maintenance technology strategy - navy metalworking center

Maintenance Technology StrategyCh i A t Ch i T tiChanging Assets – Changing Tactics

“If you want truly to understand something,y y g,try to change it”

Kurt Lewin

Todd Mellon, NAVAIRDirector Industrial and LogisticsDirector, Industrial and LogisticsMaintenance Planning/Sustainment Department30-31 January 2008

Supportability AnalysisDevelopment Technology

ICDTDS Continuous Supportability Analysis

Conduct R&M AnalysisUpdate Use Study

Select dependent variable to be optimized. Only one can be optimized at a time.

SystemAnalysis &

ControlRequirements

Analysis

Establish S&I ApproachesDevelop BCSNew TechnologyS Requirements

Conduct System Level

LORRCMTOCAo

S Analysis PlanMaintenance Planning ReviewsS T&E

FunctionalAnalysis

Maintenance ConceptCDD

yFMEA and RCM Analyses

S T&E

SynthesisSRR, IBR

Maintenance ConceptOperational requirementsR&MPMCMO&S Costs

FRPDecision

User Needs & Technology Opportunities

Logistics support resourcesAo

Concept Refinement

ConceptDecision

TechnologyDevelopment System Development

& Demonstration

ReadinessReview

Production &Deployment

LRIP/IOT&EDecisionReview

Operations &Support

A B C IOC FOC

Pre-Systems Acquisition Systems Acquisition Sustainment

Complexities Of The Logistics Support SystemLogistics Support System

n / Scenario Planning

l Asset & CM Visibility

Force Planning

ms Health Monitoring

CBM+ / Prognostics

/ Resource Optimization

n / Scenario Planning

l Asset & CM Visibility

Force Planning

ms Health Monitoring

CBM+ / Prognostics

/ Resource Optimization

Source & Develop

Support Pan & Product Baseline

FieldingProcurement

ACQUISITIONACQUISITION• New Rqmts

• Change R t

• End-Item Perf Param

• Acq Strat• Progam $

• Funct / Alloc Baseline

• Maint Plan• Approved

Config

• As-built Config• End-Items• Support

Resources

Planning & Budgeting

TYCOM

WING

Mission / Total As Fo

AIR

Systems CBM

Activity / Re

Source & Develop


FieldingProcurement


• Change R t





Config


Resources


Source & Develop


FieldingProcurement


• Change R t





Config


Resources


Source & DevelopSource & Develop



FieldingFieldingProcurementProcurement


• Change R t





Config


Resources

Planning & BudgetingPlanning & Budgeting

TYCOM

WING

Mission / Total As Fo

AIR

Systems CBM

Activity / Re

Operational Requirements

Planning

Deploy & Operate

Ops Data

Avail Equip

• Non RFI Equip• RFI Equip

• Non-RFI EquipM t i l

• RFI Equip• Material Orders

C

FLEET MAINTENANCEFLEET MAINTENANCE FLEET OPERATIONSFLEET OPERATIONS

Rqmts • Progam $ g• Pedigree Info

• End-Items & Support Resources• Returning

Assets

• End-Items• Support

ResourcesO-Level

Maintenance Management

I-level Maintenance Management • Op Plan

• Emerging Rqmts• Training Rqmts Template Other Services

NAVAIR


Planning

Deploy & Operate

Ops Data

Avail Equip




C




Assets


ResourcesO-Level



• Emerging Rqmts• Training Rqmts Template


Planning

Deploy & Operate

Ops Data

Avail Equip




C




Assets


ResourcesO-Level



• Emerging Rqmts• Training Rqmts Template


Planning


Planning

Deploy & OperateDeploy & Operate

Ops Data

Avail Equip




C




Assets


ResourcesO-Level


O-Level Maintenance Management

I-level Maintenance Management


• Emerging Rqmts• Training Rqmts Template Other Services

NAVAIR

Resource Allocation

• Non-RFI Equip• Material Orders

RFI Equip• Consumables

• Direct Induct (critical & PBLs)

• Material Orders

• BCM items

• Allowances• Filled Orders

• FMC A/C, Engines, SE

• A/C, Engines, SE for depot maint / mod

• BCMed Component

• A/C, Engine, SE depot Rqmt

Allowancing

Local Supply Management

In-Service Support

• Support Resource Adjustment

• Support R

Depot Workload

• Supply Rqmts OPNAV

CINC

Resource Allocation




• Material Orders

• BCM items




• BCMed Component


Allowancing


In-Service Support


• Support R

Depot Workload

• Supply Rqmts

Resource Allocation




• Material Orders

• BCM items




• BCMed Component


Allowancing


In-Service Support


• Support R

Depot Workload

• Supply Rqmts

Resource AllocationResource Allocation




• Material Orders

• BCM items




• BCMed Component


AllowancingAllowancing

Local Supply ManagementLocal Supply Management

In-Service Support

In-Service Support


• Support R

Depot Workload

Depot Workload

• Supply Rqmts OPNAV

CINC

DLA Depot Local Depot Supply

DLA

• Material Orders

• Demand/ TAT Data

Component

• BCMed• Comp

• BCMed Component

• BCMed Comp• Retrograde Rqst

• RFI Comp• RFI Comp

BCMedComp

• Schedule / Funded Rqmts

• Prod Lead-time• Est Del Date

ATAC Hub

Wholesale Supply

Management

Organic Depot Maintenance

Interservice Depot Maint

Commercial Depot Maint

ININ--SERVICESERVICESUPPORTSUPPORT

Resource Adjustment

Workload Management

• Consumables Order

NAVSUP

DLA


DLA

• Material Orders


Component

• BCMed• Comp

• BCMed Component



BCMedComp



ATAC Hub

Wholesale Supply

Management





Resource Adjustment

Workload Management



DLA

• Material Orders


Component

• BCMed• Comp

• BCMed Component



BCMedComp



ATAC Hub

Wholesale Supply

Management





Resource Adjustment

Workload Management


DLA DepotDLA Depot Local Depot Supply

Local Depot Supply

DLADLA

• Material Orders


Component

• BCMed• Comp

• BCMed Component



BCMedComp



ATAC HubATAC Hub

Wholesale Supply

Management

Wholesale Supply

Management





Interservice Depot MaintInterservice Depot Maint

Commercial Depot MaintCommercial Depot Maint


Resource Adjustment

Workload Management

Workload Management


NAVSUP

DLADLA

WholesaleManagement

• Component Repair Schedule/Contract

WHOLESALE SUPPLY & TRANSPORTATIONWHOLESALE SUPPLY & TRANSPORTATION DEPOT MAINTENANCEDEPOT MAINTENANCE

• Order Fulfillment (Consumables)

• Material Orders• Filled Orders

OrderDLA Wholesale

Management• Component Repair

Schedule/Contract




OrderDLA Wholesale


Schedule/Contract




OrderDLA Wholesale

Management

DLA Wholesale


Schedule/Contract




Order

Complexities Of The Logistics Support SystemLogistics Support System

Source & Develop


FieldingProcurement


• Change Rqmts





Config


Resources• Pedigree Info


Source & Develop


FieldingProcurement


• Change Rqmts





Config




Source & DevelopSource & Develop



FieldingFieldingProcurementProcurement


• Change Rqmts





Config



Planning & BudgetingPlanning & Budgeting

Rqmts g $ • Pedigree InfoRqmts g $ • Pedigree InfoRqmts g $ • Pedigree Info

IOCBA

Technology Development

System Development& Demonstration

Production & Deployment

C

FRPDesign

IOCBBAA

Technology Development

System Development& Demonstration

Production & Deployment

CC

FRPDesign FRP DecisionReview

LRIP/IOT&EDesignReadiness Review

ConceptDecision

Systems Acquisition

FRP DecisionReview

LRIP/IOT&EDesignReadiness Review

Pre Systems Acquisition

ConceptDecision

Maintenance Planning

Supply SupportSupport Equipment

Manpower and Personnel Training and Training Support

Technical Data Computer Resources Support


Manpower and Personnel Training and Training Support

Technical Data Computer Resources Support

LOGISTICSSUPPORTSYSTEM

MissionSurge

Logistics Package

Mission FocusedLogistics Package

PHS&T FacilitiesPHS&T Facilities

Design Interface

CoreLogistics Package

Integrating Capabilities

Current to Current

Integrating…Three dimensions - “Future Systems cascading effect”

• Fill capability gaps in current operations

• Apply lessons learned

Future to Current

• Spiral forward selected • Create modular, capabilities-based unit designs

capabilities from Future Systems into the Current Force

Current ForceCurrent Force Future ForceFuture Force

Current to Future

• Push proven, good ideas from Current Force into Future Force

Spiraling Future Capabilities To The Current ForceTo The Current Force

EnablingRapid Prototyping

Lessons Learned

EnablingJoint Experimentation

Assess

Relevant & ReadyT d

Science and Technology Prioritize

ResourceFuture System

TodayReady Future Force CapabilitiesNavy Focus Areas

Logistics Support System AnalysisAnalysis

• LORA• RCM• FMECA• MTA

* Maintenance Planning


DepotI-Level

O-Level• Skills• Manning Levels• Knowledge

* Manpower Training

Logistics Support System

epog

Technical DocumentationComputing Support

PHS&TFacilities

Design Interface

Continuous Supportability Analysis

*Note: Specific Logistics Element Examples

Today

Ready For Tasking

60

80100

120

Ready For Tasking (RFT)

Today

V-22

506070

Ready For Tasking (RFT)0

2040

60

J F M A M J J A S O N D J F M A M J

2-5 Yrs H-53K

010203040

J F M A M J J A S O N D J F M A M J253035

Ready For Tasking (RFT)

J J J S O J J

10-15 Yrs(1) Maintenance Execution

(2) New A/C

05

10152025

(1) DevelopmentalPrograms

+


(1) Science & Technology (S&T)Operating Environment

BAMSUAV’s

Challenges

• CorrosionSt t l F ti• Structural Fatigue

• Maintenance Repair Data (Material condition assessment))

• Push/Pull Maintenance Capability• Operational Environment (Deployed/non-deployed)

D t M i t (S h d l /C t)• Depot Maintenance (Schedule/Cost)• Material Obsolescence

BACK-UP SLIDES

Agenda

• Supportability Analysis (Technology Development)pp y y ( gy p )• Complexities of the Logistics Support • Integrating System Capabilities

S i li C biliti F d• Spiraling Capabilities Forward• Logistic Support System Analysis• RFTRFT • Challenges

80100

120

10

15

0

2040

60

80

B

5

0

5

J F M A M J J A S O

N D J F M A M J

0J F M A M J J A S O N D J F M A M J

Ready For Tasking (RFT)Overall M-Rating Accomplishment

-10

-5

40

50

60Total Cost

200,000,000

250,000,000

300,000,000

ACTUAL80

100

120% DNEC

10

20

30

50,000,000

100,000,000

150,000,000

ACTUAL

PLAN

20

40

60

0J F M A M J J A S O N D J F M A M J

Total Cost

0Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov 0


MAINT M-HR / FLT HRTRAINED MANPOWER PERDNEC / MOS

S t bilit A l i C t l M d l

System

Supportability Analysis Conceptual Model(In Plain English)

Requirements Analysis

Requirements analysis is used to develop functional and performance requirements; that is, Fleet

• Customer Needs• Requirements

Technology Input1

1

4

SystemAnalysis &

ControlRequirements

Analysis

Evaluate alternative Hows

Choose preferred

ID Product Support for operationalenvironment. Similar systems usedto:

1. Avoid past mistakes

q ; ,requirements are translated into a set of capabilities that define what the system must do and how well it must perform..

Functional AnalysisAnalyze all the functions that the system being designed must perform.

2

2

FunctionalAnalysis

What must be done

Not h t d it

Choose preferredalternative2. Substitute for data not available

3. Model Product Support

y g g pAnalysis means to break down the events into their component parts or functions. When this is established.

SynthesisSynthesize support system alternatives. Synthesis means to combine, to unify, to assemble into a

3

2

Synthesis

Not how to do it

Develop alternativeapproaches

ywhole. functional requirement.

System Analysis & ControlAlternative solutions to the functional requirements are subjected to Tradeoff Analyses to determine which best meets the performance requirements within established

4

3

FRPDecision


approaches

How to satisfy required functions

Product Support

qconstraints.

Concept Refinement

ConceptDecision


& Demonstration

ReadinessReview



Operations &Support

A B C IOC FOC

Pre-Systems Acquisition Systems Acquisition SustainmentContinuous Supportability Analysis


Perform R&M Analysis and FMEA

Perform Preventive Perform CorrectiveFunctionalAnalysis

Maintenance Analysis Maintenance Analysis

Trade OffAnalysis

Perform Task, Skills, and Time LineAnalysis

Perform LOR Analysis

Task Analysis

Update SConstraints and Requirements

Update Preliminary Maintenance Plan

S T&E

Task Analysis

IdentifyProduct Support

Test, Evaluate, and Verify S

Publish Maintenance Plan

FRPDecision


Concept Refinement

ConceptDecision


& Demonstration

ReadinessReview



Operations &Support

A B C IOC FOC

Pre-Systems Acquisition Systems Acquisition SustainmentContinuous Supportability Analysis

Supportability Analysis(Why is it important?)

The early focus of Supportability Analysis results in establishing support parameters and ifi ti i t A t d i S t bilit A l i dd

(Why is it important?)

specification requirements. As system design progresses, Supportability Analysis addresses supportability requirements and provides a means to perform tradeoffs among these requirements and the system design.

• Supportability Analysis is conducted within the framework of the Systems Engineering process.

– A primary objective of the acquisition process is to find cost effective ways of achieving readiness, commonly measured in terms of Operational Availability (Ao).

– A supportable weapon system design must be established and logistics must be planned, acquired, and sustained.

– Supportability Analysis is the most important logistics activity.

– It establishes performance requirements upon which logistics required to achieve and sustain system readiness is based.

• Supportability Analysis is a composite of the analyses required to assess design in relationship to logistics and development of logisticsrelationship to logistics and development of logistics.

• This process provides the basis for producing analytically developed Maintenance Plans and procedures, communicating requirements and constraints to system developers, and retaining an audit trail from strategy formulation to item production.

Systems Engineering System Operational Effectiveness Framework

1User Needs/Technology Opportunities

LifetimeSupport

Continuous Assessment and Improvement

Design Influence Product SupportDevelopment andMaintenance Concept

Design Interface/Maintenance Planning provides the primary integration between logistics and engineering through Systems

1

1

2

3

4

Overarching PolicyNSS/NMS/Joint vision

Joint Concept of OperationsConcept RefinementTechnology Development

FunctionalANALYSIS

Functional Flow/DATA FlowDIAGRAMS Failure Mode,

Effects, and

MaintainabilityAnalysis

Level of Repair

MaintainabilityPrediction

Reliability-Centered

MaintenanceTask Analysis

HaveRequirementsBeen Met?

Design Reviewsand Evaluation

DetailedSupport

YesSystem Test& evaluation Sustaining

SYSTEM

EvaluationTech.RefreshmentFleetFeedback

Deploymentthrough Systems Engineering.

Maintenance Planning incorporates both engineering and logistics analyses to develop plans and products for the

2

DOT Analysis ofM t i l

FunctionalArea

Analysis

Functional AreaFunctional Concept

Integrated Architecture

Joint Concept of Operations

Allocation ofSystemResources

SystemArchitecture/Selection of SystemElements

System Reliability R li bilit

Fault TreeAnalysis (FTA)

Criticality Analysis(FMECA)

Maintenance(RCM)

Task Analysis(MTA)

RequirementsFor The:

Been Met?Support Test/Evaluation

Product List

No

(Hot BedTesting)

SYSTEMSupport

System/Product Support Package• Supply Support (Spare/Repair Parts)• Maintenance Planning• Test/Support Equipment• Technical Documentation/IETM• Manpower/Personnel

and products for the weapon system Maintenance process.

Communicating maintenance requirements and constraints, and retaining an audit trail from

3

MLPF

Analysis of Materiel

Approaches

- Materiel -Process

DOTLPFProcess

Joint Capabilities Integration

Development

ICD

y yAnalysis, Modeling,and Allocation

ReliabilityPrediction

System Redesign/Improvement

• Training/CBT• Facilities; PHS&T• Design Interface; Computing Support

Cost as an Independent Variable (CAIV): Design to Affordability Analysis (Strategic Decision Making)

retaining an audit trail from strategy formulation to item production and in-servicesupport.

4 Continuous Supportability Analysis

JROCJROCDevelopment

System (JCIDS)

TechnologyRefreshment

Technology/Standards Evolution and COTS Products Market Surveillance and on-going technology, Assessment, DMS and MS

FRPUser Needs & Technology Opportunities

Concept Refinement

ConceptDecision


& Demonstration

ReadinessReview



Operations &Support

A B C IOC FOC


Maintenance Planning/Supportability Analysis

MaintainabilityReliability R&M A l iMaintainabilityAnalysis

ReliabilityAnalysis

Failure Analysis(via FMEA)


R&M Analysis

FMECARCM Logic

TaskAnalysis

MaintenanceLevel Assignment

CorrectiveMaintenance

Task Analysis

PreventiveMaintenance

Task Analysis

People, Parts, Pubs, Tools, Test Equipment, Facilities,Computer Resources, PHS&T Supportability

Analyses1Failure Modes, Effects, and Criticality Analysis (FMECA) is a Systems Engineering task required for Maintenance Planning.

Concept

ConceptDecision

Development System Development

ReadinessReview

Production &

LRIP/IOT&E

FRPDecisionReview

Operations &A B C IOC FOC


Concept Refinement Technology

Development System Development& Demonstration


Operations &Support

Pre-Systems Acquisition Systems Acquisition SustainmentContinuous

Supportability Analysis

Supportability AnalysisConcept Refinement

Functional Area AnalysisFunctional Needs AnalysisFunctional Solution Analysis

ICD

System


LORRCMTOC

Conduct Use Study• FEA• TRPPM

SystemAnalysis &

ControlRequirements

Analysis

AoA PlanAo

Maintenance Planning Strategy

Determine S , $, Aoo

, Manpower DriversM i t C t

FunctionalAnalysis

Conduct Comparative Analysis

Maintenance Concept

SynthesisITR, ASR

TDSMaintenance Concept

Use Case Scenario = Use Study + Comparative Analysis


Concept Refinement

ConceptDecision


& Demonstration

ReadinessReview



Operations &Support

A B C IOC FOC


Supportability AnalysisSystem Integration

CDDContinuous Supportability Analysis

SystemAnalysis &

ControlRequirements

AnalysisMaintenance ConceptOperational requirements

Select dependent variable to be optimized. Only one can be optimized at a time.

FunctionalAnalysis

Operational requirementsR&MPMCM

O&S CostsLogistics ResourcesS Constraints

y pLORRCMTOCAo

S Analysis PlanMaintenance Planning Reviews

Conduct Initial Task AnalysisALSPPreliminaryMaintenance Plan

FMEA R&M Analysis RCM AnalysisPM CM Servicing Calibration

SynthesisSFR, FBL, PDR, CDR

S T&E Conduct Subsystem Level

FBL, ECP

PBLAnalyze Progressive MaintenanceBIT/BITEATEO-DDiscardCLSPHMAutonomic Logistics


Concept Refinement

ConceptDecision


& Demonstration

ReadinessReview


LRIP/IOT&E

FRPDecisionReview

Operations &Support

A B C IOC FOC


Supportability AnalysisProduction & Deployment

CPDMaintenance Plan

S t


Analyze

Preventive Maintenance RqmtsC ti M i t R t

Update Maintenance Plan

SystemAnalysis &

ControlRequirements

Analysis

Determine Product Support Functions All 10 ILS Elements

Corrective Maintenance RqmtsServicing, Calibration, IEM

pS Constraints and RequirementsTest, Evaluate, and Verify Product SupportConduct S T&EPublish Maintenance Plan

FunctionalAnalysis

Functions All 10 ILS Elements

A l P d t S t

SynthesisMaintenance PlanPBL, ECP

PRR, SVR, PCR, PCA, PBL, ECPR

Analyze Product Support


Concept Refinement

ConceptDecision


& Demonstration

ReadinessReview



Operations &Support

A B C IOC FOC


CPDMaintenance Plan Continuous Supportability Analysis

Supportability AnalysisOperations & Support

Maintenance Plan

SystemAnalysis &

C t lRequirements

A l i


Analyze• Source Data from• NALDA, NALCOMIS, 3M• Recommend

Interim Action

Select dependent variable to be optimized. • Only one can be optimized at a time.

• Select Appropriate Solution• Validate Appropriate Solution• Recommend Solution for Implementation

ControlAnalysis

Functional

Identify Potential Opportunities

A i 2 d/Alt t S

p• Document in Historical Record• FST Logistics Engineering Evaluation

Tool

FunctionalAnalysis

Develop Alternative Solutions• Acquire 2nd/Alternate Source• Acquire Material Substitutes

• Provide Tech Assist• Restrict Operations

• Issue Bulletin

Dispose: SARDIP, Strike, Material Review Board

Synthesis

• Change Configuration: ECP, RAMEC• Change: Maint Plan, IMP, SM&R Code, Rwk &

Process Specs, MRCs• Improve: Tech Data Mgt, Tech Data (IRAC, TPDR), Manpower

ITR, ASR, SRR, IBR, SFR, PDR, CDR, TRR,FRR, OTRR, SVR, PRR, PCR, ECPR

•

Improve: Tech Data Mgt, Tech Data (IRAC, TPDR), Manpower• Utilization, Training, SE Posture & Utilization, Trainer Posture &

Utiliz, Supply Mgt Procs, Maint Report Sys, A/C Inv Mgt, PHS&T


Concept Refinement

ConceptDecision


& Demonstration

ReadinessReview


LRIP/IOT&E

FRPDecisionReview

Operations &Support

A B C IOC FOC


maintenance technology strategy - navy metalworking center

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