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Integrated Maintenance Management

System

Walter Riley
Director Information Systems

Mary Catherine Akamatsu


Director Enterprise Life Cycle Solutions Division
Aviation Task Force Recommendation

 Field the Common Transitional System – Aviation (CTS-A) as Unit Level


Logistics System – Aviation (ULLS-A) Software Change Package (SCP) 6.

 Resource PM LIS to Transition, Finalize Development, Field, and Sustain


CTS-A as ULLS-A SCP 6.

 CSA Approved The Recommendation

 Army G3 Directed that Fielding Would Begin 1st Qtr FY 05


What is ULLS-A(E)?
System Overview
• PC/Windows based multi-user software
developed in 160th SOAR
• Designed to operate at AVUM automates PLL
& TAMMS-A functions
• Incorporates a LAN to link functions of:
• Aircraft Logbook, Historical Records
• Supply, PC, QC, Work Orders,
• Phase Maintenance
• Decision Support System

Management
Aircraft Historical Production Phase Backshop Tech Decision
Logbook Records Module Maintenance Work Orders Supply Support

Capabilities
Functionality

Data Flow

Flexibility
Click on Module for more information
On-Going Initiatives

• Driven by requirements from the field and new


equipment fielding
• IETMs (Do not follow a Maintenance process)
• Wireless Networking and Portable Maintenance /
Logistics Device implementation
• UID integration into maintenance activity
• Published Digital Source Collector Interface Control
Document
• GCSS-A integration into the Enterprise Backbone
supported through XML data exchange
Lessons Learned

• ULLS-A (E) outpacing Army IT Support Infrastructure


• Connectivity continues to be the biggest challenge in the field
• Local connections are usually doomed

• Training
• Greater Command Emphasis makes HUGE difference in successful ULLS-A (E)
implementation
• School House needs to be included very early

• Data elements and structure definition is a key element up front


• Need logical and consistent data exchange standard
• Must identify optimum data element requirements

• Legacy business process are not in line with today’s projects

• Data elements and structure definition is a key element up front


Need logical and consistent data exchange standard
Must identify optimum data element requirements
Development Lessons

• ULLS-A Focused on the Air Vehicle


– UAS Air Vehicle is one piece of the system
– Numerous ancillary items impact UAS readiness
– ELAS UAV data capability limited
• Legacy software not sustainable (16 bit application)
• Lacks the depth of ULLS-A E in maintenance modules
• ULLS-UAS is focused on the entire system
– Flexible tracking of any item (Ground, Air, Missile, or Support System)
– Accommodate the changing mix of equipment
– Data structured toward the components
– Must accommodate the “transformation” issues
• New equipment and transfers of that equipment
• Modular nature
– Requirements never detailed enough

7
Next Generation

Current System
– Current system limited by design constraints from legacy process and by “interim
solution” until GCSS-Army status
– Current design is adequate, however, increasing demands and unforeseen
operational uses/changes due to OEF/OIF and Army Transformation
– Current system is becoming increasingly difficult to maintain and adapt to emerging
needs
New Data Structure will yield:
– Next generation capabilities; restructured database and demonstrate a decision
support system that highlights the potential of extensibility of data across an Army
Enterprise
– A more flexible, scaleable and capable database to accommodate the way the Army
is operating now in OEF/OIF and Transformation to Modular Brigades
– Readily adaptable to use with system-of-systems (UASs), ground vehicles, air-
ground support equipment; platform independent
– Lessons learned in organizing database structures to handle disparate end item data
– Experience is leveraged to reduce development time
Architecture
System Interface Description
CAFRS

IETM
Training
DSC
Vehicle
Tech Health
IMMC Data Monitoring

ULLS-UAS
Intra-Nodal Supply SARRS
Inter-Nodal

Maint.
Readiness Information
Eng.
Analysis SAMS
LOGSA
CBM DW
Operational Node Connectivity

Readiness data forwarded to


Mgt SPM
LOGSA
Data Store
Required files forwarded to Logbook Node
SAMS-E

Network above Unit


LOGSA Logbook
Logbook Node

SAMS-E

Unit Server

OLTP Data SPM Data


CAFRS
Store Store

SARSS

Platoon Stations
PC QC Shops Supply SPM Workstation

Laptop computer Laptop computer


•Deployed Enterprise

•System
•Node
•TOC
•B
•V-SAT
co
•System
• •Node

ly
upp
dS
a an M
at U
c e D To AV
n
tena ates
in r
d Ma s Mig
te est •
llec equ •Tech Supply
o
•C •xR •x
•Motor Pool •PC
•DEM •D
•tactical server at AVUM
•System

co •Node

•C
co
•A
Information and
Decision Management

Multiple
•Selected Customers Special Purpose
e ct ive Servers
e l
•S
•SPM Data Store
•DATABASE
•Readiness tive Multiple
c
•Sele Special Purpose
Servers
•Logistics

•Configuration
•Program Office
•Maintenance
•Flt Records
iple
• Unit Data • Mult
•Readines
s
•Logistics

•Configuration •GROUND
•Maintenance •POV
•Flt Records
•AVIATION
Condition Based Maintenance
Data Warehouse (CBM-DW)

Mary Catherine Akamatsu


Director of Enterprise Life Cycle Solutions Division
Westar Aerospace & Defense Group
Dependent Components of CBM+

PLATFORMS
 DSCs OIF/OEF
Analysis
Pipeline of Transmission Extract
– VMEP
CONUS • Commercial Satellite Transform 4
– HUMS • Fed Ex Load
– Future OCONUS • Mail N e
e eeddss Supply
err N
• Parts OEM • Military Usse
U
Engineering
– Remediation
Efforts
S&T Efforts

• RCM Academia CBM Other


DWH T&E
• “Off Systems”
Warehousing
and S&T

Flight Line 3 PM Flt


Outlays and

Decisions IMMC Mgt Sys


OEM
Funding Outlays

LOGSA Academia
• Improved diagnostics
• Maintenance actions based
Funding

on component health
• Reduced MMH
Decision
• Planned maintenance
• Unscheduled vs. Transmission 5
Scheduled • Maintenance Concept Impacts
2 • Training Impacts
Collection • Part Re-engineering
• Airworthiness Release (AWR)
1 • Supply Stockage
Overarching Architecture Compliance
AMCOM Condition Based Maintenance
SALE
GCSS-A
GCSS-A PLM+
PLM+ LIW
LIW LMP
LMP

In Theater JT CBM Data Warehouse


DI
Phase 1 Platform PMs
Maintenance

AT
VS Phase 2
Fleet Managers
Fleet Management
Phase 3
Supply IMMC
X
4-3 ASLT CA 3rd CAB
ISI Data Sources
Engineering
ULLS-A

HUMS Systems LOGSA


DSC

OEMs
2410
1-3 ATK
2-3 GSAB CAISI – Combat Service Support Automated
MDR Information System Interface
OIF Units Sending Standard Army STAMIS Data VSAT – Very Small Aperture Terminal
and HUMS Data JTDI – Joint Technical Data Integration
FY06 BSC Approval
CBM-related Fielding's

3rd Infantry Div


Deployed With Fully
DSC-Equipped CAB
Digital Source Collector (DSC) Equipped Aircraft*

Aircraft Type Total # Aircraft DSC Equipped Percent Complete

AH-64 686 194 28%


CH-47 452 41 9%
UH-60 1630 194 12%

TOTAL 2768 429 15%

Unit Level Logistics System – Aviation (Enhanced) [ULLS-A (E)] Fielding*


Battalions Fielded Total # Battalions Percent Completed
76 136 56%
* Includes Active, Reserve, and National Guard Units

Field 1+ Combat Aviation Brigade (CAB) A Year


Role of the CBM-DW

Direct Use
Customers

Business Intelligence (BI)


User Interface and
Extract, Transform, Load
Disparate Data Sources
Imported into CBM-DW

CBM-DW
Dependent

SOA* Data
Database

Services
Indirect
Customers

CBM-DW Receives, Normalizes and Provides Airworthiness Data


OSD Business System Certified 4th Qtr FY06 *SOA=Service Oriented Architecture
DIACAP Certified 2nd Qtr FY09
Business Intelligence (BI)
CBM-DW within the Logistics Information
Warehouse (LIW) Framework

LIW FRAMEWORK

USER INTERFACE

LOGSA
Data Warehousing Legacy Data Bases

AMCOM
CBM-DW

TACOM
CBM-DW

CECOM
CBM-DW

On Line Analytical Process On Line Transactional Process


(OLAP) (OLTP)
DW Requirements Development

User Interviews Option Development Capabilities Design


Candidate
Use Cases
• Use Case 1 CBM WIPT
• Use Case 2
• Use Case 3
Requirements
• Use Case 4

Selected Use Cases for Iterations


Evaluate and Analyze Customer Priorities and Effort Enter Development Process
Estimates are Obtained
Functional Requirements
to Scope Iteration

Ranked Feasible Combinations


Use Cases Document • Use Case 1+ Use Case 4 CBM-DW
Functional • Use Case 1+ Use Case 3
Capability
• Use Case 3 + Use Case 4
Requirements • Use Case 2

35 Business Level & 111 User Level Interviews


- Includes Engineers, PMOs, OEMs, Log Analysts
- Results in 80+ potential Use Cases
- 90+ Supplemental Specifications
CBM-DW Timeline
(Including Information Assurance)

Today
A B IOC C FOC
Concept Technology System Expansion Performance & Operations &
Refinement Expansion & Demonstration Deployment Support
FY05 FY06-07 FY08-10 FY11 & Beyond
~Q3FY05 ~Q4FY09 ~Q3FY11
Concept Design Software
Refinement 1 2 Readiness
Review
3 Qualification Test
(SQT) Review
Decision

~Q1FY08 ~Q1FY11
Establish LOGSA Start SQT
Identify IA requirements Target Production Environment

Develop acquisition IA strategy

Secure IA resources

DIACAP certification

Incorporate IA solutions

Obtain Interim Authority to Test (IATT)

Test and Validate IA Solutions

Accredit the CBM-DW/Authority to Operate (ATO)

Maintain system’s security posture throughout its lifecycle


CBM-DW Iterations Overview
FOC

Perform System
Operations & Support (OS-1)
Qualification Testing &
Performance & Deployment (PD-3) SQT
initiate new phase
scope if needed PD-2
PD-1
30 SEP 10 System Expansion & Demonstration (SD-12)
SD-11 Expand the System With
30 JUN 10 Continued Focus on
31 MAR 10 SD-10 Requirements
31 DEC 09 SD-9 Refinement
30 SEP 09 DRR SD-8
30 JUN 09 SD-7
31 MAR 09 SD-6 Define & Validate
31 DEC 08 SD-5 Requirements &
SD-4 Architecture
Data Volume Available

30 SEP 08
30 JUN 08 SD-3

User Input
31 MAR 08 SD-2 Maint Actions/Compt Lifecycle
31 DEC 07 SD-1 LOGSA Deployment
28 SEP 07 Technology Expansion (TD-6) Automatic Data Loading
29 JUN 07 TD-5 MDR Data
30 MAR 07 TD-4 ULLS-A Maintenance/IVHMS

TD-1-6 on Interim 31 DEC 06 TD-3 Fleet Visibility and IMMC 2410


Production Server Located 14 SEP 06 TD-2 MSPU Component Life Data/Condition Indicators
at AED for Evaluation/Use
20 JUN 06
TD-1 AH-64 Component Life Data –ULLS-A
Transition to LOGSA

CBM-DW Interim
Production Environment
• Located at AED
• 2 HP Database Servers running LINUX
• 2 HP Application Servers running
LINUX
– 1 TB of disk storage
• 7 x 146 GB disk drives

07
FY

Software Engineering

06

Environment Target Production


FY

Environment
• Located at Westar
• Sun Fire X4100 and X4200 Servers • Located at LOGSA
running LINUX Beginning FY 08
• Oracle OLTP, OLAP databases,
• Operational in FY08
Data Warehouse / BI tools • SUN E25000 Database Server running UNIX
• Status – Up and available • SUN T2000 Application Server running
UNIX
• SUN StorageTek 9990 SAN
• Planning for growth through 2013
– Accommodate high growth rates for data (50 TB)
– Requires large amounts of processing power
– Will be a world-class data warehouse
Accomplishments

• CBM-DW is Business System Certified without Conditions:


– Annual BSC Review – SEP 07
– BSC Changed the required color of money this year
• All primary stakeholders actively involved in CBM-DW
• Every delivery has been on time or ahead of schedule
• Delivered incremental functionality for the five primary data
sources
– ULLS-A (E), MSPU, MDR, IVHMS, 2410
• Well defined requirements process
• CMMI level 2 and level 3 processes
• Working with LOGSA on deployment of the Target Production
Environment
Questions??

26
BACK UPS
Units Reporting to CBM-DW

IMD-HUMS/
Unit Location ULLS-A MDR MSPU IVHMS

4-3 Avn Ft. Hood 19-Sep 20-Sep 1-Nov

1-3 ATK OIF 31-Oct 18-Nov 16-Nov

3-3 ATK HAAF 25-Jul Not installed

3-101 FTCKY 2-Nov Not installed

4-3 ASLT OIF 3-Nov 17-Nov

2-3 GSAB OIF 2-Nov 19-Nov

1-101 FTCKY 20-Nov 19-Nov 20-Nov

1-230 TN/MS 19-Nov Nov-20

Not applicable

Issues with data delivery mechanism


How Does The CBM Process Work?

Soldiers
1 Embedded Sensors 2 Perform 3
Plane Side Work Stations Immediate Production Control Office
Monitor Component Health
1. Provide Any Immediate Actions Maintenance 1. Plans Maintenance Activities
Data Is Downloaded After
2. Transfer Data Into the STAMIS Actions 2. Enters Proactive supply
Each Flight
actions into STAMIS

Key Enablers:
1 Imbedded Sensors Actionable Data loaded Into
2 Plane side diagnostics Maintenance CBM Data
and Supply
3 Planned Maintenance
4 Data Fusion Notifications 4 Warehouse

5 Engineering Analysis
Data Warehouse
Engineering
Program Objectives Analysis Failure Analysis
• Decrease Maintenance Burden to Determine
CI Development
• Increase Platform Readiness Component
Health and Flight Regimes


Enhance Safety
Reduce O & S Cost
Remaining 5 Prognostics
Life
(Prognostics)
CBM - DW Benefits

Data Warehouse Capability Benefits

Correlates Platform Generated Data with Enhances Proactive Equipment Maintenance and
Historical Data Failure Predictions

Provides Life Cycle Management Capability Reduced O & S Costs and Increase in
for Components and Systems Component Reliability

Provides Fleet Level View of Operating


Enhances Force Planning
Condition

Provides Performance Information with Improve Platform Reliability and reduced


Maintenance Data logistical foot print

Robust Schema Design Allows Data From


Provides Force Planners Complete Readiness
Non-Aviation Platforms to be Easily
Capability of Unit
Integrated
FY07 CBM Benefits - 9 Months
(Oct 06 - Jul 07)

Action / Benefit
System Item
Eliminates Extends Saves / Improves
• 50 hr bearing inspection (between 1750 and 2250 hrs) • MMH per Inspection - 7.4 hrs
AH-64 M/R Swashplate • Maintenance Operational Check (approx 1 hr) • Downtime Saved per Aircraft - 5.9 hrs

AH-64 Main Rotor • AVA installation for main rotor smoothing procedure • MMH Saved - 2.0 Hrs
AH-64 Tail Rotor • AVA installation for tail rotor balancing procedure • MMH Saved - 2.0 Hrs
• AVA installation for vibration check at APU installation and APU mount inspection from 250 to 500 • MMH Saved per Inspection - 28 hrs
AH-64 APU Clutch phase hrs • Downtime per Aircraft - 9 hrs

TBO from 2500 to 2750 hrs • MMH Saved per Inspection - 4.4 hrs
AH-64 Aft Hanger Bearing AH-64: 171 AC/$2.1M Efficiencies • Downtime Saved per Aircraft - 2.2 hrs
• Improves Safety w/ Continuous Diagnostic Monitoring
• 1% Readiness Increase (Not in $)
• 2254 MMH Avoided TBO from 2500 to 2750 hrs • MMH Saved per Inspection - 4.4 hrs
AH-64 Fwd Hanger Bearing • Downtime Saved per Aircraft - 2.2 hrs
• 355 Hrs Downtime Avoided (Not in $) • Improves Safety w/ Continuous Diagnostic Monitoring
• 513 Hrs Reduction in Maint Test TBO of oil cooler fan assembly from
UH-60 Oil Cooler Axial Fan Bearing
Flights 2500 to 3240 hrs
• AVA installation for high speed shaft balancing procedure • MMH Saved per Inspection - 3.3 hrs.
Engine Output Drive (Replace w/Continuous Diagnostic Monitoring) • Downtime Saved per Aircraft - 1.8 hrs
UH-60
Shaft
UH-60: 143 AC/$295K Efficiencies
• AVA installation for main rotor smoothing and • 3.3% Readiness Increase MMH Saved - 17.2 Hrs
UH-60 Main Rotor, Nose Absorber nose absorber tuning procedure
• AVA installation for tail rotor balancing
• 1237 MMH Avoided MMH Saved - 2.0 Hrs
UH-60 Tail Rotor procedure • 673 Hrs Downtime Avoided
• AVA installation for cabin absorber • 148 Hrs in MTFs MMH Saved - 2.0 Hrs
UH-60 Cabin Absorber tuning procedure
Identifies potentially cracked splines reducing probability of
Accessory Gearbox Spline generator, or gear damage due to adapter chips migrating into the
UH-60
Adapter gearbox.
Aft Transmission Fan Comb • AVA installation for 50-hour vibration check CH-47: 30 AC/$128K Efficiencies • MMH Saved per event - 4 hrs
CH-47 Transmission Fan • Downtime Saved per event - 1.5 hrs/aircraft.
• 1% Readiness Increase
• AVA installation for main rotor smoothing MMH - 2.0 Hrs
CH-47 Main Rotor procedure
• 632 MMH Avoided
• AVA installation for T55 engine vibration
• 203 Hrs Downtime Avoided MMH - 2.0 Hrs
CH-47 Engines check at engine installation • 32 Hrs Reduction in MTF’s
Direct Comparison
DSC Equipped vs. Non-equipped UH-60 Battalions (Bns)

30 Aircraft Per Bn Non-equipped (Bn 1) Non-equipped (Bn 2)

Fully Mission Capable (FMC) 65% 77%

Total Flt Hours 10,331 11,844


03-04 OIF Rotation
BASELINE DATA

OPTEMPO (Hrs/Year/Acft) 334 395


Units Operating in OIF
Under Same Command
30 Aircraft Per Bn DSC Equipped (Bn 1) Non-equipped (Bn 2) Climate

FMC* 87% 82%


Total Flt Hours 21,819 20,388 05-06 OIF Rotation
OPTEMPO
727 680
(Hrs/Year/Acft)

Advantage of DSC Equipped Aircraft (05-


(05-06 Rotation)
 1,431 Increase in Hours Flown (Bn1 vs. Bn2) = +2 Aircraft at OPTEMPO
 Unit OPTEMPO Demonstrates +2 Aircraft vs. +1.5 Expected Increase

*5% FMC Increase should provide 1.5 aircraft worth of availability.

DSC Equipped Unit Had An Increase In Combat Power


Equivalent To 2 Additional Aircraft
A Cost Avoidance > $14M
Component Condition Chart
Apache Tail Rotor Gearbox

Predicted
0.5 Failure

3 Sigma
Removal
0.4
Vibrations (IPS)

0.3 Recommend
Condition Indicators Order Time

0.2
Geometric
Mean

0.1

0
1850 1900 1950 2000 2050 2100

Tail No: 0405470, AH-64D


Time Since New (Hours)
Serial No: Tail Rotor Gearbox E17-0695
Source: CBM Data Warehouse
Component History/Timeline *

T701 Engine – Cold Section Module


Serial No: GE 001003 Left Climbing
Turn
Exceeding
Partial Power Dive
45 Deg.
Descent

>120 Knots

Torque: 100 OGE Hover

N1: 96 IGE Hover


Turbine Gas Temp: 780
Engine Oil Pressure: 56
Engine Oil Temp: 75

l l l l l l l l ll lll l l l l l
Depot Level Maint. AVIM

0 hrs. 224 hrs. 229 hrs. 427 hrs. 427 hrs.

Installed on Overspeed; Installed on UH-60 Oil Leak; Installed on AH-64


UH-60 Removed From Tail No. 456 Removed From Tail No. 789
Tail No. 123 Tail No. 123 Tail No. 456

* Source: CBM Data Warehouse


Major Milestones

 10 Sept – Milestone B Decision


 17 Sept – BSC Certification
 28 Sept – Delivery of TD-6 functionality
 Oct – Dec 07 – Transition to Target Production
Environment (LOGSA)
 FY 09 – Design Readiness Review
 FY 11 – System Qualification Test
 FY11 - FOC
Terabytes and Petabytes

Data Size Is Like... As portable as


Measurement a CD in the
Year…
(Moore’s Law*)
Bit Single binary digit One binary decision Today
Byte 8 bits One single character Today
Kilobyte (KB) 1,024 Bytes Text of one-half typed page Today
Megabyte (MB) 1,024 Kilobytes Text of one to two books Today
Gigabyte (GB) 1,024 Megabytes Text of over 1,000 books Today
Terabyte (TB) 1,024 Gigabytes Text of one-half of an academic research library (1 million books) 2010
Petabyte (PB) 1,024 Terabytes Text of one-half of all US academic research libraries 2025
Exabyte (EB) 1,024 Petabytes Text of one-half the annual volume generated worldwide 2040