aviation depot 101 - sae international · unclassifed resourcing overview •aviation depot...
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UNCLASSIFED
Naval Aviation Depot Maintenance
November 15, 2011
Aviation Depot Maintenance
• Invests today,
• For service life used yesterday,
• In order to provide readiness tomorrow
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UNCLASSIFED
Pratt & Whitney, Bridgeport, WV Engine: JT15D-5C (UC-35C); PT6A25 (T-34C)
PT6A34 (T-44); PT6A41/42 (C-12) PT6A68 (T6); PWC535A (UC-35D)
Public / Private Aviation Depot Sites
ORGANIC INTERSERVICE COMMERCIAL
Rolls Royce, Oakland, CA Engine: T56-A-14/16/425/427
(P-3,C-130, C-2A, E-2C); AE1107C (V-22); AE2100D3 (C-130J)
OC-ALC Tinker AFB, OK Acft: E-6B
Engine:CFM56-2A (E-6B) CFM56-7B (C-40), F135(JSF)
CCAD Corpus Christi, TX Engine: T700 (H-60, AH-1W/Z)
FRC SOUTHEAST Acft: P-3, EA-6B, E-2, C-2, EP-3, F-18, H-60
Engine: J52(EA-6B), F414(F/A-18E/F), F135(JSF)
FRC EAST Acft: AH-1W/Z, AV-8B, F-35, H-46, H-53, H-1, EA-6B, V-22 Engine: T58(H-46), T400(UH-1N), F402(AV-8B), T64(H-53)
Acrohelopro, Richmond, BC Engine: 250C20 (TH-57)
FRC SOUTHWEST Acft: AH-1W/Z, AV-8B, C-2, E-2, F/A-18,
EA-6B, EA-18G, H-1, H-53, H-60 Engine: LM2500 (NAVSEA)
Northrop-Grumman, St Augustine, FL Acft: F-5F/N
OO-ALC Hill AFB, UT Acft: C-130, F-16, F-35
Overseas FRC WestPac-Atsugi
AH-1W/Z, CH-46E, CH-53D/E, E-2C, EA-18G, F/A-18C-F, HH-1N, HH-60H, MH-
60R/S, P-3C, SH-60B/F, UN-1N/Y
Vector Aerospace, Andalusia, AL Acft: TH-57B/C
Helipro, Andalusia, AL Engine: 250-C20J (TH-57)
L-3, Waco TX Acft: P-3C, EP-3E
Dallas Air Motive, Millville, NJ Engine: MK511-8 (C-20D) MK611-8 (C-20G)
Sikorsky, Stratford, CT Acft: VH-3D, VH-60N Exec Helo
Boeing, Seattle, WA Acft: C-40
Sabreliner, Perryville, MO Engine: JT12A8 (CT-39)
J85-21C (F-5E/F)
Boeing, Kent, WA Acft: E-6B
GE Engine Services, Arkansas City, KS Engine: T700 (H-60, AH-1W)
Rolls Royce, Canada Engine: BR710 (C-37)
MK511 (C-20D); MK611 (C-20G)
Allen Aircraft Radio MRO, OK City, OK Acft: C-9
Pratt & Whitney, San Antonio, TX Engine: F100-PW-220 (F-16)
Gulfstream, Savannah, GA Acft: C-20A/D/G
Engine: BR-710 (C-37)
L-3, Richmond, Vancouver Engine: 250C20 (TH-57)
AVMATS, Mascoutah, IL Acft: T-39G/N
Engine: JT12A8 (CT-39)
Aerothrust Corp, Miami, FL Engine: JT8D-9A (C-9)
American Airlines, Tulsa, OK Engine: CFM-56-7B24 (C-40)
Depot Level Maintenance Sites Perform (major repair / overhaul) depot maintenance
Performed at both public and commercial facilities • Fleet Readiness Center (FRC) Sites
• Other Service Sites (Interservice / Intraservice)
• Commercial Sites
L-3, Greenville, TX Acft: P-3C, EP-3E
FRC MID-ATLANTIC Acft: C-2, E-2C, F/A-18, H-60
FRC NORTHWEST Acft: EA-6B, EA-18G,
P-3, EP-3
FRC WEST Acft: F/A-18
Columbus AFB, MS Acft: T-38C
Engine: J85-GE-5
Canada Rolls Royce (Engines)
AE2100D3 (C-130J), MK 511-8 (C-20D), MK 611-8 (C-20G)
Orenda (Engines)
J85-GE-4A/5/5M/21C (T-2, F-5)
Standard Aero (Engines)
PT6A-25 (T-34C), PT6A-34 (T-44)
Hawker Beech, Wichita, KS Acft: TC-12B, UC-12B/F/M/W
Jetworks Air, Denton, TX Acft: U/C-35C/D
Lockheed Martin, Greenville, SC Acft: EP-3C, P-3C
Stevens Aviation, Greenville, SC Acft: T-34C, T-44A/C
Hamilton Sundstrand, Windsor Locks, CT Engine: T62T-11/27/46-2
Honeywell Aerospace, Phoenix, AZ Engine: TPE331-2 (C-26D)
Allen Aircraft Radio MRO, Indianapolis, IN
Acft: C-9
Delta, Atlanta,, GA Acft: C-40
Engine: CFM-56 (C-40)
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UNCLASSIFED
Resourcing Overview • Aviation Depot Maintenance (ADM)
• Operations and Maintenance Navy (O&M,N/NR) funded
• Funds all Naval Aircraft and Engine Organic, Intra-Service
and Commercial depot workload
•Also fund directly some unique weapon system components
• 58 Unique Type/Model/Series (TMS) Aircraft
•~3900 aircraft in the Navy inventory
•Generate ~750 Airframe and ~2600 Engine/Module
maintenance events per year
•$1.1B Baseline budget / $1.3B w/OCO in PB12
•Engine repairs/overhauls driven by reliability and hours
operated
•Distributed airframe maintenance uses Planned Maintenance
Intervals based on Fixed Inductions Dates (FID)
•~40% of Airframe events performed in/near flight line by
depot field teams
3
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UNCLASSIFED 4
29%
20% 23%
9%
7%
12%
Airframes USN
Airframes USMC
Engines USN
Engines USMC
Other USN
Other USMC
Aviation Depot Maintenance ($1.6B FY11)
FY11
1A5A AF/EN/OT O&MN / O&MN,R
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UNCLASSIFED
Issues
• Forecasted budget constraints across the FYDP risk
unfunded aircraft maintenance (backlog)
• Aviation Depot Maintenance has relied on Overseas
Contingency Funding to execute full requirement
• Current modeling approaches have focused on risk
as a function of depot recovery • Maximum one year recoverable backlog of 100 Airframes / 340 Engines
• Difficult to map backlog impact to future readiness
• Configuration details within a TMS not currently tracked
for PPBE purposes
• Developing impact of specific aircraft inventories against
future schedule demands to show impact
5
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UNCLASSIFED
INTEGRATED MAINTENANCE PROGRAM Notional
PMI 1 180 Days PMI 2 56 Days 4 Years Operational
Fixed
Scheduled Induction
Date
4 Years Operational
Fixed
End Date
Repeat Cycle
• Fundamental shift by the Navy
• Moved away from conditional inspections (ASPA) and
SDLM for all major TMS
• Maintains more consistent level of material condition
• Improved ability to forecast future workload and stabilize
requirements within the PPBE process
Heavy Industrial
Induction Field Event
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Requirement
Review
Process
Primary Aircraft
Authorization
(PAA)
Aircraft Inventory
Integrated Maintenance
Work Load Standards
AIR 6.0
Minimize
Inventory Risk
With Available
Funding
Funded
/Backlog
Maintenance
Forecasted
Workload
w/Unit Cost
by Depot
Depot Core
Minimums
Source of Requirement
ADM Pricing
Model
Title 10 CNO
Fleet SYSCOM
Flight Line
Entitlement
Requirements Collections and Modeling Process
TMS PMI
Schedules/Engine
Demands
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Wide Variance in Unit Cost
Slide 8
$0
$1,000,000
$2,000,000
$3,000,000
$4,000,000
$5,000,000
$6,000,000
$7,000,000
$8,000,000
$9,000,000
$10,000,000
0
2,500
5,000
7,500
10,000
12,500
15,000
17,500
20,000
22,500
25,000
27,500
30,000
EA-6
B PM
I 2 (
3)
EA-6
B PM
I 3 (
6)
EA-6
B PM
I 4 (
13)
C-2
A PM
I 1 (
4)
C-2
A PM
I 2 (
4)
FA-1
8C PM
I 2 (
37)
FA-1
8F PM
I 2 (
1)
FA-1
8A PM
I 2 (
6)
FA-1
8D
PM
I 2 (
14)
MV-2
2B PM
I 1 (
7)
MV-2
2B PM
I 2M
( 2
)
E-2
C P
MI 1 (
5)
AV-8
B PM
I 3 (
6)
AV-8
B PM
I 2 (
11)
MV-2
2B PM
I 2 (
8)
AH
-1W
PM
I 1N
( 2
0)
AH
-1W
PM
I 2N
( 1
0)
UH
-1Y
PM
I 1 (
8)
MH
-60S PM
I 1N
( 2
4)
UH
-1N
PM
I 1N
( 8
)
MH
-60R PM
I 1N
( 1
)
UH
-1N
PM
I 2N
( 1
)
MH
-60S PM
I 2N
( 1
1)
MH
-60R PM
I 2N
( 2
)
FA-1
8D
PM
I 2M
( 2
)
FA-1
8C PM
I 2M
( 3
)
SH
-60B PM
I 1N
( 7
)
SH
-60B PM
I 2N
( 3
)
FA-1
8D
PM
I 1 (
3)
FA-1
8A PM
I 1 (
4)
FA-1
8C PM
I 1 (
12)
AV-8
B PM
I 1 (
6)
FA-1
8D
PM
I 1M
( 7
)
FA-1
8C PM
I 1M
( 1
0)
CH
-53E PM
I D
( 2
5)
MH
-53E
PM
I D
( 5
)
E-2
C PM
I 2 (
2)
E-2
C P
MI 2H
( 2
)
P-3
C PM
I 1 (
4)
C-2
A PM
I 3 (
4)
P-3
C
PM
I 2 (
2)
EA-6
B PM
I 1 (
2)
FRC-CHP/JAX/NIS Airframe Events by Workload Standard
$.108M avg
1,322 avg mhrs
$.278M avg
3,688 avg mhrs
$.50M avg
5,703 avg mhrs
$1.33M avg
9,002 avg mhrs
$1.44M avg
11,092 avg mhrs
$1.22M avg
13,717 avg mhrs
$6.4M avg
19,554 avg mhrs
$3.1M avg
21,821 avg mhrs
$4.2M avg
27,652 avg mhrs
Work
load S
tandard
-
H
ours
Unit
Cost
per
Event
Determining which TMS
can take risk may cause
large shifts in
cost or backlog
DLHs
Cost
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UNCLASSIFED
Understanding Funding Shortfall Impact?
• Developing new thinking on how to take and reflect
risk when funding is constrained
• Currently report unfunded depot workload as a function of number of
airframes and engines not funded (backlog)
• Backlog is an easier understood metric for those outside the
maintenance community
• A Direct Labor Hours (DLHs) metric would be more reflective of depot
production risk but not tied to readiness impact
• New modeling efforts are being developed to better link
aircraft production to readiness demand • Will link necessary production to future inventory demands necessary to
meet readiness goals
• Will emphasize meeting Flight Line Entitlement required for tiered
readiness
9
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UNCLASSIFED
Conclusions
• Requirements process is well defined and uses
accredited pricing models to balance funding risk
• Planned Maintenance Intervals with Fixed Period End
Dates has been an effective tool to establish and
manage depot requirements
• Next evolution of modeling fidelity will add stronger
tie to future demand to show impact if funding is
constrained
10
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UNCLASSIFED
Questions?
11
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UNCLASSIFED
Backup Slides
12
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Backlog – 500K DLH Combinations
| Brief Title Slide 13
0
20
40
60
80
100
120
140
160
180
200
1.3K 3.7K 5.7K 9.0K 11.0K 13.7K 20K
Manhours
(K
)
ManHours per Unit
500K Manhours Lines
55 19
12
8 7
5
3
150
units
2
33
4
2 1
1
69
110
30
16
7
4
83
25
13 22
18
4
6
4
33 Units *3.7K manhours/unit
Example
150 @ 1.3K = 195K
33 @ 3.7K = 122K
16 @ 5.7K = 91K
4 @9.0K = 36K
2 @11.0K = 22K
1 @13.7K = 14K
1 @20.0K = 20K
= ~500K manhours
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Flightline Entitlement Aircraft for a
representative 12 aircraft squadron
32 month Deployment Cycle
Maintenance Basic Intermediate Sustain Deploy Sustain
R+1 R+2 R+3 R+4 R+5 R+6 R+7 R+8 R+9 R+10 R+11 R+12 R+13 R+14 R+15 POM PDL R+24 R+25 R+26 R+27 D+1 D+2 D+3 D+4 D+5 D+6
Navy Flight Line Entitlement Total FLETMS = Navy Tac Air by FRTP Phase+ Training and Support PAA
3 2 1
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Basic Integrated Deployment Sustain Sustain Maintenance
CDR Pete Morrison, OPNAV N32 FHP RO