RAAF SRP1 a resounding success Special: At Last! The competition for MHP is on

Transcription

1 Spring 2004 RAAF SRP1 a resounding success Special: At Last! The competition for MHP is on

2 Hungary joins NFTC, triggering purchase of additional aircraft. See article on page 6

3 Features Editorial Sylvain Bédard Special: Maritime Helicopter Team optimistic about MHP Government of Canada s competition for Maritime Helicopter Project finally under way. 4-5 RAAF F/A-18 undergoes prototype modification in Mirabel L-3 MAS meets the challenge of SRP1 and prepares for transitional phase to Australian industry. 6-7 New L-3 MAS targets industry position as provider of choice L-3 acquisition of Bombardier Military Aviation Services builds on experience to provide outstanding capabilities. 8-9 Different goals, similar successes on two model CF-18 programs L-3 MAS helps assure extended CF-18 service life through center barrel replacement and Joint Forces interoperability through avionics upgrading and modernization New Commercial Services Director plans comprehensive support Gerald Sosontovich discusses his vision for center of excellence supporting Bombardier CRJ*, Challenger* and Global* fleets. 12 ON YOUR WING is published semi-annually by: L-3 MAS 10,000 Helen-Bristol Street Montréal International Airport-Mirabel Mirabel (Quebec) J7N 1H3 Editor: Rachel Thibault Editorial Consultant: Leah Curley Communications Inc. Collaborators : Wayne Crowe, Bruno Mercier, René Blouin, Ugo Paniconi, Gerald Sosontovich Design: L.A.D. Communications Inc. Telephone: (450) Fax.: (450) info.marketing@l-3com.com To make use of the contents of this publication, you must first obtain permission from L-3 Communications MAS (Canada) Inc L-3 Communications MAS (Canada) Inc. All rights reserved. PRINTED IN CANADA L3C-0002 (03/04) A new team for 2004 and beyond A new year a new company. In November of 2003, the Military Aviation Services of Bombardier Aerospace changed hands, joining American defense electronics giant L-3 Communications growing portfolio of aerospace companies. Our new name is L-3 MAS, and you will find more about the acquisition in this issue of On Your Wing. While the name of our Mirabel facility has changed, the activities go on unabated. As you will see from our special feature report, the competitors for Canada s Maritime Helicopter Project are finally out of the gate, and we anticipate a favorable finish for L-3 MAS and its industry team. In February, we achieved an important milestone on our Structural Refurbishment Program Phase 1 (SRP1) contract with the Royal Australian Air Force when we successfully completed the first RAAF F/A-18 prototype. It was a challenging and rewarding experience, which you will find more on in this issue. Another major success story covered in this issue of On Your Wing concerns our role in extending the service life and insuring Joint Forces interoperability for the Canadian Forces CF-18 fleet. We are also pleased to introduce you to our new Commercial Services Director and provide an overview of our new plans in the commercial sector plans that will leverage the considerable resources our people, facility and experience represent. In closing, I would like to assure you that while we move forward with a new name, our commitment to you continues. We are always on your wing. Sylvain Bédard President L-3 MAS On Your Wing 3

4 Teamwork MARITIME HELICOPTER TEAM OPTIMISTIC ABOUT MHP Breadth and scope of ISS contract make L-3 MAS a key component in a winning team The Government of Canada s longawaited competition for its Maritime Helicopter Project (MHP) is finally under way. The Request For Proposal (RFP), which was issued on 17 December 2003, solicits bids by 30 April 2004 for the supply of 28 maritime helicopters and 20 years of In-Service Support (ISS). Three industry teams initially registered to compete, but only two will move forward from the pre-qualification round: the Maritime Helicopter Team, comprising Sikorsky, General Dynamics Canada and L-3 MAS, and Team Cormorant, headed by Agusta- Westland. Maritime Helicopter Team hard to beat Sikorsky is proposing the H-92 SUPERHAWK to fill the aircraft acquisition contract, with General Dynamics Canada (GDC) providing the Integrated Mission System (IMS). L-3 MAS will lead the ISS effort. We are very optimistic about our chances, said Sylvain Bédard, President of L-3 MAS. Sikorsky and GDC are offering a superior product. And L-3 s capabilities and experience, combined with L-3 s proven ability to assemble and manage strong industry teams, make us an ISS contender that will be hard to beat. In addition to the initial 20-year period, the ISS contract includes options to extend in five-year increments, providing significant potential for long-term growth. The real appeal for L-3 MAS, however, is the challenging breadth and scope of its mandate. This is an opportunity to demonstrate the full capabilities of our organization, commented Serge Le Guellec, L-3 MAS Vice-President, Programs and Contracts. The requirements of this RFP are rigorous and extensive. The potential here is huge not only to show what we can do, but also to stretch ourselves and grow with the program. A challenging mandate If the H-92 SUPERHAWK is selected, L-3 MAS will play an important role in both acquisition and ISS contracts. 4 L-3 MAS

5 Responsibilities related to the acquisition contract could include engineering and design of the structural and mechanical provisions for the folding tail pylon and the layout of the helicopters exterior finish and markings, as well as completion and final delivery of the 28 H-92 Maritime Helicopters. L-3 MAS will also be involved in Engineering and Airworthiness Certification of the new helicopters, assisting Sikorsky in the development of a continuous Airworthiness Program. a comprehensive Configuration Management program; support the DND Weapon System Manager with Fleet Maintenance & Operational Planning; develop, implement and maintain complete life cycle management programs; select an industry team to provide optimum support while maximizing Canadian content; establish and maintain a Logistics Support Analysis data repository for the MHWS; and support the development of maintenance instructions and technical data. The ISS contract would charge L-3 MAS with lead responsibility for ISS set-up and provision of extensive ISS activities. The mandate includes development of a Maritime Helicopter Weapon System (MHWS) technical support concept, ensuring a smooth transition from production to in-service, as well as management and control of all ISS work in strict accordance with cost, schedule and performance requirements. This will involve planning, executing and controlling work performed by subcontractors as well as establishing a Contractor Management Office in the Ottawa area and Contractor Field Offices at each operating unit, to act as the point of contact for the customer (Department of National Defence/DND) for all ISS issues. L-3 MAS will also support Sikorsky in the development and management of an Accredited Technical Organization; implement and maintain Field Service Representatives and Inspection, Repair and Modification services, Third Level Maintenance, Supply Chain Management and Supply Support services are also part of the ISS mandate, along with a host of other responsibilities. Sikorsky is proposing the H-92 SUPERHAWK to fill the aircraft acquisition contract, with L-3 MAS leading the ISS effort. Key opportunities for L-3 MAS include the growth of material management in support of the contract, the expansion of engineering support and fleet management, which builds on L-3 MAS s considerable experience developed under national and international F/A-18 programs and the C-23 program in the US. On Your Wing 5

6 Success Story RAAF F/A-18 UNDERGOES PROTOTYPE MODIFICATION IN MIRABEL On 18 February 2004, RAAF Hornet S/N A departed Mirabel on its homeward flight, following successful installation of 19 SRP1 prototype modifications, aircraft reassembly and flight testing. The program was complex, and some unexpected repairs were required along the way. Despite these obstacles, all work was completed with only eight days slippage over the 18-month term of the contract, making this important SRP1 milestone a satisfying experience for both L-3 MAS and its customer. Phase 1 of the Royal Australian Air Force (RAAF) Hornet Structural Refurbishment Program (SRP1) is an effort aimed at correcting structural deficiencies and ensuring aircraft airworthiness up to the retirement of the fleet. The contract was awarded in August 2002, naming Bombardier Aerospace, now L-3 MAS, as prime contractor. One year later, in August 2003, RAAF aircraft serial number A arrived at the L-3 MAS Mirabel facility, where it underwent installation of the SRP1 prototype modification kits. When it made its successful test flight on 29 January 2004, the occasion marked the conclusion of a challenging five-month prototyping effort. Many challenges The arrival of the aircraft marked the first induction of an RAAF F/A-18 at the L-3 MAS facility, challenging the development team with preparatory work beyond the completion of drawings, tooling and mod kits. Our Maintenance Planners had to review existing procedures very carefully, commented Bruno Mercier, RAAF Program Manager, L-3 MAS. In many cases, we had to adapt to conform to the specific requirements of the RAAF. The tooling is presently undergoing significant changes to optimize it for the production phase. The extensive disassembly and inspection involved was also a first for 6 L-3 MAS

7 an Australian Hornet, and unexpected cracks at the wing front spar caught everyone by surprise. While repair schemes were available, they had to be revised and extended to cope with the damage to highly critical areas. The fast turnaround achieved would not have been possible without the infrastructure available in Mirabel, nor without the expertise gained under the International Follow-on Structural Test Program (IFOSTP), a collaborative effort with the DND and the RAAF, and DND s CF-18 Airframe Life Extension (ALEX) program. Unforeseen corrosion was also identified in the wing fold transmission. Once again, the general techniques available had to be adapted to correct the problem. The RAAF s satisfaction is highlighted by the Australian Government Defence Material Organization s Company Scorecard, which underscores the high level of confidence provided by the exceptionally open and flexible approach taken by (L-3 MAS) to satisfying their responsibilities under the Contract. Transition phase begins The RAAF is also pleased with L-3 MAS s participation in the Hornet Industry Coalition (HIC), which reflects the company s commitment to support the Australian industry that will be responsible for performing the remaining fleet installations. A new project team was recently formed to initiate the transition phase. Called Low Rate Initial Production (LRIP), this phase contracts L-3 MAS to implement the SRP1 modifications on six aircraft at Williamtown, New South Wales, Australia, while providing hands-on training. The work is planned for the April to December period of this year. At Mirabel to support flight test were (from left) Sergeant Paul Richards, Flight Sergeant Dimitri Dufour, Squadron Leader Jason Murray and Sergeant John Hovius. On Your Wing 7

8 Strategy NEW L-3 MAS TARGETS INDUSTRY POSITION AS PROVIDER OF CHOICE FOR GOVERNMENT AND CIVIL AIRCRAFT SUPPORT AND MODIFICATIONS The acquisition of Bombardier Inc. s Military Aviation Services business by L-3 Communications was completed on 31 October Building on past and on-going experience, the newly named company offers outstanding capabilities. These include its strong military aircraft fleet portfolio, its proven ability to leverage expertise onto commercial projects and its reputation for managing complex endto-end projects. Best known as the industry s largest merchant supplier of defense electronics, L-3 Communications has been steadily expanding its capabilities and extending its influence by acquiring businesses that build on its broad base. A case in point was the decision to add Bombardier s Military Aviation Services organization to L-3 s growing aerospace family. As a holding company, L-3 takes a hands off approach, giving its individual business units the benefit of its vast resources and synergies, while allowing each to maintain operational integrity. This philosophy is reflected in the name of the company newly formed in November 2003: L-3 MAS. 8 L-3 MAS

9 The company s client base includes the Canadian Forces, the United States Department of Defense (DoD), the Australian Defence Forces, prime contractors and OEMs and other international military organizations, making L-3 MAS a leader in systems engineering support and avionics modernization. L-3 MAS will also continue to provide a full range of technical services in the areas of aircraft maintenance, repair and upgrade for military aircraft and business and regional jets, and the refurbishment and modernization of selected commercial aircraft. The acquisition solidifies L-3 Communications leadership position in the growing aircraft modernization market, leveraging synergies with L-3 s Integrated Systems and Spar Aerospace businesses and providing access to new platforms, such as the Canadian Ministry of Defence s Maritime Helicopter Program and other international opportunities. With L-3 Communications background as a major defense contractor and L-3 MAS s successful track record in managing government programs, the two enjoy a high degree of cultural commonality, facilitating the transition and providing a familiar feel and security for long-standing customers. Headquartered at its Mirabel facility in Quebec, Canada, L-3 MAS also has facilities in Cold Lake (Alberta), Ottawa (Ontario), Bagotville (Quebec), Fredericton (New Brunswick), and Bridgeport (West Virginia, USA). About L-3 Communications Headquartered in New York City, L-3 Communications is a leading provider of Intelligence, Surveillance and Reconnaissance (ISR) systems, secure communications systems, aircraft modernization, training and government services and is a merchant supplier of a broad array of high technology products. Its customers include the U.S. DoD, Department of Homeland Security, selected U.S. Government intelligence agencies and aerospace prime contractors. To learn more about L-3 Communications, please visit the company s web site at On Your Wing 9

10 Customer Delight DIFFERENT GOALS, SIMILAR SUCCESSES ON TWO MODEL CF-18 MODIFICATION PROGRAMS In 2001, L-3 MAS signed contracts for two CF-18 modification programs. The first, in February, with DND, aimed at extending the service life of the CF-18 fleet through center barrel replacement (CBR). The second, signed in June, was a subcontract from The Boeing Company involving work on the CF-18 Modernization Project, a program designed to ensure CF-18 interoperability for Joint Forces missions through avionics upgrades and modernization. Different though their goals may be, these programs have enjoyed similar successes, meeting and often exceeding customer expectations. We couldn t be happier with these programs, commented Dixon Kenny, Vice-President Marketing and Business Development at L-3 MAS. Each has given us an opportunity to demonstrate our knowledge and expertise, and both have earned us lavish praise from contented customers. CBR program off to a quick start and picking up speed When DND contracted L-3 MAS to perform CBR on 40 of its CF-18 aircraft, the complexity of the work initially dictated an eight-year schedule. The aircraft designated as the prototype was to be completed in December 2003, with work on the following 39 jets to begin in January 2004 and continue at a rate of 10 aircraft per year. To everyone s satisfaction, L-3 MAS quickly established a faster pace for this program, with the first CBR being completed by February 2003 more than nine months ahead of schedule. In June 2003, the prototype aircraft performed a highly successful post-modification flight test, and has since accumulated more than 160 hours of flight. The efficiency of the process at L-3 MAS and the swift success of the prototype project advanced the start on the remaining 39 aircraft by more than a year. By the end of February 2004, a mere two months from the anticipated start-up date, work on five more aircraft had commenced. Two had already had their center barrels replaced and were undergoing re-splicing a task requiring a high degree of precision and highly specialized tooling. One of the aircraft was being de-spliced into three parts to expose the center barrel for replacement, while the remaining two were in the preparation phase. The rate of production has also accelerated, with the third aircraft in the jig for less than half the time of the first. It is expected that the speed of production will continue to pick up until the seventh aircraft, when it should stabilize. To accommodate the faster pace of work and achieve the goal of 10 aircraft per year, L-3 MAS is now installing a second jig in the CF-18 hangar at Mirabel. In mid April 2004, with this jig in place, a second production line will begin operation. As René Blouin, L-3 MAS CBR Project Manager, commented, There are lots of challenges ahead, but that s what makes this job so interesting. In the meantime, our customer is very happy with our progress and with the performance of the prototype aircraft. Our team is extremely competent, motivated and supportive. All in all, it is really a pleasure to work in such an environment. Modernization program delivering model performance Seventy-eight of the 80 aircraft involved in the CF-18 Modernization Project have been scheduled for avionics modifications at Mirabel from January 2003 through Referred to as ECP 583, the avionics upgrade package will equip the CF-18s with 10 L-3 MAS

11 Final preparations are made for the first test flight of the prototype aircraft in DND s center barrel replacement program. improved communication and navigation capabilities, including a new mission computer, the APG-73 radar, a new stores management set, a secure radio system and a combined interrogator/transponder system. The four-year program is quickly proving successful, thanks to the outstanding communication and teamwork amongst all parties. Activity at L-3 MAS began in 2002, with detailed production planning. A dedicated mod-line hangar was set-up at the Mirabel facility and a pre-production readiness review was conducted, paving the way for the induction of the first pre-production aircraft in January Interface processes between Boeing, the Canadian Forces and L-3 MAS were defined early in the program. Just as importantly, an open attitude was adopted by all involved, fostering the continuous sharing of problems, concerns and improvement ideas. As a result, potential risks and issues have been identified and proactively addressed on the project, while opportunities have been promptly exploited. On 30 October 2003, Boeing recognized L-3 MAS with a Certificate of Appreciation for outstanding service and contributions leading to the successful production phase of the CF-18 Modernization Project. Looking beyond the spirit of partnership that characterizes the CF-18 Modernization Project, the mod-line approach implemented by L-3 MAS must also be credited for a measure of the program s success. For example, all mod-line technicians have been provided with detailed work instructions and work is organized by aircraft area. L-3 MAS also breaks apart the Boeing kits to match installation instructions by work area. The size of the L-3 MAS facility at Mirabel is an added efficiency factor. The mod-line hangar accommodates eight aircraft at a time, allowing L-3 MAS to induct and deliver two aircraft per month. As On Your Wing goes to press, 18 modernized CF-18 jets have been delivered by L-3 MAS to Boeing. The program is very much on schedule, and L-3 MAS s participation has favorably impressed DND, who view it as a model well worth following. Boeing recently presented L-3 MAS with a Certificate of Appreciation for its outstanding support. According to Robert FitzPatrick, Boeing CF-18 Modernization Site Manager at Mirabel, L-3 has achieved a level of quality that we can all be very proud of. He went on to say, The commitment by the technical and administrative personnel is greatly appreciated. On Your Wing 11

12 Vision NEW COMMERCIAL SERVICES DIRECTOR PLANS COMPREHENSIVE SUPPORT OF CIVIL FLEETS A recent arrival at L-3 MAS, Gerald Sosontovich is no newcomer to aviation. A career spanning 20 years and a wide range of responsibilities with industry leaders Rolls-Royce, Innotech, Bombardier Aerospace and CAE explains his breadth of experience and personal scope, and makes him the ideal candidate for the role of Commercial Services Director at L-3 MAS. In my 10 years at Rolls-Royce, I think my most satisfying accomplishments were improving inventory and forecasting activities and developing an in-house customer support team for the company s corporate repair and overhaul services group, which moved us to the number one position for many years, Sosontovich said. As a Six Sigma agent at Bombardier, my focus was constant improvement of organizational processes. But it was during his years at Innotech, followed by a stint as General Manager of the Bombardier Global Express* Modification Line, that he honed his skills and nurtured the concept he plans to implement at L-3 MAS. My goal is to set up a center of excellence to insure long-term support of Bombardier CRJ, Challenger and Global aircraft fleets with heavy maintenance, special mission installations, component repair and refurbishment capability. And this is the right place to do it, he said, pointing to the stability and experience of the qualified work force at the L-3 MAS Mirabel facility, and to his own proven ability to build partnerships with outside suppliers in the completions field. Approximately 150 engineers are on staff to support the program and the list of technical services and capabilities available at Mirabel is extensive. We can do, structural, systems engineering and paint you name it, Sosontovich continued. With our Bombardier heritage, we know these aircraft best. In addition, we can and will leverage the skills we ve developed on the F/A-18 program to provide more and more complex and technical installations and solutions for the commercial market and additional aircraft types. Bring it on home, is his message to Bombardier and to operators of Bombardier CRJ, Challenger and Global jets, whether the task is to modify precompletion or to modernize in-service aircraft. For information on L-3 MAS Commercial Services, please contact Gerald Sosontovich at (gerald.sosontovich@l-3com.com). 12 L-3 MAS * Trademarks of Bombardier Inc. or its subsidiaries.