Lean Six Sigma A Methodology for Cultural Change and Continuous Process Improvement (CPI)
Next Generation Continuous Process Improvement (CPI)
Transcript of Next Generation Continuous Process Improvement (CPI)
Next Generation Continuous Process Improvement
(CPI) A Breakout Session @ DoD Maint Symposium
Stu Paul Deputy, Aviation Fleet Readiness Branch of OPNAV N43
8-9:30 Tuesday 13Nov2012
FRC WESTPAC
NAF ATSUGI
Det Guam
Det Okinawa
Det Singapore
Det Korea
Det Iwakuni
FRC SEFAC
SOLOMONS
Naval Aviation Fleet Readiness Centers
FRC SOUTHWEST
NORTH ISLAND
SEAOPDET
Det Point Mugu
SEAOPDET
Det NAVCAL Lab
Futenma
Det NAVCAL Lab
Iwakuni
AFFILIATION WITH: MALS-39 Pendleton
MALS-13 Yuma
FRC WEST
LEMOORE
SEAOPDET Lemoore
Det Fallon
FRCSW Det
Det Fort Worth
Det China Lake
FRC SOUTHEAST
JACKSONVILLE
SEAOPDET
P-3 OPDET
Det Mayport
Det Key West
FRC NORTHWEST WHIDBEY ISLAND
ELU Det P3 OPDET SEAOPDET VANOPDET Det Everett FRCSW Det
FRC MID-ATLANTIC
OCEANA
SEAOPDET Oceana
Det Norfolk
SEAOPDET Norfolk
Det Pax River
Det New Orleans
Det NAF Washington
SEAOPDET Beaufort
FRCMA ACFT Dept
Voyage Repair Team
FRC EAST
CHERRY POINT Det McGuire
AFFLIATION WITH:
MALS-14 Cherry Point
MALS-26 & 29 New River
MALS-31 Beaufort
HMX-1 Quantico
MALS-49 Stewart
• 6,500+ Sailors & Marines
• 20 IMAs
• 6,000 Engine/Module/ Accessory Repairs
• 580,000 Component Repairs
• $2.0 Billion Operation Mission Funded
I-LEVEL • 11,500 Civilians
• 3 Depots + 1 GOCO Operation
• 1,500 Engine/ Module Repairs
• 70,000 Component Repairs
• 700 Aircraft Repairs
• $2.0 Billion Operation NWCF Funded
D-LEVEL
COMFRC HQ
PAX RIVER
Oct 2012
2
FRC NORTHWEST
AIRCRAFT (15) E/A-6B, E/A-18G, P-3 ENGINES (146) T56, J52 COMPONENTS (20,407) ALQ-99, E/A-6, canopies, components for above TMSs
FRC WEST
AIRCRAFT (31)
F/A-18 (PMI 2, AEPD),
E/A-18G
ENGINES (659)
F414, T56
COMPONENTS (28,690)
F/A-18 RADAR, composites,
components for above TMSs
FRC WESTPAC (Formerly NAPRA)
AIRCRAFT (30)
H-53, C-130, E/A-6B,
F/A-18, H-46, H-60, H-1
P-3, E-2, E/A-18G
FRC SOUTHWEST
AIRCRAFT (162)
F/A-18, E-2, C-2, H-1, H-60, AV-8 (PMI 2,3),
H-53 (PMID), (PMI 1N, 2N, PMI 2 Mods, P&E)
ENGINES (309)
LM2500, T700, T56
COMPONENTS (40,823)
Instruments, E-2 radar, composites, components
for above TMSs
FRC SOUTHEAST
AIRCRAFT (72)
E/A-6B (PMI 1, 2, 3, 4), P-3
(PH 1, 2, 3, SSI), F/A-18 (PMI
1, 2, 1M, 2M), H-60 (PMI 1N, 2N)
ENGINES (1280)
T56, J52, TF34, F414, T700, F404
COMPONENTS (50,956)
Electro-Optics, air refueling
stores, racks/launchers, components
for above TMSs
FRC EAST
AIRCRAFT (130)
AV-8B (PMI 1, 2, 3, 4, SWRK),
H-53 (AWI, SDML, PMID), H-1
(BSL, 1N, 2N, SDLM), EA-6B
(PMI 2, 3, 4), CH-46 (PMID,
SDLM, AWI)
ENGINES (144)
T58, F402, T64, T400, T56
COMPONENTS (26,395)
Dynamic components, rotor
blades, props, blades/vanes,
APU/GTC, components for
above TMSs as well as E-2
and P-3 props
MAINTENANCE LEVEL
D – DEPOT I – INTERMEDIATE
FRC MID-ATLANTIC
AIRCRAFT (85)
F/A-18 (PMI 2), E-2 (PMI 1),
C-2 (PMI 1, 2), H-53 (ISR),
H-60 (PMI 1N, 2N),
ENGINES (1,904)
F404, T56, T700, T64, T400
COMPONENTS (56,936)
F/A-18 Electro-Optics, Radar,
composites, E-2, C-2, H-60, H-1
C-130, EA-6B, Radar,
instruments, components for
above TMSs
VOYAGE REPAIR TEAM
Repair & Overhaul USN, USCG,
FMS air capable assets and
ALRE components
FRC Totals
Military: 6,293
Civilians: 9,349
Contractors: 2,314
Total Employees: 17,956
FRC Products (Last 12 Months)
FRC SEFAC
Repair, modification and overhaul of common and peculiar Support Equipment and Test Cells
Oct 2012 3
Maint Is Complicated and Interesting and possible to ‘BPR’ and ‘CPI’
4
Acft Inventory 2000-2019 Significant Intro of New T/M/S
DoN Aircraft Inventory Analysis
Aircraft Inventory for
T/M/S in Service
in FY00
Aircraft Inventory for
31 New T/M/S
since FY00
Inactive
107 107
101
96
92
9593
95
98
101103
101
98
93
90 90
85
81
78
107
0
500
1,000
1,500
2,000
2,500
3,000
3,500
4,000
4,500
2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019
To
tal
Air
cra
ft I
nve
nto
ry
0
10
20
30
40
50
60
70
80
90
100
110
120
# o
f T
yp
e/M
od
el/S
eri
es
107 T/M/S 78 T/M/S
4,055 A/C
410 A/C
1,901 A/C
2,053 A/C
5
Transition underway; NEPA/Basing decision complete
Projected transition timeline; NEPA and Basing decision required
PB12
07 08 09 10 11 12 13 14 15 16 17 18 19 20 22 23 24 25
EP-3A
FA-18C
P-3C
EA-6B EA-18G
BAMS UAS
P-8A
C-2A C-X ?
T-6AT-34C
Firescout
E-2C E-2D
EP-X ?
H-60B/F
F-35C JSF
MH-60R/S
FA-18E/F
T-45CT-39
EA-18G
F-14/18C FA18C
Naval Aviation Platform Introductions
6
Navy has a history of ‘CPI’ that causes ‘Cost Change’ with better ‘Readiness’ generation
10/17/11 Totals % ACTUAL TO:
$ K $
FY BRAC Plan FRC Projection ACTUAL BRAC Plan FRC Projection
COMFRC 07 $97,131 $94,833 $125,724 129.4% 132.6%
08 $164,367 $190,218 $208,484 126.8% 109.6%
09 $264,097 $287,324 $311,153 117.8% 108.3%
10 $311,231 $305,379 $326,835 105.0% 107.0%
Aug-11 11 $314,518 $347,837 $335,516 106.7% 96.5%
Completions FYDP $1,151,344 $1,225,592 $1,307,712 113.6% 106.7% F I N A L
MPN Interdiction Cost Avoidance AIRSpeed
$ K $ $ K $ $ K $
FY BRAC Plan FRC Projection ACTUAL FY BRAC Plan FRC Projection ACTUAL FY BRAC Plan FRC Projection ACTUAL
07 $3,395 $3,395 $3,395 07 $17,166 $25,505 $51,231 07 $65,617 $62,259 $62,259
08 $10,873 $10,873 $10,792 08 $60,999 $58,986 $82,290 08 $68,151 $97,302 $97,302
09 $16,549 $16,549 $16,549 09 $147,137 $59,055 $84,847 09 $68,730 $180,962 $185,239
10 $18,486 $18,486 $18,486 10 $202,905 $92,480 $129,802 10 $70,355 $175,079 $159,397
11 $19,135 $19,135 $19,135 11 $208,456 $127,056 $125,934 11 $72,147 $186,866 $175,498
FYDP $68,438 $68,438 $68,357 FYDP $636,662 $363,082 $474,104 FYDP $345,001 $702,469 $679,695
Source: FMB / N1 Source: NALCOMIS "Deckplate" Source: FCAP/CPIMS
Civilian Salary Supply ~ APN Base Oper. Support
$ K $ $ K $ $ K $
FY BRAC Plan FRC Projection ACTUAL FY BRAC Plan FRC Projection ACTUAL FY BRAC Plan FRC Projection ACTUAL
07 $7,280 $0 $5,165 07 $3,178 $3,178 $3,178 07 $496 $496 $496
08 $14,223 $12,936 $7,979 08 $9,021 $9,021 $9,021 08 $1,100 $1,100 $1,100
09 $16,309 $15,387 $9,146 09 $13,871 $13,871 $13,871 09 $1,501 $1,501 $1,501
10 $3,966 $3,814 $3,631 10 $13,939 $13,939 $13,939 10 $1,580 $1,580 $1,580
11 $449 $449 $618 11 $12,751 $12,751 $12,751 11 $1,580 $1,580 $1,580
FYDP $42,226 $32,586 $26,539 FYDP $52,760 $52,760 $52,760 FYDP $6,257 $6,257 $6,257
Source: NALCOMIS Deckplate / AIRSpeed workload
loss Source: FMB Source: CNI
MIL Personnel Actions CIV Personnel Actions CIV Personnel moves
FY BRAC Plan FRC Projection ACTUAL FY BRAC Plan FRC Projection ACTUAL FY BRAC Plan FRC Projection ACTUAL
07 -111 -111 -111 07 -108 -108 -83 07 87 58 50
08 -139 -139 -139 08 -211 -211 -125 08 67 44 24
09 -42 -42 -42 09 -236 -236 -134 09 0 0 26
10 0 0 0 10 -50 -50 -92 10 0 0 10
11 0 0 0 11 0 0 -124 11 0 0 0
FYDP -292 -292 -292 FYDP -605 -605 -557 FYDP 154 102 110
Source: FMB / N1
Source: NALCOMIS Deckplate
workload loss Source: TFM
Great, but what are you doing lately and
tomorrow?
$1.3B in past cost change carefully counted
7
Numerous new CPI ideas in-work
Maint Optimization Event Based Maint ARAT BCM-I (more of it) I-level AIRSpeed w/ FCAP
ILSMS Ideas in ‘Imagineering’ phase
8
Maintenance Optimization Initiative Goal
• Aggregate repair capability & demand to the most successful, high throughput Level 2 sites
– Minimize redundant Level 2 capability (some consolidations)
– Allow potential to draw down some sites to mostly Flight-Line Services
– Use repair hub allowances to replenish sites without repair capability
• No item enters the wholesale system (Level 3) without passing through a Level 2 site that has established repair capability
If Level 2 capability exists, no component goes BCM without going through a site that has capability
9
Candidate Example – F/A-18 APU
Level 2 Repair Cost $1K AFM
BCM Repair Cost $32K AVDLR
Does not include
manpower, repair or
shipping costs
Potential $2M ROI
*Under PBL contract. Navy is charged by each item processed.
10
Potential $3.8M ROI in 05A
Site Example - Jacksonville
FRC Mayport (Only 20 Miles Away)
FRC SE North Island has 100% RFI Rate
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NIIN
NIIN NIIN
NIIN
Work Center
Whole Site
NAS Fallon AT/FLIR W/C 610
Mitigation - Candidate Sequencing
Sequence 5
Sequence 4
Sequence 3
Sequence 1
Sequence 2
Sequence 5
Sequence 4
Sequence 3
Sequence 1
Sequence 2
No constraints – can be executed within 90 days
Simple constraints – can be executed within 180 days (SE, Allowance Relocation)
Moderate constraints – can be executed within 1 year (TRR Redux)
Difficult constraints – can be executed within 2 years (Manpower)
Extreme constraints – can be executed within 3 years (MILCON)
Candidate Sequencing
Ensures manpower, performance and
allowancing postures are fully capable prior
to implementation.
Candidate sequencing handbook available in Word
format.
12
NIINs: +615
Items: +1982 Man-Hours: +52924
NIINs: +273 Items: +518
Man-Hours: +14173
NIINs: +242
Items: +1439 Man-Hours: +13422
NIINs: +116 Items: +119
Man-Hours: +3100
NIINs: -15 Items: +2
Man-Hours: +2522
NIINs: +587
Items: +2250 Man-Hours: +38486
NIINs: +10 Items: +51
Man-Hours: +5041
NIINs: +643
Items: +2146 Man-Hours: +54570
NIINs: 0 Items: 0
Man-Hours: 0
NIINs: -185 Items: -343
Man-Hours: -762
NIINs: -81
Items: -110 Man-Hours: -748
NIINs: +477
Items: +1629 Man-Hours: +25218
Must take an ‘Enterprise’ view of the FRC’s Workload Net Changes (All Three Phases)
FRCSW PT Mugu
FRCSW North Island
FRCW Lemoore
FRCW Fallon
FRCNW Whidbey Is.
FRCSE Jacksonville
FRCMA Norfolk
FRCMA Oceana
FRCE M-D-L
FRCMA Pax River
NIINs: -15 Items: -27
Man-Hours: +77
FRCMA Washington
NIINs: -95 Items: -125
Man-Hours: -194
FRCW China Lake
NIINs: +38
Items: +402 Man-Hours: +2088
FRCW Fort Worth
Current manning levels support these changes
NIINs: -18 Items: -38
Man-Hours: -24
FRCSE Key West FRCSE Mayport
FRCMA New Orleans
13
EBM Concept
• EBM: a maintenance concept enabled by detailed RCM and maintenance task analysis data and a robust software application for efficient maintenance scheduling – Instead of packages (phases, specials, etc.) each maintenance
task and relevant aircraft usage parameters are tracked individually by their engineering derived intervals
– Tasks are grouped into preventive maintenance events whose content and schedule are based on: • Unique operating profile (usage and environment) of each aircraft • Planned operational schedules • Other planned “events” such as modifications (budget driven) • Unplanned “events” such as unscheduled down-time (random)
14
“What the aircraft needs, when it needs it, based on operating conditions and schedule”
14
EBM Benefits
• Anticipated cost savings – Decreased consumable demands for preventative maintenance
• Reduced maintenance burden (MMH) – Includes reduction from updated RCM analysis and EBM savings
• Improved planning capability – Better prediction of when maintenance is due based on planned usage (FH,
landings, cats / traps, etc.) – Improved knowledge of future maintenance resource requirements by
calculating the logistics requirements of each tasks as far into the future as needed
– Easier to adjust to changing operational requirements (e.g. Surge)
• Better aircraft material condition – Right maintenance at the right time as driven by the RCM interval for when
tasks should be done
• Improved aircraft availability – Decreased downtime for maintenance
15 15
16
Consumables Results
16
Savings / ac / year $25 K
Implementation Year +1 Implementation Year +2 Implementation Year +3 Implementation Year +4
TMS Fleet
Size
Savings TMS Fleet
Size
Savings TMS Fleet
Size
Savings TMS Fleet
Size
Savings
AH-1W 150 $3.7 M EA-6B 97 $2.4 M E-6 16 $0.4 M F-18 1056 $26.4 M
UH-1N 82 $2 M AV-8B 129 $3.2 M C-130 90 $2.2 M V-22 99 $2.5 M
E-2C 63 $1.6 M T-45 205 $5.1 M H-60 463 $11.6 M AH-1Z 8 $0.2 M
C-2A 35 $0.9 M P-3 169 $4.2 M H-53E 183 $4.6 M UH-1Y 26 $0.7 M
Imp. Yr. Total: $8.2 M Imp. Yr. Total: $14.9 M Imp. Yr. Total: $18.8 M Imp. Yr. Total: $29.8 M
Prior Yr. Total: $ 0 Prior Yr. Total: $8.2 M Prior Yr. Total: $23.1 M Prior Yr. Total: $41.9 M
FY Total: $8.2 M FY Total: $23.1 M FY Total: $41.9 M FY Total: $71.7 M
Five year savings total $216.6M
16
ARAT - Aviation Rapid Action Teams “Targeted, Applied, Direct Engineering and Logistics at Fleet Maint levels”
• ARAT mines Logistic data + talks to Fleet level Maintainers directly.
• ARAT musters hand picked Engineers, Super-techs and Loggee’s and ‘boots-on-the-deck’ investigates opportunities to resolve critical costs and readiness degraders.
• Enhance I-level repair capability
• Enhance I-level by imbedding D-level expertise (BCM-I’ish approach)
• Works with FST directly to resolve maintainability or even engineering deficiencies (ex PLCU A-7 SRA 35mA transformer)
• Challenges the ICRL’s, LORA, etc.
• Price challenges PLCU: a $52,515 consumable that could easily be repaired that we were using 1 per week 17
• COMFRC ARAT R-TOC Initiative surpassed it’s first year goal of $15.7M by more than $2M in FY12!
• Finalizing FY13 candidate list • September total cost avoidance by type / model
– V-22: $237,903 – F/A-18: $646,131 – Sep total: $884,034 – FY12 cumulative total: $17,850,604
COMFRC ARAT September 2012 Cost Avoidance Summary
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BCM-I (more of it)
• BCM-I looks at the tens of thousands of AVDLR’s (LRU’s) coming off aircraft and going thru I-levels that can’t be repaired, then determines ‘if’ embedded D-level artisans are appropriate to effect repairs on site.
• ~$125M per year in ‘cost avoidance’ being achieved now; some possibility for expansion.
• Tangential technical rub-off and increased level II to level III to FST comms important.
• Readiness ‘lift’ important, but harder to measure.
D-level Artisan working with I-level MARINE
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I-level AIRSpeed
• ‘Continuous’ Airspeed events and CPI pressure on all activities
• Examine differing RFI/BCM success rate from site to site and take steps to bring all retained repair sites to ‘best performance’ capability of most successful site.
20
FCAP Elements (Fleet Capability Alignment Program)
• The FCAP Process • Overall program involved NIIN Analysis, ‘FCAP Projects’ and reporting
– NIIN Analysis Tool
– Analysis & AIRSpeed project identification
– Enables sites to compare their repair success globally against all other ‘I’ level activities with like capabilities
– Identifies opportunities to improve repair success
– Target AIRSpeed events at those opportunities
– The FCAP software tool
– Measures the impact of improved repair processes & capabilities to the Flying Hour Program (FHP)
21
NIIN Analysis (Improve C1/C3 Capability)
Lemoore has avery successful repair rate. Large variation of repair success fleet-
wide. MALS-11 and Oceana could potentially save $1M on this NIIN through CPI.
22
Integrated Logistics Support Management System
( If You Can’t Scrutinize It, It’s Hard To CPI It )
23
• Standardized Data Triage Process, Tools and Language
– TMS Logistics Assessment enhanced by the implementation of Integrated Logistics Support Management System (ILSMS) • Exploit unprecedented access to maintenance and supply data • Advanced analytical and demand forecasting capability
• Improve Visibility of T/M/S Readiness & Cost Drivers • Root Cause Analysis of Identified Issues • Actionable Mitigation POA&M’s with provider organizations
Unprecedented Data Availability
ILSMS Aggregates Data
in One Tool
Logistics Assessment will be a key enabler in enhancing weapons system availability and reducing O&S cost 23
ILSMS DECK PLATE
AIRRS
TDSA
OOMA
NAVSUP WSS
DLA FRC
NAE
VAMOSC
CAVTS
N42
ILSMS Data Sources
Flight Records(NAVFLIRS)
Supply History (60 Series)
Maintenance Actions
X-ray data
Audited Flight Hours
RT-79 Records
Applicability List
Completed TD’s
WUC Baselines
Current Stock Posture
NIIN-PN/Cage Cross Reference
Allowances
Organic repair schedules
FRC G drivers
Backorders
ERP Schedule Board
(Due in/Projections)
Current Stock Posture
NIIN-WSDC Cross Reference
Backorders
Due in/Projected Procurement
Material Usage History
Current Readiness Metrics
Historical Fleet/Program Cost
Current FY Fleet Cost
AFAST
ICRL
Tracked Issues:
Program specific issues that require tracking/data or tie into
other decision processes i.e. (IMC/BULKHEADS/KAPTON)
Comments:
Allows for commenting by all stakeholders on most critical
areas- especially part number/NIIN and BUNOs
VAL/Reference Tables PN_NIIN_HOFNIIN_WUC_XREF ORG codes TEC Codes Supply Codes Most codes appx E of 4790
NAVAIR-6.8.2 / 6.8.4 ILSMS Analytic Module of DECKPLATE 24
Logistics Assessment
Readiness “Kill Chain”
25 UNCLASSIFIED / FOR OFFICIAL USE
ONLY
NAE Readiness &
Costs Metrics
Root Cause Analysis
Actionable POA&M
Issues Affecting Readiness & Cost
and more . . .
OPNAV / HQMC
Resource Sponsors
Provider Organizations
SURVEILLANCE DETECT TRACK ID/ENGAGE LAUNCH CONTROL LETHALITY ASSESS
Logistics Impacts Each Link of the “Kill Chain”
NAVSUP
T/M/S Data Driven
Analysis
CR
CFT
CURRENT READINESS & COST FUTURE READINESS: DESIGN FOR SUPPORTABILITY
Retail Supply
Support Equipment
Maintainer in Place
Execute Maintenance
Operate
Capture Data
CPI
Design for Supportability
Test
Support Concept
Wholesale Supply
Training
Tools/Tech Data
Readiness “Kill Chain”
25
Questions? Comments?
This was a fast raster scan of the CPI activities we in Naval Aviation are pursuing; I’ll be happy to talk to any of you off-line if you’d like more info. Stu Paul C:703.835.7558 [email protected] [email protected]