Fleet Readiness Center Southwest - SAE · PDF fileFleet Readiness Center Southwest ... FRC...
Transcript of Fleet Readiness Center Southwest - SAE · PDF fileFleet Readiness Center Southwest ... FRC...
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
MFG
Pro
. Con
t.M
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Tech
Lib
rary
QA
Mat
eria
ls L
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E n g in e e r in gR e s e a r c h e s t h e
F a i lu r e
E n g in e e r in gP ro v id e s
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 >
10.0
MFG
Pro
. Con
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Lib
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QA
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eria
ls L
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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
MFG
Pro
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t.M
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lann
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Tec
h Li
brar
yQ
AM
ater
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Lab
Engi
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FIS
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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
ab10
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FG P
ro. C
ont.
MFG
Pla
nnin
gTe
ch L
ibra
ryEn
gine
erin
gFI
SCAi
rcra
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ne
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
ab10
.0M
FG P
ro. C
ont.
MFG
Pla
nnin
gTe
ch 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
Mat
eria
ls L
ab10
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FG P
ro. C
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MFG
Pla
nnin
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P re p are a3R for
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
P rod u c esH a rd C o py
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>
QA
Mat
eria
ls L
ab10
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FG P
ro. C
ont.
FISC
Engi
neer
ing
Tech
Lib
rary
MFG
Pla
nnin
gAi
rcra
ft Li
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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