Enabling Intensive Life Cycle Support Management by Machine Readable Unique Item Identifiers

Item Unique Identification (IUID) Objective

IUID is a common sense approach:
Mark items1 with machine readable unique item identifiers (UIIs) Centrally register UII pedigree data and value for each marked item Retrieve UII from item in use through automatic data capture Make UII a common key in acquisition, supply, maintenance and financial data bases to associate:
Value to items Maintenance history to items Item accountability to organizations Locations to items

IUID helps to achieve value and extend resources:

Exploits automatic data capture to improve productivity Enhances precision of logistics, contracting, and financial business transactions Consistently captures the value of items DoD buys, controls these items during their use, and improves item performance Tracks items in property accountability, inventory, and financial management systems toward achieving compliance with the Chief Financial Officers Act. Expands the population of serialized items (UIIs) available for intensive life cycle management support processes

Items over $5,000 in unit cost + serially managed, mission essential or sensitive items under $5,000 + DoD serially managed embedded items regardless of cost and their parent item
1

IUID Registry Statistics

(through 7 June 06)
Goal: 97M UIIs
IUID Registry Population
300,000
400

Registry Growth 700,000 600,000 500,000

Contractors

350

250,000
300

200,000
250

UIIs

150,000

200

400,000 300,000
UIIs Legacy UIIs New UIIs In GFP Status Prime Contractors

150

UIIs Projected UIIs

100,000
100

200,000 100,000 Jan-04 Jul-04 Jan-05 Jul-05 Jan-06 Jul-06 Jan-07

50,000
50

nJu 04

nJu

nJu

pSe 04

5 -0 ar M 4 -0 ec

pSe 05

6 -0 ar M 5 -0 ec

pSe

Date

05

06

06

257,772 Items registered 205,431 New items 52,341 Legacy 354 Contractors have delivered new UIIs 208 of the contractors (59%) are small businesses

Average growth rate over 15,000 UIIs/week 44,171 Items are in GFP status 3,620 contracts with GFP listed

UIIs by Component
(Through 7 June 06)

New UIIs

Air Force Navy Army Marine Corps SOCOM DLA

Life Cycle Management Support and Asset Visibility Dynamics Today

Items have to be identified at every step
DRMO Ship BER TroubleDepot shoot Repair Induct at Depot

Test Package/Preserve Purchase Ship Ship

Ship Wholesale Supply

Transactions are not net-centric

Wholesale Supply Troubleshoot War Reserve Ship Field Repair, I-level Test

Ship

Package/Preserve Retail Supply

Item identification is manual

Retail Supply

Install

Remove Field Repair Troubleshoot Olevel Use/Break Test

2500 Acft/5000 Firewalls

Identify + Track = Manage: Supply Chain Use of the UII

DRMO Ship BER TroubleDepot shoot Repair Induct at Depot

Test

In Process

In Transit
Ship Wholesale Supply

In Process

Package/Preserve Ship Ship

Purchase

In Storage
Ship

IDENTIFY
Wholesale Supply

MANAGE
In Process
Troubleshoot

In Transit

In Storage
Supply Chain Stages
In Process In Storage In Transit War Reserve Ship

Package/Preserve Retail Supply Remove

Field Repair, I-level

T TRACK

In Transit

In Process

Test

In Use
Retail Supply Install

Field Repair Troubleshoot Olevel Use/Break Test

2500 Acft/5000 Firewalls

I+T=M Track by UII Observe the progress of

In Storage

Manage by UII To control, or direct the functions of

In Use

Life Cycle Support and Visibility Enabled by Automatic Information Data Capture
Automatic identification and data capture (AIDC) eliminates error-prone and timeconsuming manual data collection and data entry. AIDC provides quick, accurate, and cost-effective collection and entry of data.

STEP 1: Mark Items

WAWF

STEP 2: Register Data

STEP 3: Automatic Data Capture

Identify Item

Unique Item Identifier (UII)

Class I Subsistence Class II Clothing & Individual Equip Class III Fuels & Petroleum (Packaged) Class IV Construction (Installed Equip) Class V Ammunition Class VII Major Items Class VIII Medical Class IX Reparables

Retrieval
IUID Registry

Updates

Transactions

STEP 4: Application Processing

Store Use

Estimated Scope of UII Coverage

Metric UII Items in DoD Inventory Quantity (millions) 67.7 Acquire

Maintain Expend/ Dispose

Property in Possession of Contractors

Total UIIs

29.5
97.2

Why Intensive Life Cycle Management Support?

CH-47 Helicopter Fleet Management Process
Identify Problems on Item-by-Item Basis
Inherent Reliability Diagnostic Error Operation Induced Quality Defects
Process is enabled by marking items with machine readable UIIs in data matrix

Manage the Fleet

Aircraft Performance

Manage Stock

Stock Levels
Budget

Backorders

Flying Hour Program

Demand Rate

Inventory Management

Supply Availability

Fleet
Management

Repair Events

Cycle Time

Configuration Management

Define Cost Drivers

IUID as a Fleet Management Enabler

CH-47 Helicopter Fleet Management Process
User Requirement
D3WUH0CH5 D3WUH0CH5 D3WUH0CH5 D3WUH0CH5 D3WUH0CH5

PMO Support
Safety -16

Team Support

-13

Customer Support Center

Forms, records, agreements Data Delivery Systems (AIS)

DD250

D3WUH0CH5

FEDLOG

Soldier Focused Logistics

Information Safety Messages Diagnostics Knowledge Mgmt. Customer Support Technical Data Training Feedback

Forms, records, contracts

2410

Data Delivery Systems (AIS)

D3WUH0CH5

D3W UH0 Transmission, Aft CH5 145D2300-4

Industry OEM CSFR

Maintenance & Supply Actions

D3WUH0CH5

Organic Assistance Depot Inter-Service USAALS TMDE AVIM Etc. D3WUH0CH5

Machine-Readable UII is the consistent key from factory to field!

Legacy Unique Item Tracking

(a) Serial Number Tracking (SNT) efforts exist today for such items as highvalue parts, classified assets, aviation safety-of-flight parts and many missile system components. They may or may not be registered as Unique Item Tracking programs. (b) Unique Item Tracking (UIT) programs for selected items maintain visibility of each uniquely identified asset for the primary purpose of inventory control and/or engineering analysis. Security, accountability, safety, maintenance, operational readiness, warranty applicability, and other areas that may benefit from the tracking process are also reasons for UIT.

Registered Unique Item Tracking (UIT) Programs

Note: No uniform use of machine-readable marking UIT Program Program Originator DoD Small Arms Serialization Program (DoD SASP) Security Risk Category I Non-Nuclear Missiles and Rockets Radiation Testing and Tracking System (RATTS) Program Navy Depot Level Reparables (NDLR) Program The Army Maintenance Management System (TAMMS) Equipment Data Base (TEDB) Aviation Component Tracking Program Tritium Unique Item Tracking Program Controlled Cryptographic Items (CCI) DoD 4140.1-R Requirement DoD 4140.1-R Requirement

Army
Navy Army Army Army Army

Capabilities Enabled by Unique Identification of Items

Key: Machine-readable marking required to enhance data capture
Usage Function
Tracking Item Performance, Age and Modification Results

Enabling Capability
Track performance of items by manufacturer and by lot Reduce the premature condemnation of life-limited items through enhanced availability of accurate usage data Track performance of various configurations for comparing, controlling, and scheduling of modification and updates of items as improvements are identified Separate cause from symptom and then track the configuration of components to speed the correction-of-deficiency process and to assist in determining if an approved engineering change has accomplished its intended purpose Isolate failures and their causes through identification of specific configurations of an item and its parent component or system Increase the reliability of repaired components via the identification and removal of bad actor components Enable identification of problem equipment through historical analysis; ordering spares that match the configuration of the end item; and better scheduling of maintenance Reduce the need for complete replacement of parts and subassemblies by having detailed histories of systems and equipment Improve maintenance data collection systems through use of automatic data capture Improve requirements calculations and issue decisions by being able to order parts by specific configuration, and by updating source, maintenance and recoverability codes, which result in better provisioning. Improve weapon system readiness by improving system availability. Improve system safety by tracking usage data on life-limited, safety-related components, and establishing the capability to locate quickly parts with a suspected or confirmed safety problem so that they can be inspected, analyzed, and removed Consistently account for the physical security of sensitive items and the accountability of nonsensitive items with speed and precision

Failure Analysis and Reliability Improvement

Maintenance Productivity

Supply Productivity

Safety and Accountability

Machine Readable IUID Enabled Capabilities

Note: SNT/UIT do not uniformly enable machine-readable data capture
Supply Class Class I Class II Class III Class IV Class V Class VI Class VII Class VIII Class IX
IUID/SNT3 IUID/SNT6 IUID/SNT7 IUID/SNT3 IUID/SNT6 IUID/SNT7 IUID/SNT3 IUID IUID/SNT7 IUID/SNT3/UIT4 IUID/SNT6 IUID/SNT7/UIT8 IUID IUID/SNT6 IUID/SNT7 IUID/SNT3/UIT5 IUID/SNT6 IUID/SNT7 IUID2 IUID IUID2 IUID IUID2 IUID IUID2 IUID IUID IUID IUID IUID IUID IUID1 IUID2 IUID

Engineering Design

Tracking Item Performance

Failure Analysis

Maintenance Productivity

Supply Productivity

Safety and Accountability

IUID IUID IUID1 IUID2 IUID

Notes: 1 Packaged products; 2 Installed equipment; 3 Classified assets; 4 TAMMS TEDB; 5 SASP; CIC CAT 1 Items; RATTS, Tritium, CCI; 6 DMLSS; 7 - High-value parts, aviation safety of flight parts, missile components; 8 NDLR, TAMMS-A SNT/UIT Legacy item tracking programs

IUID Enabled Intensive Life Cycle Support Management

Capabilities Requirements Objectives Payback Resources Strategic Serialized Asset Management Value

Speed and Precision in Data Capture

Financial Management Warranty Management Tracking Item Performance & Age Failure Analysis Reliability Improvement Engineering Design Analysis Maintenance Productivity Supply Productivity Safety Accountability

Processes

Analysis

Automated Data Collection

Item Unique Identification (IUID)

Information Systems

Supply Chain Events Machine Readable Marking Unique Item Identifier (UII)

Uniquely Identified Items

IUID Spectrum in Supply Chain Management

Spectrum of IUID Impact in Supply Chain Management Processes
IUID Reqmt Flag Supply UII Mark Process Induction Track Issue Handling Packaging Infrastructure Transactions Software AIT AIS DLMS

DLA Visibility ISSUE How do we flag UII marking requirements for items that DLA buys?

UID Traceability TEAM DLA

Team Leads: Lydia Dawson (OSD-UID) (703)695-1098 Lydia.Dawson@osd.mil Roy Geiger (DLIS-XLB) (269)961-4317 Roy.Geiger@dla.mil DRMS/RMP Bruce Propert (OSD-UID) (703)325-9502 David.Propert@aca.army.mil Pam Rooney (OSD-UID) (703)393-0504 Pam.Rooney@wfinet.com Jim Craig (OSD-UID) (703)556-2886 Jim.Craig@ngc.com Cinda O'Laughlin (DLIS DRMS)(269)961-4317 Cinda.O'Laughlin@dla.mil Ken Hopkins (DLIS RMP) (269)961-5700 Kenneth.Hopkins@dla.mil Terry Felter DLIS Cataloging Policy (269)961-4446 Terry.Felter@dla.mil Dave Osburn DLIS UIT (269)961-4708 David.Osburn@dla.mil Ed Floyd DLIS UID (269)961-4328 Edward.Floyd@dla.mil

IUID: Enabler for Broader Intensive Life Cycle Support Management

DOD Item Inventory
1 Items over $5,000 in unit cost or serially managed, mission essential or sensitive items under $5,000 or DoD serially managed embedded items regardless of cost and their parent item
NALCOMIS NALDA

DOD items uniquely identified1, marked with machine-readable data matrix to enable automatic information data capture and registered in the IUID Registry
SASP

SNT

UIT

UICP

NDLR
CIC CAT 1 FACTS DSS DMLSS ATAC TRITIUM TMARS COE CAV AFEMS CCI DPAS PBUSE TEDB TAMMS-A

RATTS
LMP AWRDS

Examples of Existing and Planned Accountability, Maintenance or Security Systems

Preliminary Inventory of Existing Service Property Systems

Air Force ST/STE Maintenance AFEMS DMAPS CAMS Army DPAS SPBS-R TAMMS A ULLS G ULLS A TAMMS A TEDB TEDB ULLS A ULLS - G Navy eTIMS DECKPLATE SNT NALCOMIS 3M AEMS AIRRS ATCM AIM SNT CAMS Other FEPMIS PCARSS

Engines Major Assets

CEMS REMIS

AFEMS Air Force Equipment Management System DMAPS Depot Maintenance and Production System CAMS Core Automated Maintenance System CEMS Comprehensive Engine Management System REMIS Reliability & Maintainability Information System DPAS Defense Property Accountability System SPBS-R Standard Property Book System Redesign TAMMS A The Army Maintenance Management System Aircraft ULLS G Unit Level Logistics Ground ULLS A Aviation TEDB TAMMS Equipment Data Base

eTIMS Navy Electronic Tooling Information Management System SNT Serial Number Tracking NALCOMIS - Naval Aviation Log Com Operating Maint InfoSys 3M - Maintenance and Materiel Management AEMS - Aircraft Engine Management System AIRRS Aircraft Inventory Readiness and Reporting System ATCM Aeronautical Time Cycle Management AIM Asset Information Management FEPMIS Federal Excess Property Management Information System PCARSS Plant Clearance Automated Reutilization Screening System CAMS Capital Asset Management System

Integration of Legacy SNT and UIT with IUID

NALCOMIS NALDA NDLR SASP CIC CAT 1 FACTS PBUSE ATAC DPAS TRITIUM DMLSS RATTS AWRDS COE TMARS CAV CCI DSS TEDB AFEMS UICP

Step 1 Mark all items with UII in a data matrix symbol when new or retrofit marking if practical, otherwise construct virtual UIIs for serialized items being tracked by legacy SNT/UIT and register pedigree data in the IUID Registry as shown
Various Formats

TAMMS-A LMP

Service Applications

IUID XML

Manual Web Entry

IUID Registry

Integration of Legacy SNT and UIT with IUID

Inventory Systems GEX NALCOMIS GEX AFEMS
NALDA NDLR SASP UICP

Step 2 Enable an infrastructure for automatic information data capture

GEX

Property CIC CAT 1 Systems FACTS GEX GEX

DSS ATAC TAMMS-A

PBUSE

TEDB

Step 3 Use the UII as the common key in transactions

DPAS
TRITIUM DMLSS

LMP

DFAS
COE TMARS CCI

IUID Registry

RATTS

AWRDS CAV Maintenance

Systems GEX GEX

Step 4 Mark virtually identified items with UII at appropriate trigger events

Transactions Direct interfaces

Data Capture Opportunities

Trigger Points for IUID Registry Updates

Supplier Receive Ship Notice Receive Item

Warehouse Receive Item

User

Maintenance Receive Item Receive Item

Disposal

ACQ SYSTEM INTERACTION VIA WAWF

RECEIPT IN SYSTEM OF RECORD

RECEIPT IN SYSTEM OF RECORD

RECEIPT IN SYSTEM OF RECORD

RECEIPT IN SYSTEM OF RECORD

IUID Registry -- EDI Standards Format, User Defined Format, Flat File Input

Acquire Store Use Maintain Dispose

Electronic Data Interchange Environment

OEM OEM OEM
Aviatio Groun n d Groun PLCS Syste d DEX ms Syste PLCS ms DEX PLCS DEX

OEM OEM OEM

Groun System d s Groun Syste PLCS d DEX ms Syste PLCS ms DEX PLCS DEX

Ground

OEM OEM OEM

DEX XML

DEX XML

DEX XML Update Transactions

Groun Ships d PLCS Groun Syste DEX d ms Syste PLCS ms DEX PLCS DEX

Maintenance DEX Configuration DEX Physical Security DEX IUID Registry

DEX

Roles and Responsibilities

Roles
Program Managers Contracting Officers Contractor DCMA or Destination IUID Registry Administration Storage Destination Top Level Accountability Systems Maintenance Depot Disposal (DoD 4160.21M)

Responsibilities
Define population of individual items to be marked, tracked or managed Work with engineering community, contractors and depots Get requirements on contract Insert UID clause in all supply contracts Delivers UII and registers pedigree data Maintains stewardship of GFP Inspects and accepts UII item Oversight of Government Furnished Property Establish interfaces with WAWF and SSAM Systems Maintain the IUID Registry Receipt transactions involving UIIs Receipt transactions involving UIIs Maintain UII accountable property records current and correct in the applicable system of record. Report lost, destroyed or expended UIIs Receipt transactions involving UIIs Mark legacy items as required Receipt transactions involving UIIs Report disposition of UIIs

Improving Maintenance Of Military Gear

IUID enables Speed and Precision in the DoD Supply Chain through Better Information:

Better communication between maintainers on the front lines and depots Better tracking of replacement components More awareness of the history of parts Restructuring the work to eliminate waste
Rapid Access to Information Part identification Maintenance history Hours deployed in the field Home depot Manufacturer
Identify Item

Integrated Asset Visibility through IUID: Policy

Total life cycle management of all items with Unique Item Identifiers (UIIs) will include cradle to grave asset visibility:
UIIs shall be identified in the Federal Logistics Information System (FLIS) as requiring asset tracking under a specific tracking initiative, or as requiring IUID under IUID policy. Information systems will capture and be capable of information exchange of all business events that effect changes to the condition and/or location of these items as a by-product of standard logistics transaction exchange under the Defense Logistics Management System (DLMS). The DoD IUID Registry will be capable of identifying and reporting the current condition and location of all items for which IUID is applicable, exclusive of security sensitive assets. The DoD Components may employ independent updates to the registry to comply with this policy where non-DLMS compliant systems impede execution of this policy.

Integrated Asset Visibility through IUID: Potential Business Event Transactions

Potential business events to capture and either report to the IUID registry or have available in the Defense Automatic Addressing Systems Center (DAASC) data store for interrogation.
Shipment by Vendor to DSS Shipment by Vendor to Customer (DVD) - govt. or another contractor Receipt by DSS from vendor Receipt by DSS from another DSS Depot DSS recording a change in ownership/condition Receipt by DSS from Maintenance Depot (organic or contractor) Receipt by DSS from customer (material return) Issue by DSS release to transportation carrier Delivery by carrier to receiving port of debarkation (AOD) Issue by (AOD) to transportation carrier Delivery by carrier to receiving port of embarkation (AOE) Issue by (AOE) to transportation carrier Delivery by carrier to receiving theater distribution point Issue by theater distribution point to customer Item shipped to DRMS Item received by DRMS DRMS donation, demil or sale

IUID in the UIT Environment

UIIs need to appear on package identification as well as in the transactions
DLMS transactions have been modified MIL-STD-129 changes are being proposed DoD 4500.9-R and DoD 4000.25-1-M are being reviewed

UIT is thwarted by errors of execution that begin with the shipper

Incomplete package identification Incomplete documentation

IUID and UIT processing in DSS both use UII terminology

DSS UIIs are control numbers unique within DSS UIT needs to incorporate UIIs that are globally unique item identifiers

UIIs are generated in receiving if serial numbers are missing from package identification and documentation
Replacement UIIs cannot be generated from item serial numbers Missing UIIs must be obtained from item marks or the registry

Mismatched receipts and due-ins are generally irreconcilable

Inordinate resources can be expended to correct misidentification Must be solved at the source Packagers and shippers require proper AIT and data transmission capabilities

IUID Impact
Enabling common AIT infrastructure by synching the marking standards Bigger universe of marked items requiring visibility Will impact all Automated Information Systems (AIS) Broader application than prior approaches
Full life cycle management support
Bottom Line: Opportunity to build on and surpass prior efforts

BACK UP

Classes of Supply
Class I. Subsistence, including gratuitous health and welfare items. Class II. Clothing, individual equipment, tentage, organizational tool kits, hand tools, administrative, and housekeeping supplies and equipment. Class III. Petroleum fuels, lubricants, hydraulic and insulating oils, preservatives, liquid and compressed gases, bulk chemical products, coolants, de-icing and antifreeze compounds, together with components and additives of such products, and coal. Class IV. Construction materials including installed equipment and all fortification and/or barrier materials. Class V. Ammunition of all types (including chemical, biological, radiological, and special weapons), bombs, explosives, mines, fuses, detonators, pyrotechnics, missiles, rockets, propellants, and other associated items. Class VI. Personal demand items (non-military sales items). Class VII. Major end items. A final combination of end products that is ready for its intended use; that is, launchers, tanks, mobile machine shop, and vehicles; etc. Class VIII. Medical materiel, including medical-peculiar repair parts. Class IX. Repair parts and components including kits, assemblies and subassemblies, reparable and consumable items required for maintenance support of all equipment, excluding medical-peculiar repair parts.

Class X. Materiel to support nonmilitary programs, such as agriculture and economic development, not included in classes I through IX.

DODD 4151.18, March 31, 2004, Maintenance of Military Materiel

3.2.5. Employ Serialized Item Management (SIM) techniques to effectively manage populations of select items throughout their life cycle. SIM programs shall focus on providing comprehensive and timely data for each identified item. DoD materiel shall be equipped with Automatic Identification Technology (AIT) allowing for paperless identification, minimizing data entry requirements, and facilitating digital storage and retrieval of essential information including maintenance history. SIM programs shall build on existing serial number tracking initiatives and leverage continuing progress in AIT.