INTEGRATED

MAINTENANCE PLAN

CAPT GORDON COWARD AIR 6.1A

CAPT BOB BLAKLEY AIR 3.2A
 The Push Behind Going to Fixed PED
SDLM $$
Increased Operational
Commitments (Desert Decreased Facilities(BRAC) Requirement
$ Millions
Storm) Bow Wave
ASPA
Deferrals

FY Funding

Years

Pre IMC/P: SDLM / PED Adjusted by ASPA to fit Op Tempo & Budget Constraints

• Unpredictable Depot level maintenance budget

• A/C material condition declining
• Multitude of ISR/PE repairs

Post IMC/P: Fixed PED w/Integrated Maintenance

• Improved Material Condition

• Based on Reliability Centered Maintenance Analysis
• Integrated Maintenance Levels (where appropriate)
• Budget Predictability
 CNO DIRECTION
ESTABLISH
ESTABLISH A
A PLAN
PLAN TO
TO
TRANSITION
TRANSITION TO
TO FIXED
FIXED
OPERATIONAL
OPERATIONAL SERVICE
SERVICE
PERIODS
PERIODS THROUGH
THROUGH THE
THE
IMPLEMENTATION
IMPLEMENTATION OF
OF
RCM-BASED,
RCM-BASED, SUSTAINED
SUSTAINED
MAINTENANCE
MAINTENANCE PLAN.
PLAN.
 TOTAL SOLUTION
ALL PARTS MUST RECEIVE EQUAL CONSIDERATON

Integrated Maintenance Concept/Plan

OPERATIONAL ENGINEERING BUSINESS

SOLUTION SOLUTION SOLUTION

-Fleet buy-in -Improved readiness

-Executability -RCM Analysis
-Task Packaging -Depot concerns
by O and D level -Cost
-Supportability -Structural integrity
 Integrated Maintenance Concept/Plan
IMPLEMENTATION
• S-3B IMC/P LIFE CYCLE FLEET BENEFITS
• F/A-18 A-D
• Improved Aircraft material
Maintenance
• AH-1W
RCM Specification condition
• E-2C ANALYSIS Development • Reduced Depot Out of
• H-60B, F, H Service Time, increased
PROTOTYPE Aircraft Availability
Supportability
! UH-1N Age Exploration Analysis • Scheduled maintenance
& Sustainment
• H-53E & BCA tasks are performed at the
• H-46E right interval, by the
• C-2A appropriate skill level
• C-130 F/R, T Baseline/ unconstrained by traditional
Implement/
Transition
• EA-6B Monitor locations.
Execution
• F-14 A-D Planning • Reduced O-level down time
DEVELOPMENT
and maintenance req’ts
• AV-8B
• Reduced In-service Repairs.
FUTURE
• Integration between Sailors
EMPHASIS OPNAV/
• ENGINES Fleet and Depot Artisans.
Approval
• Commercially
DEVELOPMENT
Supported Platforms
SUSTAINING
 H-60 IMC PROGRAM BRIEF
ASPA1 ASPA5+
SDLM

7Days

7Days

7Days

7Days

7Days
18-24 MOS 4 Years 1 Year

11- 12 YEARS SINCE LAST DEPOT INDUCTION

Repeat Fixed
PMI Period
Cycle End Date
PMI 1 PMI 2 PMI 3 PMI 4
FI D

FI D
FI D

PMI 1
FI D

45 Days

112 Days
70 Days
45 Days

45 Days
POI POI POI POI
POI
685 Days 660 Days 685 Days 618 Days
685 Days

2 Years 2 Years 2 Years 2 Years 2 Years

Total Operational and Maintenance Service Period

Fixed Service Period (FSP)
 LOCATIONS
WHIDBEY
WHIDBEY
ISL
ISL
NASLemoore
NAS Lemoore EA-6B
EA-6B
F-18
F-18
Norfolk/Oceana
Norfolk/Oceana
CampPendleton
Pendleton NavalBase
Naval Base
Camp
H-1 F-18
F-18
H-1
E-2
E-2
F-14
F-14

NASNorth
NAS NorthIsland
Island CherryPoint
Cherry Point
H-60,F-18,E-2/C-2,
H-60, F-18,E-2/C-2, H-1,H-53,
H-1, H-53,H-46,
H-46,
S-3
S-3 AV-8B,EA-6B, F-18
AV-8B,EA-6B, F-18
MCASMiramar
MCAS Miramar
F-18
F-18
NSMayport
NS Mayport
H-60
H-60
CCAD
CCAD
H-1,H-60
H-60 NASJacksonville
NAS Jacksonville
H-1,
EA-6B
EA-6B
P-3
P-3
MCASBeaufort
MCAS Beaufort H-60
H-60
NAFAtsugi,
NAF Atsugi,Japan
Japan F-18
F-18 S-3
S-3
MCASKaneohe
MCAS KaneoheBay,
Bay,HI
HI E-2
E-2
F-18
F-18
H-60
H-60
H-1 Field Site
H-1
H-53
H-53
Depot Site
 EXAMPLES OF BENEFITS
SEEN BY THE FLEET
S-3B:
• Reduced O-level down time by 25 days per year
• Eliminated 19K maintenance man-hours per year
• Elimination of Calendar day inspections beyond the 56 day (benefit underway)
AH-1W:
• “SDLM” Cost Avoidance of $830K per A/C inducted
• Reduced Phase Maintenance tasks 50% (from 100hr intervals to 200 hr
interval)
• Reduced OTS by 126 days (SDLM 310 days, IMC 184 days over full cycle)
EA-6B:
• Out of service time due to scheduled inspection decreased by 67% (28, 56 and
224 day inspections rolled to the 364 day)
• Post Cruise Inspections revealed that aircraft that have been through a PMI
event had a better material condition and less corrosion than was historically
noted
SCOTT NAST BRIEF
Integrated Maintenance Data Collection
• Work Deck
(similar to maintenance requirement cards)
– Maintenance Guide
• provides standard guide through each maintenance
event
• supports similar rapid maturation of process at all sites
– Data collection template
• is the template for written feedback from all sites
• data collection parameters are identical for all sites
– data transfer
• data entry from work deck into data base
 Work Deck card - front example
CARD NAVAIR 01-H1AAC-IMC-SPEC NAVAIR 01-H1AAC-IMC-WD
DATE 9 August 2001 DATE 9 August 2001 ELEC PWR NA
BASELINE
99 REVISION DTD REVISION 3 DTD 24 May 2002
HYD PWR NA
TRADE BUNO INSP/TEST/REPAIR
WORK ZONE
/ TASK NO. STRUCTURE TAILBOOM COLDWORKING COND AIR NA

NOTE: Ensure all IMC disassembly and inspections have been completed prior to tailboom removal should the tailboom have to be removed.

8 – 2UY0004 1. Ensure that LES CP 80-50-EE-9238 with Amendment 1 has been complied with. This is a onetime rework of specific areas on the
tailboom.

End of Card

TASK NUMBER START DATE FINISH DATE MMHRS TOTAL STAMP

2UY0004

Form SOP H1-001-A Rev 3 Rev Date: 24 May 2002

 Work Deck card - back example
CARD NAVAIR 01-H1AAC-IMC-SPEC NAVAIR 01-H1AAC-IMC-WD BUNO
TRADE
DATE 9 August 2001 DATE 9 August 2001 BASELINE
STRUCTURE
99A REVISION DTD REVISION 3 DTD 24 May 2002

TAILBOOM COLDWORKING
TYPE
LENGTH WATERLINE DEFECT EST MMHRS
TASK MAL CRIT DISCR QA
/WIDTH/ /BUTTLINE/ NBNC WUC RPR DESCRIPTIVE DEFECT/DESCRIPTIVE REWORK TO
NO. CODE CODE P/N STAMP
DEPTH STATION ETC TIME REPAIR

L FS
W BL
D WL

L FS
W BL
D WL

L FS
W BL
D WL

L FS

W BL
D WL

L FS
W BL
D WL

L FS
W BL
D WL

Form SOP H1-001-A Rev 3 Rev Date: 24 May 2002

 Data Access and Presentation
• IMC Web Site
– common portal for:
• data entry
– example page
• reports
– examples
» standardized reports
» discrepancies discovered on airframe model
» mal code frequency
» mal code frequency times cost in man-hours
• RCM data entry and analysis
• messages search
Website Browser Page

The blue buttons allow the user to browse through

the website. The grey bar on the left is for
administration. It is not shown on the regular web
page.

The next page shows the data entry from remote

sites page, and is accessed through the admin area.
Data Entry Form
“Reports”
3D Viewer
3D Viewer Search Engine
3D Viewer Populated
“Reports”
 MAL CODES
AVG RPR TIME X AVG MALCODE
TRUNCATED

500

450

400
AVG RPR TIME X AVG MALCODE HITS

350

300

250

200

150

100

50

0
190 105 170 020 070 246 800 093 804 846 160 935 135 780 350 117 302 127 429 087

MALCODE
 MAL CODES
AVERAGE MALCODE COUNT ALL SITES
TRUNCATED
400

350

300

250
AVERAGE COUNT

200

150

100

50

0
105 170 070 020 246 190 093 800 160 804 350 117 935 302 846 429 135 780 801 425 440 022 381 766 306 114 074 710

MALCODE
BACKUP SLIDES
 Background
Aircraft Age & Inventory
AVERAGE AIRCRAFT AGE
AIRCRAFT AVERAGE AGE (YEARS)

25 HELICOPTER
24 ACTIVE INVENTORY
23
22 FY1997 AVERAGES: COMBINED
21 FY1997 AVERAGES:
16.7 YRS –HELICOPTER
20 16.7 YRS –HELICOPTER
14.7 YRS –COMBINED
19 14.7 YRS –COMBINED
13.6 YRS –FIXED WING
18 13.6 YRS –FIXED WING
17
16
15
FIXED WING
14
13
12
89 90 91 92 93 94 95 96 97 98 99 00 01 02 03
FISCAL YEAR

NUMBER OF AIRCRAFT • DoN in a Shrinking Budget Environment

" Life Cycle Support Costs ratio has increased
7,000 ACTIVE INVENTORY
6,500
6,000

Naval Aviation TOA

5,605
5,487
5,500 5,250
5,497
5,000
4,925 4,514
4,500 4,228 4,169
4,406
4,000
4,167 4,079
3,500 Life Cycle Support Costs
3,000
89 90 91 92 93 94 95 96 97 98 99
FISCAL YEAR
SOURCE: ACTIVE AIRCRAFT INVENTORY FY89-99 BASED ON
FY89-96, A-II INV DATABASE, AND A-II JUL 97 REPORT Years

What is RCM?
A life cycle process that:
• Establishes and adjusts
preventive maintenance
(PM) requirements for
all maintenance levels. RCM Plan *
Bases PM on the failure
characteristics of the
equipment
• Allows equipment to
realize its inherent
reliability at lowest cost
Reliability Centered Maintenance
Fleet Benefits
RCM LIFE CYCLE • Improved ACFT material condition
• Increased ACFT Availability
Develop Failure mode analysis
• PM tasks completed at the right interval,
by the appropriate skill level
unconstrained by traditional locations
• Reduced O-level down time and
maintenance requirements
• Reduced ISR cost
Task
Evaluation & • Integration between O/I/D as
appropriate
Data collection Selection
• Savings generated by RCM is
across the Fleet
Package
Implement, ! P-3 Flap Actuator $6 Million over 5 years
O/I/D
Monitor & Trend Maintenance ! EA-6B Landing Gear $7 Million Dollars
Top Degraders Tasks over 5 years
! T-45 84 day Corrosion Inspection Large
Reduction in Labor man-hours and
airplane down time
! E-6 Aft Engine Mounts $1.5 Million over
Requires PRL funding life of A/C
! AH-1 Change to IMC 30% reduction
labor man-hours 50% reduction in Depot
turnaround time
* RCM plans is approved by NAVAIR