
Complete
D+6Complete Release of Parts to CMXG
for Repair
Daily Task Requirements
DLA Collaborative Forecasting – Parts
(Digital Data Exchange)
AF Collaborative Forecasting – Parts, Materials, Tools, Equip
CONCERTO
Mx Work Request (MWR/ICARR/IETM)
Drawings and Standard Visual Work Tech Orders
(JEDMICS, CENTRA& IETMS)
CAFDEx/ECSS
Acft Schedule (PDMSS/ECSS)
Routed Item Tracking (AF-GET and ROCIT)
Supportability Data
Equipment Database (FEMS)
J025A Automated Project Order System
AMREP UpdateAMREP Update
BOM (G005M/IETM)
HVM ProcessVersion: 20 July 09
Visual Management of
Progress
Engineering Approval
Required?Yes
No
Begin Work at Risk?
Operation Previously
Developed?
Engr Supv Approval or
Update Solution
No
Work Request Received Through
IETM
Yes
Aircraft Maintenance Team Develops Solution
Load Operation in IFS Against Serial
Number
Update IETM with Final Configuration Data of Work
Performed
Yes
No
DMAPS, DFIMS & JOPMS
Time and AttendanceWork Certification
Aircraft Maintenance Team (AMT) Additional Workload Request Decision Process
Supportability Process(P001)
Additional Workload Request Process
Supportability Review Process
IETM(Parts Config)
Review Operations for
each Tail Number in PDMSS/ECSS
P001. Supportability Review Process
Required tools, parts, tech data, etc by operation number for next cycle on each aircraft
Supportable?
Safety of Flight?
Possible Work Around?
No
No
Yes
Accomplish Next Cycle
NoAF/DLA Expedite
Process
Load Requirement Into PDNSS/ECSS Against
Appropriate Cycle
Yes
YesFunding Approval Process
World Wide Intelligence Data
on Future Requirements
- Expected mission and operational requirements (impact to fatigue driven inspections)- Expected environmental impacts (corrosion, system and avionics impacts)- Surge Requirements- Modification Requirements
RFID Tags on aircraft, routed items, special tools and
support equipment
Operation Loaded in IETM
P003. Requirements Validation and Verification Process
Industrial Engineer Reviews Process
Val/Ver?
On Equipment Validation/Verification of New
Requirement Process
PDMSS/ECSS
Effectivity, Initial Reqt, Recurring Reqt
Update Requirement
Review Requirement
Detailed Requirement Draft in Standard
Visual Work Format
No
Yes
Resource Requirements
Special Tools
Hazmat/Pharmacy Items
Job Routed Items
Standard Visual Work Tech Data
MOD-DOCKPRE-DOCK
POST-DOCK
2
Industrial Engineer E & I Engineer IE Tech
Cell HVM Team
Supportability(Task Kitting)
SupervisorScheduler Quality/Safety
Aircraft Maintenance Team Characterizes Issues
AMT Determines Scope of Resolution Cell Resolve IssueYes
1 3
On Site Integrator
Tied to: • Operation Number
• Acft/Date/Time/Dock
Kit AssemblyJust-in-time
Pre-position at P.O.U.
Kit Component Aggregation
Pull
Fix with Current AMT Resources?
FOM – Facilitate Other Maintenance
MRSR PROCESS
Strategic Planning
NO
Corrective Action ProcessFlow/Disposition
Maintenance History &
Requirements
Supportability Review Process
(DLA Retail Supply)Consumables and Depot
Level Repairables
Special Tools
Hazmat/Pharmacy Items
RPC Items
Standard Tech Orders
Funding for Parts
Pre-Dock Activities * Wash * Inventory * Maintenance Safe * Tailored Disassembly
Post-Dock Activities * Fuel Work * Records Review * Flight Acceptance
Field HVM Plans &
ScheduleMaintenance
History & Requirements
HVM In The Field
Pre-Induction Inspection Prior to 1st
HVM Cycle
ACRONYMS
AF-GET Air Force-Global Enterprise TrackingAMREP Aircraft MisAMT Aircraft Maintenance TeamCENTRADFIMS Defense Industrial Financial Management SystemDMAPS Defense Maintenance Accounting and Production System FCF Functional Check FlightFEMS Facilities and Equipment Management SystemICARR Inspection Corrosion and Repair RecordingIE Industrial EngineerIETMS Interactive Electronic Technical Manual SystemJOPMS Job Order Production Master SystemMRSR Maintenance Requirement Supportability ReviewMWR Maintenance Work RequestROCIT
AMRD
Kit Warehouse
Kit Staging
Does Kit consist of
bulk or heavy items?
Coordinate
delivery of bulk
or heavy item
Deliver kit to POU,
scan to delivery
point
No
AMT
Provide list for kit delivery from Daily
Standard Work sequence (24 hrs in
advance)
Review additional resource needs and
drives change to BOM
Yes
Mechanic
begins task
Mechanic needs
additional
resources
Material handler delivers addition
al material
/ resourc
es
Work card
complete by end of
shift
No
Begin Deliver
y Proces
s
Receive
Delivery
Signal from AMT
Scan “Out for Delivery
”
Kit complete, ready
for delivery
AMT / Material handler reviews
need
Material handler obtains needed items from
integrator
warehouse
Mechanic
signals for
additional
resources/
completes
feedback card
Yes
Kit retrieva
l
Complete kit build
Pre-deliver
y validation OK
Yes
No
Mechanic
reviews kit for
completion
Accepts
Rejects
Yes
No
Kit Delivery Process
The asset is removed from the
aircraft
The asset is inspected by E&I personnel or a
mechanic
An inspection tag is attached to the
asset
The FLS attaches a barcode tag and all
the required paperwork to the
asset
The FLS scans the asset it into the PDMSS/ROCIT
database for tracking
Is the asset serviceable or unserviceable
The asset is taken to the Integrator’s
Kit Area(delivery scan)
Asset is delivered to appropriate support shop. Delivery scan accomplished
Asset processed in PDMSS/ROCIT
with EDD’s established
Repair actions accomplished
Serviceable
Un
serviceable
The asset is placed in a waiting area designated for unserviceable
assets
The asset is placed in a waiting area designated for serviceable
assets
Supply or Job Route item?
Job Route item
Unserviceable / Serviceable
Supply Warehouse
Supply item
Asset processed in PDMSS/ROCIT
closing repair and allow for pick-up
FOM asset incorporated into
kit and/or delivered with support materiel to mechanic
END
FOM Flow Process
Begin Kit Build
Standard and non-standard task list for BOW with
BOM provided by MRSR/AMT
Remove kit from build staging area
Generate task kit content list (BOM)
Gather required parts and
,reparables for the kit Visually inspect for
obvious damage, expiration date or
calibration requirements
Visual inspection
good
Return defective part, order/obtain
replacement
No
Place item in kit
Move kit to delivery staging
area
End process
Apply Tail Number(See Kit Label
Process Guide)
Apply security “seal”
Yes
Gather required Consumables
Gather required Tech Orders
Gather required Hazmat
Gather required PPE
(non-personal)
Gather required Tools
Gather required Specialty Tooling
Gather required Test Equipment
Gather required IPV
Gather Required(Expendables)
Blue Straw items
Document kit completion
In stock at Kitting
warehouse
Rep CON
No
Repairable Consumable
Yes
Initiate PQDR process
Kit Build-UpKit Design begins
Obtain contents listed on Daily Standard Visual Work card(parts, hardware,
tooling, consumables, hazmat, etc)
Contents includes large, bulk or FOM
parts
Includes tooling or special
tooling
Content includes test equipment
Contents exceeds 35 lbs
Contents fit on shadow board
Build Tub style kit No
Equipment dedicated to kit
Yes
Obtain test equipment from PSC
No
Kit ready for StagingDesign
multiple kits instead of
single
Yes
Tool dedicated to kit
Yes
Obtain tool from PSC
No
Kit contains PPE
Kit contains Hazmat
Yes Yes
NoNo
BuildShadow Board
BuildCustom Kitor establish coordinated
delivery
Yes
YesNo
Obtain PPE from PSC
No
Yes
YesObtain Hazmat
Return tools, test equipment, PPE
and Hazmat once design and layout
are complete
No
MRSR determines kit required to
support task or kit requires
modification
Document Kit has been designed for
correlated task
Document Kit Label
(See “Kit Label” in Process Guide)
No
Kit Design
Begin Retrograde
Remove highest priority kit from
rack
Process any remaining
HAZMAT in accordance with AF regulations
Kit contains HAZMAT
Kit contains Special tooling
Kit contains Repairable
Kit contains basic tooling
Turn parts in to Supply
Route Tooling back to PSC
Verify all tools remain
Remove and dispose of FODNo No
YesYesYes
NoScan materiel
usage
Return unused materiel to stock
Standard Build Kit
Yes No
YesNo
Return kit to staging area for
next kit buildEnd
AMT
Process kit content consumption for billing and material forecasting
Receive feedback on kit content and sequencing to Daily Standard Work
Drive modification to BOM, sequencing or kit if feedback is validated
Kit Retrograde
DLA provisioned consumables(Pre-defined by acquisition code or RPF%)
IPV
Unserviceable Job Routed Assets
Serviceable
HAZMAT
Consumables Sources of
Supply
Onsite CMXG / EMXG Back
Shops
Special Tooling / Special Test Equipment
Other supply points to the Integrator
Unserviceable Job Routed
Assets
Repair Services Source of Supply
HAZMAT Sources of Supply
Blue Straw / Expendables(Non aviation consumables)
Alternative Commercial Sourcing of Immediate Material Needs
Contracted Integrator provisioned consumables(Pre-defined by acquisition code or RPF%)
Stock Positioned Consumables
Kitting Materiel
Integrator’s Kitting Warehouse
Kit Design, Construction, Build-Up, Delivery, and Retrograde Process
100% DLA provisioned consumablesOR Consumable Supply Warehouse
Unserviceable / Serviceable
Supply Warehouse
Unserviceable Supply Assets
Unserviceable
MISTR at an offsite location Unserviceable Assets
Serviceable Assets
Serviceable
Supply Points
Pre Induction Inspection
107/103 Data
781 Data
Aircraft Tail Nr Cycle Work
Package
E&I Initiates MWRPlanner Reviews
MWRTrigger Card
Exists?Reject MWR
MWR Supportability
Review
Task Supportable in
this Cycle?
Yes
No
Yes Incorporate into Work Package and Execute
HVM Master Ops List
MRSR Disposition
No
In Work Spec?Yes Planner creates
MWR
No
PAO Approves Work
Yes
Submit Request for additional work
to PAO
No
Deferred Work
AMT Decision
AMT MWR Flow
PDMSS/Oracle CMRO
Visual Work Cards
Available?Yes
NoDevelop SVWCProcess PXXXIETM
MRSR develops fully supportable , sequenced, executable work package
4 Cycles – 18 Month Interval to integrate/replace current 15 Month Isochronal Inspection
Standard Work Cards drive out Process variability
Actual requirements drive material purchases rather than historical probability AMT provides
continuous real time support
Integrator delivers POU task kits to mechanic
Data analysis critical to defining requirement
Warner Robins Air Logistics Center
People First…Mission Always
HVM Future State“Swim Lane” View
6
HVM Process Map with Products25 May 2010
Exe
cute
th
e P
lan
De
velo
p S
up
po
rtS
et
the
R
eq
uir
em
en
t
Approved Additions, changes
or deletions to Tech Data
(Fully Defined Req’t)
Data Analysis Process
(RCM & Tail #)
Requirements Review Board
(RRB)
Data Collection Process
Recommended Changes to Tech
Data(Scheduled Mx Reqt)
“Good” Usable Data
MRSP-S Bill of Work (BOW)
MRS Review
DistributedDaily Visual Work Cards (DVWCs)
FullySupportable Tail #
Bill of Work (BOW) Including:DVWCs, Sequenced & man-
loaded, Kit Requirements List,
Aircraft Maintenance support Team
(AMsT)
Product and / or
Data
Task Kitting Process
Repaired Aircraft
Aircraft in need of repair
Production CellPoint of Use
Task Kits
Requirements Process
Materiel ProcessProduction
Process
Maintenance Requirements Supportability
Process – Tactical (MRSR-T)
Tail # BOW changes
Aircraft & Missiles Requirements
Document (AMRD) Process
MRSP-S Supportability
MDSBill of Work
SupportableMDS #
Bill of Work
MRSP-O Materiel Planning
Aircraft Condition Data Generation &
BOW feedback(inc PII)
New Reqt?
Y
N
Fleet Mgt & Aircraft Scheduling
Aircraft Induction Schedule
Data Collection Process
(Start Process over again)
Supportable?
Baseline
MRSP-O - Tail # Bill of Work (BOW)(Including review)
ApprovedSupportable
Tail # Bill of Work
Y
Defines Right Requirement
Builds Daily Std Work Package-Accomplishes supportability-Tailors package to tail number- Defines sequence -Feed Financial process
Executes tailored work packagePoint of Use Task KitsMan-loads a/c- High Burn Rate
Warner Robins Air Logistics Center
People First…Mission Always
• PDM & ISO not synchronized
• PDM scheduled every 5-6 yrs
Cycle 1 HSC
•1000
•0• Vel
ocity
(hr
s/da
y)
•500
HVM State
HSC HSCCycle 2 Cycle 3 Cycle 4
•ISO •HSC•ISO •HSC •ISO•HSC•ISO
•1000
•0
•500
• 145-220 hrs/day
• 160 Flow Days
Current State
• Vel
ocity
(hr
s/da
y)
• Goal: 500 + hrs/day
High Velocity Maintenance Life Cycle Comparison
• Integrated Scheduled Mx (PDM & ISO)• High velocity, multiple cycles over 5-6 yrs
Improved AA
Less A/C on ground
Reduced O&S Cost
Efficient MX Process
•C-130
•18 month interval
7
Warner Robins Air Logistics Center
People First…Mission Always
Implementation StrategyConcept development: Summer 07 – Spring 08Process development: Spring 2009
Creation of daily standard work: Ongoing Creating supporting data: Ongoing
Process validation: Summer 2009-Spring 2011 9 validations
Pilot Program: Fall 2011-2012 AFSOC C-130 aircraft: 18 – 21 months post PDM
Fleet-wide deployment: 2013+ Remaining C-130 fleet transitioned by MAJCOM
C
HVM Concept Development
Process Validation & Demonstration Production & Deployment Operations & Support
HVM HPT Charter
HVM Process Development
Aircraft Induction Readiness Review
A B
AFSOC ImplementationFleet Implementation
Val #1 Val #2
8
Val #3Val #4 Val #5
Warner Robins Air Logistics Center
People First…Mission Always9
Benefits of SLIM to HVM
AircraftAvailability
HVM
ECSSCAMGLSC
PLM
AAIP
HVM for PDM/ISO
WR-ALC C-130 Prototype
Optimizes the PDM process (the “how”)
Includes all supporting processes
Optim
ize the field/depot
requirements
(the “what, w
hen and where”)
Expands HVM to be “scalable and transportable”
Ove
rarc
hing
ent
erpr
ise
initi
ativ
es
Std Work Supply Chain Ops Lifecycle Mgmt Sourcing Tech Development
RCM
CBM+
MSG-3
IntegrityPrograms
SLIM
•SLIM focuses on overall weapon system performance assessments•Efficient & effective data collection and analysis•Proactive action using the analysis results•Integrating CBM+, RAM, RCM/MSG-3, WSIP, MFOQA, and EAVI efforts
Benefits Enables Optimized MX RequirementsFacilitates increased knowledge of aircraft condition
Warner Robins Air Logistics Center
People First…Mission Always 10
Discussion/Questions
High Velocity Maintenance
Warner Robins Air Logistics Center
People First…Mission Always
HVM & MSG Relationship
HVM defines the “How” maintenance is accomplished• Optimizes Maintenance processes – “Mechanic Centric Focus”
–Establishes processes to achieve “high daily touch labor rates” through detailed advanced planning with supportability; choreographed, synchronized work packages; aircraft man-loading; implementation of daily standard work; pre-positioned point-of-use task kits –Moves toward single “Maintenance System”
• Incorporates ISO’s (C-130)
MSG-3: Defines the “What” needs to be done • Established the appropriate inspections and optimum interval for
accomplishing the inspections–Ensures you accomplish the “Right “ maintenance at the “Right” time.
11
The optimum MX solution would employ the MSG-3 methodology as the foundation for HVM processes to be applied to achieve the most
effective scheduled maintenance program
Warner Robins Air Logistics Center
People First…Mission Always 12
HVM & SLIM
12
High Velocity Maintenance-Improving “How Mx is Done” – standard processes and synchronized to optimize flow time- Pre-planned support, Point of Use task kitting, mechanic centric focus to increase velocity
MSG-3- Overall system level approach- Hierarchical zonal inspections- Structures: Logical process for determining Mx requirements
- Safe life vs Damage Tolerant- Accidental, Environmental or Fatigue Damage Considerations
- Mechanical Systems/Engines - Uses RCM Approach
Maintenance ta
sks a
nd interva
ls
ASIP- Inspection Reqts for tracked zones
CBM+ What- Diagnostics- Prognostics- Data Analysis- RCM
CBM- Real-time assessment of condition - Embedded sensors - External tests and measurements - Maintenance only upon evidence of need
CBM+ How- Interactive Training- Portable Maintenance Aids- Interactive Electronic Technical Manuals- Integrated Information Systems- Automatic Identification Technology
What Maintenance to Perform
Feedback How Maintenance is Performed
RCM- Assess system functionality - Identify failure modes and effects- Determines consequence of failure - Logical process to determine actions and insure mission success
Feedback