2006 DOD Maintenance SymposiumReno, Nevada

Fleet Readiness Center Southwest

“Move Your Cheese Now!”Captain Fred Cleveland, USN

Commanding Officer

Who We Are---FRC Southwest

• Fix it once• Fix it right• Fix it on time

Alignment

Depot PrioritiesAlignment

Cycle-Time Reduction

Reliability

I2D Integration

Material Management

Reduce Cost of Doing Business

Depot PrioritiesAlignment

Cycle-Time Reduction

Reliability

I2D Integration

Material Management

Reduce Cost of Doing Business

Enterprise Alignment

Enterprise Alignment

Enterprise AlignmentFleet

SupportFleet

Support

NAE/NAVAIR GoalsBalance Current and Future ReadinessReduce the Cost of Doing BusinessEnhance AgilityImprove Alignment Implement Fleet-Driven Metrics

NAE/NAVAIR GoalsBalance Current and Future ReadinessReduce the Cost of Doing BusinessEnhance AgilityImprove Alignment Implement Fleet-Driven Metrics

CNO PrioritiesMission Accomplishment

Sustain Combat Readiness

Build a Fleet for the Future

Develop 21st Century Leaders

CNO PrioritiesMission Accomplishment

Sustain Combat Readiness

Build a Fleet for the Future

Develop 21st Century Leaders

Sec Nav PrioritiesOptimize the WorkforceProsecute the GWOTBuild the Navy-Marine Corps for TomorrowEmphasize Safety, Manage RiskReinforce EthicsLean/Six Sigma

Sec Nav PrioritiesOptimize the WorkforceProsecute the GWOTBuild the Navy-Marine Corps for TomorrowEmphasize Safety, Manage RiskReinforce EthicsLean/Six Sigma

Focus on InnovationThat amplifies by leveraging

aligned goals

What We’re Doing

Plan / Actual * Helo-line: (46) / (44) H-60 IMC aircraft

(59) / (59) H-1 IMC aircraft,(9) / (8) H53 IMC aircraft

* E-2/C-2: (9) / (7) E-2 aircraft(9) / (8) C-2 aircraft

* F/A-18: (53) / (47) PMI-1s (32) / (32) PMI-2s (13) / (11) Crash Damaged aircraft (13) / (7) CBR+ aircraft (3) / (3) "E/F" AEPD aircraft

* Field Service: (25) / (23) EA-6B IMC aircraft (6) / (6) AV-8 IMC aircraft

•Components: 39,159 / 34,279 Units3,813 / 3,460 PBL units3,591 / 3,000 DMISA units1,235 / 829 FMS units

28,164 / 24,990 FE units 154 / 126 4Z units

2,202 / 1,874 Concurrent units

* LM2500 Engines: (10) / (13)

* Mobile Facilities: (57) / (56)

* Calibration: (14,218) / (12,850) units

* Manufacturing: (1,822) / (1,644) items

Components (34,279) - 88%of FY2006 plan

Components (34,279) - 88%of FY2006 plan

Aircraft (247) - approx 94% of FY2006 plan

Aircraft (247) - approx 94% of FY2006 plan

FY-06 Production Results

Ensured Commander, Naval Air Forces “Ready

For Tasking” Aircraft Goals

X

Site Key West

WESTAIMD LEMOORE

NADEP NI Det Lemoore

Site FallonNADEP NI Det Fallon

Site Fort WorthAIMD Atlanta (FA-18 Support)

NAVAIRES Fort Worth

SOUTHWESTMALS-11 & 16 MiramarNADEP NI Det Miramar

AIMD North IslandNADEP North Island

NADEP North Island DET NI

Site PendletonMALS-39 Pendleton

NADEP NI Det Pendleton

Site Pt. MuguSite YumaMALS-13 YumaNADEP NI Det Yuma

NORTHWESTAIMD WHIDBEY ISLAND(Crane ALQ-99 workload)

Site New RiverMALS-26 & 29 New RiverNADEP CP Det New River

SOUTHEASTNADEP JACKSONVILLENADEP JAX Det Cecil FieldAIMD BrunswickAIMD JAX

Site MayportAIMD MayportNADEP JAX Det MayportNAWCAD LKE Det Mayport

Site BeaufortMALS-31 BeaufortNADEP JAX Det Beaufort

Site Patuxent River

Site N. OrleansAIMD Atlanta (E-2C Support)NAVAIRES New Orleans

MID ATLANTICAIMD OCEANA AIMD NorfolkAIMD NAS Corpus ChristiNADEP CP Det OceanaNADEP JAX Det NorfolkNADEP JAX Det OceanaNAWC Lakehurst Det Norfolk

EAST NADEP CHERRY POINT MALS-14 Cherry PointAIMD Willow GroveFRC East Det Lakehurst

FLEET READINESS CENTERS (FRC)THIS MONTH!

A MAJOR TRANSFORMATION IN DELIVERY OF AVIATION MAINTENANCE!

FRC SouthwestA Presence Far Beyond San Diego

FRCSW regularly supports 6 pacific fleet Aircraft Carriers while in-port or at sea. We also resource numerous long and short-term detachments at many sites around the country and the globe. The FRCSW

team provides immediate worldwide Warfighter support wherever and whenever needed!

NADEP North IslandKaneohe

Fallon

China Lake

NAPRA, Atsugi, Japan

Guam

Dallas

Patuxent River

Atlanta

Whidbey Island

Yuma

Lemoore

Pt Mugu

Camp PendletonMiramar

The Naval Aviation Enterprise. . .Transforming into Fleet Readiness Centers

Satellite

InventoryControlPoint

AIMD

DEPOT Satellite

Satellite

F R CAIMD

“I2D”

INTEGRATION –

More than just a “Hand Off”

COE: Jewelry StoreSatellite: Wal-Mart

DEPOT

On site Artisan skills allows for increased capability by leveraging infrastructure and

technology.

Facilitates positive upstream impacts that transcend the NAE

CenterOf

Excellence(COE)

Stovepipe processes

More “Move your cheese now!”

A Simple FRC Principle

Don’t Do Stupid Stuff!

Remove atsquadron

Order/Wrap

Pickup by ASD

UnwrapScreen at IMA

BCM at IMAPack/Wrap/Ship

At ASD

Stow/Unstowat DDDC

Detrash/Induct at DCondemn!

I2DFRC Planning

Lemoore• Radar BCM Interdiction Team

•Number to Date: 1 • APG-65 Pwr Supply Converter

Value to FHP: $4,601•RFTF Bench Round Robin: 1

•Composites, Hydraulic, Avionics Interdictions•Number to Date: 44

Value to FHP: $ 383,179

FY06 BCM Interdictions: up 41% from FY2005Value to Flying Hour Program: $10,433,021To date 344 items (51% more units)

Whidbey Island

Whidbey Island•Canopies, EA-6B Flight Controls, P-3 Components

•Number to Date: 188

Value to FHP; $7,462,727

Pt. Mugu• Finalizing BCM Analysis• 3-artisans planned for support

YUMA• Finalizing BCM Analysis

NORIS Petri Dish:•AirsSeed Plans in Final (Avionics)•BCA with Reserves week of June 6 •BCM Interdictions

•Number to Date: 51

Value to FHP: $159,597

MALS 11•Composites, Hyd, Avionics Interdictions

•Number to Date: 59

Value to FHP: $ 2,422,917

F/A-18 PMI 1TAT SOLD & INFLOW ACFT

050

100150200250300350400450

RJ28

RJ39

RJ42

RJ46

RJ49

RJ52

RJ56

RJ59

RJ62

RJ69

RJ74

RJ77

RJ80

RJ83

RJ86

RJ90

RJ93

Phase 2 Cut over-

F/A-18 HOURS Paid vs Actual

0

2,000

4,000

6,000

8,000

10,000

12,000

RH97RJ01 RJ07 RJ11 RJ14 RJ19 RJ22 RJ25 RJ28 RJ31 RJ34 RJ37 RJ40 RJ43 RJ46 RJ51 RJ54 RJ57 RJ60 RJ63 RJ68 RJ71 RJ75

Paid WLS HRs Actual Expended HRs

AIRSpeed/LEAN Success Stories

Phase 1 Cut over-

•Phase 1, Visual Synchronizationprovided reduction in costby 18 % down by 1744 man-hours

•Phase 2, Single Piece Flow reducing TAT by 33% to 120 Days

•Quality Reduction in MAF per man-hour down by 29% from first half of year

$1.9M in FY$1.9M in FY--06 AIRSpeed Labor 06 AIRSpeed Labor EfficienciesEfficiencies

E-2/C-2 - Single Piece Flow

52 ' 40 '

D IT M C O

E 2E & E

M E T A LE L E C T

C 2 S L E PM E TA L

E 2E & E

M E T A LE L E C T

C 2 S LE P K IT C A G E

8 5 ' 85 ' 85 ' 41 ' 4 1 ' 37 '

1 4 '

1 7 '

75 'E 2 A S S E M B L Y C 2 A S S E M B L YE 2 / C 2 D IS A S S E M B L YC 2 S LE P

E LE C T

C 2 S L E P E L E C TR IC A L B U IL D U P

C 2 S LE PM E TA L

Synchronized Pull system based on Fleet Flightline Requirement

< P ro c e s s N a m e >

10.0

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QA

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D is p o s it io n

P la n n in g R e c ie v e sE n g in e e r in gD is p o s it io n

M a t e r i a lD e t e r m in e dA c c e p t a b le

Accumulate All

Materials andTooling

Y E S

D e liv e ry o f t h eM a n u f a c t u r in g

P la n t o t h e S h o pF lo o r

P & E C re a t e s N e wW o rk O r d e r a n dB O M in M R P I I

NO

P & E F o r w a rd sN e w W o rk

O rd e r a n d B O Mt o F I S C

< P ro c e s s N a m e >

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Pro

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M a t e r ia lR e c e i v e d f ro mo u t s id e s o u rc e

B y F I S C

R e le a s e E n t ir eW o rk P a c k a g e T oP r o d u c t io n C o n t r o l

Accumulate

Materials and

Tooling

W o r k P a c k a g eR e c e i v e d b y

P ro d u c t io n C o n t ro lM a r e r ia l C u t /C o u p o n w i t h

E x c e s sre t u rn e d t o

F I S C I f G G / G F

R e q u ir e L a bT e s t ?

E x c e s sre c ie v e d b y

FISC

Y E S

C h e m ic a lT e s t

m a t e r ia ls

P a s sT e s t ( s ) ?

P r e p a r e Q V T R

I n f o r m e dt h a t

M a t e r ia lF a ils

I n f o rm e d t h a tM a t e r ia l F a ils

Accum

ulate All

Materials and

Tooling

Y E S

NO

R e w o rk L o o p i f M a t e r ia l is D e t e rm i n e d U n a c c e p t a b le

R e t u rn B O M t oP la n n i n g

A p p r o v e s A llM a t e r ia l C e rt s

Y E S

S t re n g t ht e s t f o r

m a t e r ia l s

NO

G e n e ra t e s / 3R e p o rt a n d

s e n d s t o P & E

I n f o r m e dt h a t M a t e r ia l

F a i ls

G e m e ra t e3 R t o s e e i ft h e F a ilu r e

isa c c e p t a b l e

E n g i n e e r in gR e c e i v e s 3 R

R e q u e s t

Aw

ait

Material

Receipt

M a t e r ia l &D o c u m e n t a t io n

A c c e p t a b le ?

NO

R e q u e s tV e n d e r P ro v i d e

R e p l a c e m e n tM a t e r i a l a n dC e r t i f i c a t io n s

M a t e r i a lA v a il. G G /

G F

NO

Aw

ait Material

Replenishm

ent

F I S C P u l lsA v a il a b l e

M a t e r ia l, I s s u e sB u lk C u t

R e q u e s t a llG G / G FM a t e r i a l

f ro m F I S C

Y E S

F ISCM o v e s i n

M R P I I

F o r w a r d A l lM a t e r i a l T o

C ut

S u b m it3R ?

Y E S

N O 3 R G e n e r a t e d

< P ro c e s s N a m e >

10.0

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F I S C r e c e iv e sW o r k O rd e r / B O M

f r o m P la n n in gL o g in b o o k

M a t e r ia lA v a ila b le G G /

GF ?NO

R e q u e s t C o s t &L e a d

C o m m e r c ia lC o s t o v e r $ 2 5 0 0 NO

I n p u tR e q u it it io n i n t o

M R P I I

P r o c u re V iaG o v t . P u rc h a s e

C a rd

G o v t C o n t r a c tin p la c e ?Y E S Y E S

P ro c u re m e n tM e t h o d

N A V C O M P T 2 2 7 6

NOP ro c u r e , F il e C o p y

a n d P ro v id e D o cN u m b e r a n d B O M

t o P la n n e r

Y E S

R e w o r k L o o p i f M a t e ria l L a b t e s t f a il u re

I n f o rm s P la n n in g o fA v a i la b il it y o n t h eB O M a n d s e n d s it

b a c k

M a t e r ia lA v a il a b le D L A / ?

Y E S

NO

< P ro c e s s N a m e >

QA

Mat

eria

ls L

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MFG

Pla

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P la n n e rP ic k s U pw o rk f ro m

Q u e u e

B a s e d o n "P ic k -U p " t h e jo b isa s s i g n e d t o a

P la n n e r a n d L o g e din t o M R P I I

P la n n e r P re p a re st h e W o rk O rd e r

w it h R o u t e r , a n yS u b -R o u t e rs ,

M a t e r ia l N e e d s a n dS e rv ic e s N e e d e d

I s it C S I b a s e d o nD o c u m e n t a t i o n ?

Y es

R e v ie w R o u g h D r a f to f W o rk O rd e r

P a c k a g e & P ro v id eC o m m e n t s

R e v ie w R o u g h D r a f to f W o rk O rd e r

P a c k a g e & P ro v id eC o m m e n t s

R e v ie w R o u g h D ra f to f W o r k O rd e r

P a c k a g e & P ro v id eC o m m e n t s

R e v is e W o rk O rd e rb a s e d o n f e e d b a c kf ro m Q A , M a t L a b

a n d F S T E n gF e e d b a c k

NO

R e v ie w F in a l W o rkO rd e r P a c k a g e f o r

A p p ro v a l

R e v ie w F in a l W o rkO rd e r P a c k a g e f o r

A p p ro v a l

R e v ie w F in a l W o r kO rd e r P a c k a g e f o r

A p p ro v a l

F o r w a rd e d B O M t oF ISC

C o l le c t iv e l yA p p ro v e d ?

Y E S

NO

Is N INA v a i la b l e ? Y es

D e v e lo p s B ill o fM a t e r ia l f o r R a w

S t o c k

R e q ie s t N I Nf ro m F I S CV ia M e m o

NO

R e c e i v e M e m of ro m P & E s

R e q u e s t in g N I N

C re a t e N I N &I n p u t I n t oD a t a b a s e

S e n d N I Nb a c k t o P & E

V i a M e m o

E n g in e e r in g R e v ie wB o a re R e v ie w s f o rF in a l A p p ro v a l a n d

S ig n a t u re o f P a c k a g e

< P ro c e s s N a m e >

QA

Mat

eria

ls L

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L o g - in t o L o gB o o k (H a rd

C o p y ) in B L D G4 7 2 P la n n in g

S c re e n e r S c re e n sTe c h D a t a P a c k a g e

f o r C o m p le t e n e s s

Te c h D a t aP a c k a g e

C o m p le t e ?

NO

Y E S

I d e n t i f ie sC a t e g o r ie s f o r

D a t a b a s e(C u s t o m e r, T ra d e ,C S I o r N o t , N e w o r

R e p e a t )

L o g in t oM R P I I b yS c re e n e r

C re a t e s S u p p o rtW o r k O rd e r

(S W O )

Aw

aitsPlanner Pickup In Trade

Queue

W o rk O r d e rm o v e d t o t o

Tr a d e Q u e u eF o r " F I F O "

P ic k u p

W o rk O rd e rJ O N A c t iv a t e d

in T A A

W o rk O r d e rJ O N A s s ig n e d

b y S c re e n e r

24 hr Delay

while

activating

W o rk O rd e r J O NE s t a b li s h e d a n dA c t iv a t e d in T A A

<P roc e ss Na m e >

QA

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En g in ee rin g

I s t h e Pa rtC SI

NO

Y E S

E n g in e e ringR e c eiv e s 3R

R e qu e s t

En g in ee rin gR e s e a rc h e s

t h e Pa rt

E ng in e erin gPro v ide s

D is p o s it io n

L o c al M f gD e c is io nNO

Y E S Pre p a re42 3 5 / 10

Y es

NO

C o m m e rc ialMf g

As s e m b le sTe c h D a t aPa c k ag e

D ra win g sA v a ila b le inJ E D MI C S ?

Y E S

NO

R e c e iv e sR e q ue s t t o

As s e m b le Tec hD a t a Pa c k ag e As s e m b le s H a rd

C o p y D ra win g sf o r Te c h D a t a

P ac k a g e

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D ra win g s f o rFISC

A s s e m bleTe c h D a taP ac k a g e/A t ta c h t o4 23 5 / 1 0

BatchD

elivery toM

FGPlanning inBLD

G 472

N O (I nc . Tec h D at a )

E n g ine e rD e t e rm in e s

C rit ic a lC ha ra c te r is t ic s

< P ro ce s s N am e>

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Tech

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E & E I de n t if iesN e e d f or A irc ra f t

Pa rt

E& E R e c e iv esA p p ro v a l f rom

S u p erv is o r

E &E S e nd sM a t er ia l R eq u e s t

( t e ar d o wn a n dd is p o s it io n ) t o F I SC

in M R P I I

F I S C A c c e pt sMa t e r ial R e q ue s t

F I S C R e s e a rc h e sP ro c ure m e nt

M et h o d

L o c al M f gD ec is io n

N SN /C o m m e rc ial

Mf g

NO

Y E S

F I S C C h e c k s f orC S I D e t e rm in a t ion

in C M ProD a t a b as e

Is C S ID e t e rm in a t io n in

C M P ro

N

Y

NEED AIRCRAFT

PART

MFG PLAN TO ARTISAN

ENG CSI Determination

4.3 Green BeltJeff King

CT reduction from 13 days to 2 daysSavings in Prod

Overhead Man Hrs Negotiated

MFG Plan ENG Approval

4.3 Green BeltDick Hogan

Ct Reduction from 17 days to 3 daysSavings in Prod

Overhead Man hrs Negotiated

ENG Chemical and Strength Test for

Mfg Materials4.9 Green BeltKen LaVere

Ct Reduction from xx days to 2 days

Savings in Prod Overhead Man Hrs

Pilot Complete Pilot Complete –– Replication on FReplication on F--18, Implementation on all E18, Implementation on all E--2/C2/C--22

Eng/Log Support

6.0 Process

Local Mfg Request Devel.

NAVSUP GBLCDR Ken

FlahertyCT reduction from 16 days to 4 days with Savings in

Transaction fees

ID & Approve Needed AC Part

E2/C2 6.0 GBDenise Brent

Ct Reduction from 5 days to 1 day with

Savings in Prod work/hrs

MFG Planning Process / Approval

MFG 6.0 GBJB Thurmond JR

CT Reduction from 8 days to 3 days with Savings in

Man Hrs/Wk Years

Procurement of Materials/Tools

NAVSUP GBLCDR Ken

Flaherty reduction from 8 to 4 days with Savings in

Transaction fees

Forwarding and Accumulation

MFG 6.0 GB John Rubio

CT reduction from 18 days to 4 days with Savings in

Man Hrs

Tech Data Package Assembly

6.8 Green Belt Rebecca Buchta

CT Reduction from XX days to <1 DayEliminate ReworkReduction in Man

hrs/yrs

E-2/C-2 Local Mfg BB Project Touches All Areas of NAVAIR NI

MFG Planning Before and After Lean/Six Sigma

300250200150100500

USLProcess Data

Sample N 777Location 3.37588Scale 0.754739

LSL *Target *USL 15Sample Mean 39.1158

Overall CapabilityZ.Bench -0.88Z.LSL *Z.USL -0.17Ppk -0.06

Observed PerformancePPM < LSL *PPM > USL 801802PPM Total 801802

Exp. Overall PerformancePPM < LSL *PPM > USL 811880PPM Total 811880

Process Capability of 13-0 from ID to ArtisanCalculations Based on Lognormal Distribution Model

37.530.022.515.07.50.0

USLProcess Data

Sample N 36Location 1.90643Scale 0.39403

LSL *Target *USL 15.00000Sample Mean 8.47222

Overall CapabilityZ.Bench 1.20Z.LSL *Z.USL 0.29Ppk 0.10

Observed PerformancePPM < LSL *PPM > USL 194444PPM Total 194444

Exp. Overall PerformancePPM < LSL *PPM > USL 115637PPM Total 115637

Process Capability of From E&E to ArtisanCalculations Based on Loglogistic Distribution Model

Before Lean/Six Sigma –Process was 20% capable of

Meeting 15 Day TAT

After Lean/Six Sigma –Process Is 80% Capable of

meeting 15 Day TAT

FY-06 AIRSpeed Yield Summary

Aircraft Lines

• F-18 PMI-1

• H-1

• E-2/C-2

• CH-53

Manufacturing

Components

Labor Hours Flightline Inventory/Cycle Time

Down 20% - $1.9M Execution At or Above Entitlement

Down 10% 1.8M FY-07 WLS Reductions

WIP Reduction8 AH-1W ($8M Inv)

C-2 SLEP APN-5 Reductions 2K Hours Re-wire, 1.5K Hours

SLEP

C-2 @ F/L (Adding Re-wire for 30 Days C/T)

E-2 Gap Driven by Mods

At WLS Was over 300 days, delivered last aircraft at 218 days, driving

towards 175 days over next three aircraft w/Current Staffing

50% Reduction in Sheet Metal Cycle Time

$10.4M Repair Interdiction Savings

E2/C2 PMI-2/PMI-3 SLEP Lean Effort

F/A-18 PMI-1/CBR+Lean Effort

CH-53, H-1, H-60Lean Effort

Business Unit Material Ordering Projects

FISC Lean 6 Sigma

E2/C2 Manufacturing BB Project

BOM Improvement Projects

ComponentsLean Effort

ManufacturingLean Effort

F/A-18 Manufacturing BB Project

Product Axis

Process Axis

= Lean/Six Sigma Project

= Product Line Lean EffortConnect the dotsin the value chain!!

Focus for Innovation

• Weak Signal Management• Industrial Information Technologies• Accelerated Supply Chain• Coherent Human Capital• Relevant Technology

Fleet Readiness Center Southwest

A National asset, providing flexible, responsive, integrated maintenance solutions and cost-wise readiness to our nation’s Warfighters

FRCSW

Strategically Positioned to Support our Navy and USMC Warfighter's

CNAF/COMFRC