VSM WORKSHOP DOD MAINTENANCE SYMPOSIUM …Subject: DoD Maintenance Symposium Panel Presentation -...

19 Aug 2009

VSM WORKSHOPLeadership Outbrief

Presented by: Mr. Garry NewtonDeputy Commander, Fleet Readiness Centers

Presented to: COMFRC LEADERSHIP

27 Oct 2009

DOD MAINTENANCE SYMPOSIUM FRC Transformation Overview

Presented by: Mr. Garry NewtonDirector, Industrial OperationsDeputy Commander, Fleet Readiness Centers

2File: 20091014_FRC transformation overview_V3.pptPresenter: Deputy, COMFRCSubject: DoD Maintenance Symposium Panel Presentation - Transformation

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NAVAL AVIATION MAINTENANCE TRANSFORMATION HISTORY

1995 Established Integrated Maintenance ConceptFirst significant moves of depot capability closer to the flightline

2001 Implemented AIRSpeed throughout NAEImplementation of industry-proven process improvement tools

2005 Established Fleet Readiness CentersReturning ready-for-tasking aircraft back to the Fleet faster by moving maintenance closer to the flightline


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NAVAL AVIATION INTEGRATED MAINTENANCE CONCEPT

OCONUS LOCATIONSMCAS Kaneohe Bay, HI H-60Andersen AFB, Guam H-60STAE Singapore C-130NAF Atsugi Japan / NAPRA Det Okinawa E-2, F/A-18, H-60, H-46, H-1, H-53, EA-6BNAPRA S. Korea H-53

FIELD SITE

DEPOT SITE

FULL-TIME DEPOT MAINTENANCE AT EVERY MAJOR NAVY & MARINE CORPS AIR STATION WORLDWIDE

Shifted from on-condition to

CALENDAR-BASEDaircraft maintenance,

taking Depot Maintenance

to the Fleet


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INDUSTRIAL STRATEGY FOR NAVAL AVIATION

Workforce RevitalizationTransformations that facilitate changes in skills, knowledge,

ability, experience and organizational construct in

concert with changes in weapons, technologies, and supporting

processes.

Optimize the Industrial Base

Develop the industrial capabilities to support future

Naval Aviation requirements that are of the proper size and mix between Organic, Commercial,

and Inter-service.

Logistics TransformationOrganizational realignments, process improvements, and

integration across the value chain to produce aircraft ready for

tasking at the right time, the right place and at the right cost.

Capital InvestmentPrioritization and provisioning of investment dollars in support of the above strategic objectives.

Core-Sustaining CapabilityProvide the most up to date

industrial capability to sustain Naval Aviation’s current readiness

requirements with the right capability for the right cost that

conforms to USC Title 10.


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FRC NORTHWESTWHIDBEY ISLAND

Det Everett

FRC Southwest Det Northwest Whidbey

Island

FRC WESTLEMOOREDet Fallon

Southwest Det West LemooreDet Fort WorthDet China Lake

FRC WEST PACNAF Atsugi, Japan

Det GuamDet Okinawa

Det SingaporeDet Korea

Det IwakuniDet Australia

FRC SOUTHWESTNORTH ISLANDDet Point MuguSite Pendleton

MALS-39NADEP NI Det Pendleton

Site YumaMALS-13

NADEP NI Det YumaDet NAVCAL Lab

FutenmaDet NAVCAL Lab

Iwakuni

FRC SOUTHEASTJACKSONVILLE

Det MayportDet Key West

FRC EASTCHERRY POINT

MALS-14 Cherry PointSite New River

MALS-26 & 29 New RiverSite Beaufort

MALS-31 BeaufortNADEP JAX Det Beaufort

Site QuanticoHMX-1 Quantico

Site Robins AFBMALS-42 AIMD AtlantaSite McGuire AFBAIMD Willow Grove

Site Stewart ANGBMALS-49

FRC MID-ATLANTICOCEANA

Det NorfolkDet Pax River

Det New OrleansDet NAF Washington

Det AtlantaFRCSE Det MA

OceanaDet Beaufort

FRC SEFACSOLOMON’S ISLAND

*Dets in red indicate closing activities

D-LEVELI-LEVEL• 6,000+ SAILORS &

MARINES

• 20 IMAS

• 6,000 ENGINE/ MODULE/ ACCESSORY REPAIRS

• 580,000 COMPONENT REPAIRS

• $2.0 BILLION OPERATIONMISSION FUNDED

• 10,000 CIVILIANS

• 3 DEPOTS

• 1,500 ENGINE/ MODULE REPAIRS

• 70,000 COMPONENT REPAIRS

• 700 AIRCRAFT REPAIRS

• $2.0 BILLION OPERATIONNWCF FUNDED

OPTIMIZING THE INDUSTRIAL BASEINTEGRATE AND OPTIMIZE


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LOGISTICS TRANSFORMATION PILLARS

• Distribute

– Moving Depot Capability Forward

– Establishing High Velocity Repair Loops with Brokered R/R

• Consolidate

– BRAC-Related Closures

– Consolidating Repair Sites and Creating Centers of Excellence

• Optimize

– AIRSpeed Saturation

– Supply/ Maintenance Consolidation of Connectivity

CHOOSING THE RIGHT APPROACH BASED ON THE SITUATION


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DISTRIBUTED DEPOT MAINTENANCE

• EXAMPLE OF IMPROVEMENTS– F/A – 18 A-D Hydraulic Drive Unit (HDU) Repairs

• 44 HDUs Interdicted• $1.15M in AVDLR Cost-avoidance

– F/A – 18 A-D Horizontal Stabilizer Actuator Repair• $3.31M in AVDLR Cost-avoidance to date

– H-53 Main rotor Blade Repairs• 27 Rotor Blades Interdicted• $2.05M in AVDLR Cost-avoidance to date

Disassemble Inspect

I- Repair

Re-AssembleNot Repairable

Disassemble Inspect

Assemble

Transport D-Repair Assemble

I-Repair

Disassemble Inspect

Assemble

D-Repair Assemble

Distributed Maintenance Example

Non-Distributed Maintenance Example


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NAS Brunswick, MEP-3,C-130 Prop / -14 Level 1

NAS Pax River, MDP-3, C-130, E-2,C-2 Prop / -14 Level 1

Stuart ANGB, NY (MALS-49)C-130 Prop / -16 Level 2

MCAS Futenma, OkinawaC-130, P-3 Prop / -16 Level 1

NAS JRB Willow Grove, PAP-3, C-130 Prop / -14/ -16 Level 2

NAS New OrleansP-3, C-130 Prop / -14/-16 Level 1

NAS Whidbey Island, WAP-3 Prop / -14 Level 1

MCAS Kaneohe Bay, HIP-3, C-130 Prop / -14 Level 1

NAS Misawa, JAP-3 Prop / -14 Level 1

NAS Jacksonville, FL

NAS Sigonella, ItalyP-3, C-130 E-2, C-2 Prop

NAS Pt. Mugu, CAP-3, C-130, E-2, C-2 Prop-14 / -427 Level 2-425 Level 1

CONSOLIDATION EXAMPLE(AIMD / MALS / Depot / Commercial)

P-3 / C-130 / E-2 / C-2 Propellers and Engines

MCAS Miramar, CA

NAS JRB Fort Worth, TXC-130 Prop / -16 Level 2

C-130 Prop / -16 Level 2

NS Bahrain

MCAS Cherry Point, NCC-130 prop / -16 Level 1(NADEP CP Propeller CFA)

NAS Norfolk, VAE-2/C-2 Prop / -425/-427 Level 2

NAS Atlanta, GAE-2/C-2 Prop

-425 Pres / Depres

-14 / -425 Level 1-16 Level 3-427 Level 2

Rolls Royce -427 Depot

Standard Aero-14/16/425 Depot

NADEP CPP-3/E-2/C-2 Props

PPIP-3 Props

NAF Washington-16 Pres / Depres

P-3 prop / -14 Level 1(NADEP Jax Engine CFA)

NAF Atsugi, JapanE-2/C-2 Prop / -425/-427Pres / Depres Only

Closed Sites

NS Rota

NAS Keflavikk

NAS Adak

NAS Barbers PT

Closed Sites

NAS Kadena

NS Diego Garcia

NAS Roosevelt Roads

NAS Agana

NAS Moffet Field

Navy ActiveRed MarinesNavy Reserve

Warner RobbinsC-130 Props

P-3 Prop BU / OTW RGB

Infrastructure Adjustments throughClosure vice Optimization

-25 Repair Sites Worldwide- Wide Performance variation- Supporting different operating environments


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Greatest cost savings, C130 Support RiskFY04 Constant Year $ Reg / TMS1 INVESTMENTMILCON $0SE $0CONTAINERS $0INITIAL SPARES $0PCS COST $83,322OPERATIONS & SUPPORTMANPOWER -$32,402,654AFM $0AVDLR (Excl CRR) $01A5A (incl. Civ Manpower) $0Commercial I-Level Repairs N/ATRAINING -$3,177,834SPARES $0TRANSPORTATION $3,222,135PERSONNEL SUPPORT -$5,229,847TEST CELL SUPPORT/YEAR $0

INVESTMENT $83,322

OPERATIONS & SUPPORT -$37,588,200Total Cost FYDP Deltas (Negative indicates Savings) -$37,504,878

LOCATION NEC/MOS BA COB POB 5 Reg / TMS1NAS BRUNSWICK ME 6418 41 28 23 25NAS WILLOW GROVE PA 6418 19 19 19 8MALS-49 (Stuart ANG) 6226 4 4 4 10NAF WASHINGTON 6418 0 0 0 0NAS NORFOLK VA 6423 35 17 25 30NAS JACKSONVILLE FL 6418 49 41 45 36MALS-14 (Cherry Point) 6226 10 7 5 0NAS ATLANTA GA 6423 0 0 0 0NAS SIGONELLA IT 6418 47 47 47 4NAS NEW ORLEANS LA 6418 25 18 14 8MALS-41 (Fort Worth) 6418 6 6 6 12MALS-11 (Miramar) 6226 9 9 9 0NAF ATSUGI JA 6423 4 4 3 4NAS MISAWA JA 6418 33 21 33 10NAS PT MUGU CA 6418 10 3 6 3NAS PT MUGU CA 6423 26 21 19 30NAS WHIDBEY ISLAND WA 6418 28 15 17 40MALS-36 (Okinawa) 6226 9 9 9 10NS BAHRAIN 6418 3 2 2 6MALS-24 (Kaneohe Bay) 6418 24 13 16 10

Total 382 284 302 246

T56 / PropI Level Optimization

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NAS Brunsw ick, ME(BRAC)

NAS Pax River, MD

Stuart ANGB, NY (MALS-49)

NAS JRB W illow Grove, PA(BRAC)NAS W hidbey Island, W A

MCAS Kaneohe Bay, HINAS Jacksonville, FL

NAS Sigonella

NAS Norfolk, VA

NAS Atlanta, G A(BRAC)

NAF W ashington

(Brunswick Sqd to Jax)C130 Capability established

NS BahrainProp BU / OTW RGB Only

Legend: Blue I-1Gray I-3

Orange: Min

19 / 8

4 / 10

47 / 4

49 / 61

35 / 30

0 / 0

0 / 0

3 / 6

24 / 10

9 / 0

33 / 10

36 / 33

28 / 40

Region / TMS 1Hybrid Scenario.

Combination o f Capacity driven by region and TMS based (scenarios 1&2)

(w/BRAC and flow)

McGuire AFB (VR-64)Eng Pres-Depres (VR-53 C130Tx4)

(Atlanta Sqd to NO)

(Feed by Jax/ NORVA CNAF dir)

6 / 12

(Feed by Jax/ NORVA CNAF dir)

25 / 8NAS JRB Fort W orth, TX NAS New Orleans

MCAS Futenma, Okinawa

Eng Pres-Depres

NAF Atsugi, Japan4 / 4

NAS Misawa, JA

9/ 10

NAS Pt. Mugu,

MCAS Cherry Point, NC10 / 0

MCAS Miramar, CA

Current Man Tota l: 382Projected Man Tota l:246

Reduction of 136

Note: CNAF / CNAFR direct Module / QECA Movement

CONSOLIDATION EXAMPLE

• RESULTS– OPTIMIZED REPAIR NETWORK– MORE TRANSPORTATION (WITH

CLEAR PROTOCOL)

• OUTCOMES– FASTER REPAIR CYCLES– LESS MANPOWER– LESS EQUIPMENT– LESS OVERALL COST

Presenter

Presentation Notes

One site requires significant MILCON Controls and Accessories are $1.5 M to purchase hardware


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OPTIMIZATION (BEST PRACTICE REPLICATION) Optimization Cost Avoidance

EOY Trend ~ $105M

06 RFI % 07 RFI % 08 RFI % 09 RFI %

100%

95%

90%

85%

80%

75%

70%

65%

60%

55%

50%

BRAC APPROVAL TARGETED CPI PROJECT PLANS

RFI TRENDS

COMP PROJ

Presenter

Presentation Notes


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FLEET READINESS CENTER TRANSFORMATIONSUMMARY

• ACCOMPLISHMENTS– DELIVERING COST-EFFECTIVE

READINESS TO THE FLEET

– CREATING A CONTINUOUS PROCESS IMPROVEMENT CULTURE

– CONNECTING THE DOTS ACROSS ORGANIZATIONS AND PROCESS

• CHALLENGES– BLENDING ORGANZIATIONAL

CULTURES

– CREATING AN ENVIRONMENT OF SHARED RESPONSIBILITY AND MUTUAL ACCOUNTABILITY

– OVERCOMING POLICY AND PROCESS BARRIERS

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