Depot Contributions to Weapon Systems Readiness

Transcription

1 Depot Contributions to Weapon Systems Readiness RDML Michael Hardee USN, Commander, Air Depots, Naval Air Systems Command DOD MAINTENANCE SYMPOSIUM 26-OCT-06 RENO, NEVADA

2 Outline Naval Air Depot Overview Production In Theater Challenges & Metrics Transformation Strategies Summary 26 OCT 2006 NAVAIR Depot Contributions to Weapon Systems Readiness Slide 2

3 Annual Naval Aviation Industrial Support To The Fleet $2.0B 700 Aircraft 1500 Engines & Modules 70,000 Components Support Equipment Calibration In Service Repair Fleet Support Teams 10,000 Skilled Personnel Focused on Providing the Warfighter What They Need, When They Need It, at the Right Cost Maintenance & Modifications Depot Ops & IMC Dets: North Island West Coast TACAIR Jacksonville East Coast TACAIR Cherry Point Marine Aviation OCONUS Repair: NAPRA Pacific/IO OIF/OEF Worldwide Support Equip Repair 26 OCT 2006 NAVAIR Depot Contributions to Weapon Systems Readiness Slide 3

4 Deployed: OIF/OEF Support -Global War on Terror- Over 100 personnel in support of expeditionary maintenance 1335 in-service repair field teams Mod teams to incorporate missile warning mods on CH-46E s Permanent detachment at Al Assad to perform in-service repair/inspection Performed: 100,000 hrs of expeditionary maintenance 50,000 hrs of in-service inspections 200,000 hrs of in-service repairs 30,000 stop-gap manufacturing of out-of-production parts 1400 tech assistance responses Provided: 150 emergency/expedited shipments of parts Over 300 improved reliability engines for deployed H-46s 200 H-53 engines with titanium nitride coated blades/vanes to improve durability/reliability Expedited engineering development of critical mods to include ASE and armor 26 OCT 2006 NAVAIR Depot Contributions to Weapon Systems Readiness Slide 4

5 Metrics Production to Plan (A/C, Engines, Components) TAT (on-time delivery) WIP Cost/NOR Quality Reliability/Time on Wing (TOW) 26 OCT 2006 NAVAIR Depot Contributions to Weapon Systems Readiness Slide 5

6 Challenges Constrained Budgets Fleet Response Plan (FRP) Faster Air Wing deployment turnaround Quicker readiness refresh after deployment Increased requirement for up jets on flight line Higher utilization of aircraft, engines and components Material Condition Aircraft consumption: work content growth Increased utilization of aircraft GWOT, OIF, OEF Variability of inducted aircraft Material Availability Increasing replacement factors Variability in material condition of inducted retrogrades Difficulty in forecasting quantity & type of component workload Long lead time for procurement Parts obsolescence Cost growth Manpower Aircraft consumption requiring increased skills i.e. sheet metal Market constraint for qualified artisans 26 OCT 2006 NAVAIR Depot Contributions to Weapon Systems Readiness Slide 6

7 Transformation Strategies Accelerated retirement of oldest, higher cost airframes Improving reliability of components AIRSpeed Integrated Maintenance Concept (IMC) Fleet Readiness Centers 26 OCT 2006 NAVAIR Depot Contributions to Weapon Systems Readiness Slide 7

8 AIRSpeed Value Delivered Jacksonville Cherry Point North Island P-3 Reduced TAT by 24 days (225 days to 201days) Improved Stability / Reduced Variability by over 40 Days (79 Std Dev to 69 Std Dev) Sold 22 Aircraft vs. 19 Aircraft in FY04 Reduced WIP by 5 Aircraft (from 17 to 12) EA-6B Reduced WIP from 17 Aircraft to 9 WIP reduction returned 2 Squadrons to the Fleet Aircraft Returned to the Fleet Faster (FY04 vice FY05) Reduced Cycle Time from 463 Days to 380 Days Increased On-time Deliveries from 31 percent to 83 percent Lean, Six Sigma Tools Focused on reduction in cost, TAT, and WIP Enterprise Application TOC H-46 Reduced TAT by 35 days Gained 3719 WLS Hours WIP reductions resulted in 11 more assets to the fleet H-53 Reduced TAT by 145 days Gained 1200 WLS Hours WIP reductions resulted in 16 more assets to the fleet AIRSpeed F/A-18 PMI 1 Reduced TAT by 50 days (from 190 days to 140 days) Reduced WIP by 12 aircraft Results achieved despite work content growth from 6453 hours to 8335 hours E-2 PMI 2 TAT reduced from 225 days to 180 days PMI 1 TAT reduced from 100 days to 35 days Cost-wise readiness & dominant maritime combat power to make a great Navy/Marine Corps team better! 26 OCT 2006 NAVAIR Depot Contributions to Weapon Systems Readiness Slide 8

9 IMC Locations Shifted from on-condition to calendar-based aircraft maintenance Taking Depot Maintenance to the Fleet Full time depot maintenance at every major Navy & Marine Corp Air Station worldwide NAPRA NAPRA S. S. Korea Korea H-53 H-53 NAS NAS Lemoore Lemoore F/A-18 F/A-18 Point Point Mugu, Mugu, CA CA E-2 E-2 Camp Camp Pendleton Pendleton H-1 H-1 NAS NAS North North Island Island H-60, H-60, F/A-18 F/A-18,E-2,,E-2, C-2, C-2, H-53 H-53 NAF NAF Atsugi, Atsugi, Japan Japan / / NAPRA NAPRA Det Det Okinawa Okinawa E-2, E-2, F/A-18, F/A-18, H-60, H-60, H-46 H-46 H-1, H-1, H-53, H-53, EA-6B EA-6B STAE STAE Singapore Singapore C-130 C-130 Whidbey Whidbey ISL ISL EA-6B EA-6B Paxtuent Paxtuent River, River, MD MD F/A-18, F/A-18, H-60 H-60 NAS NAS Fallon Fallon NV NV H-60 H-60 Hill Hill AFB, AFB, UT UT C-130 C-130 MCAS MCAS Yuma, Yuma, AZ AZ AV-8B AV-8B MCAS MCAS Miramar Miramar F/A-18 F/A-18 MCAS MCAS Kaneohe Kaneohe Bay, Bay, HI HI H-60 H-60 Andersen Andersen AFB, AFB, Guam Guam H-60 H-60 MCAS MCAS Beaufort Beaufort F/A-18 F/A-18 St. St. Augustine Augustine EA-6B EA-6B Norfolk/Oceana Norfolk/Oceana Naval Naval Base Base F/A-18, F/A-18, E-2, E-2, F-14, F-14, H-60 H-60 Cherry Cherry Point Point H-1, H-1, H-53, H-53, H-46, H-46, AV-8B,EA-6B AV-8B,EA-6B NS NS Mayport Mayport H-60 H-60 NAS NAS Jacksonville/Cecil Jacksonville/Cecil Field Field EA-6B, EA-6B, P-3, P-3, H-60 H-60 S-3, S-3, F/A-18 F/A-18 Field Site Depot Site 26 OCT 2006 NAVAIR Depot Contributions to Weapon Systems Readiness Slide 9

10 FRC & BRAC Law What Does it Mean?- Disestablish / Reestablish (I-Levels and Depots into FRCs) Moves Hours Moves People Moves Facilities Mandates Savings 26 OCT 2006 NAVAIR Depot Contributions to Weapon Systems Readiness Slide 10

11 Fleet Readiness Centers Integration of Intermediate and Depot Organic Maintenance INTERMEDIATE 6,000 + Sailors and Marines ashore 3,900 Sailors shipboard 20 Aircraft Intermediate Maintenance Departments and 11 Marine Aviation Logistics Squadrons 6,000 Engine/Module Accessory Repairs 580,000 Component Repairs $2.0 Billion Operation DEPOT 10,000 Civilians 3 NAVAIR Organic Depots 70,000 Depot-level Component Repairs 700 Depot-level Aircraft Repairs 1,500 Depot-level Engineering and Module Repairs $2.0 Billion Operation 26 OCT 2006 NAVAIR Depot Contributions to Weapon Systems Readiness Slide 11

12 Fleet Readiness Center Locations FRC WEST AIMD Lemoore NADEP NI NI Det Det Lemoore Site Site Fallon NADEP NI NI Det Det Fallon Site Site Fort Fort Worth AIMD Atlanta (FA-18 support) NAS NAS JRB JRB Fort Fort Worth FRC NORTHWEST AIMD Whidbey Island FRC MID-ATLANTIC AIMD Oceana AIMD Norfolk AIMD NAS NAS Corpus Christi NADEP CP CP Det Det Oceana NADEP JAX JAX Det Det Norfolk NADEP JAX JAX Det Det Oceana NAWCAD LKE LKE Det Det Norfolk Site Site Pax Pax River Site Site New New Orleans AIMD Atlanta (E-2C support) NAS NAS JRB JRBNew Orleans Site Site NAF NAF Washington FRC SOUTHWEST AIMD North Island NADEP North Island NADEP NI NI Det Det NI NI Site Site Miramar MALS-11 & Miramar NADEP NI NI Det Det Miramar Site Site Point Mugu Site Site Pendleton MALS-39 Pendleton NADEP NI NI Det Det Pendleton Site Site Yuma MALS-13 Yuma NADEP NI NI Det Det Yuma FRC SOUTHEAST NADEP JAX JAX NADEP JAX JAX Det Det Cecil Field AIMD JAX JAX AIMD Brunswick Site Site Mayport AIMD Mayport NADEP JAX JAX Det Det Mayport NAWCAD LKE LKE Det Det Mayport Site Site Key Key West FRC EAST NADEP Cherry Point MALS-14 Cherry Point AIMD Willow Grove Site Site New New River MALS-26 & 29 29New River NADEP CP CP Det Det New New River Site Site Beaufort MALS-31 Beaufort NADEP JAX JAX Det Det Beaufort FRC FRC East East Affiliation HMX-1 Quantico Site Site Robbins AFB AFB MALS-42 AIMD Atlanta 26 OCT 2006 NAVAIR Depot Contributions to Weapon Systems Readiness Slide 12

13 Primary Function Statement & FRC Fundamental Design Tenets Requires Process, Organization, & Culture Change Primary Function FRCs provide relevant quality airframes, engines, components, and services to meet the NAE s aircraft Ready for Tasking (RFT) entitlements at improved efficiency and reduced cost. In order to perform to entitlement requirements, FRCs provide seamless integrated off-flightline repair, in-service industrial scheduled inspections/mods, and deployable Sea Operational Detachments. Fundamental Design Tenets Seamless integration of I/D Level maintenance to create optimized twoactivity-level (on-flightline and off-flightline) maintenance TMS focus for maintenance planning, budgeting & execution Metrics driven operation Enterprise Cost reduction achieved through workforce reshaping and reduced material requirements 26 OCT 2006 NAVAIR Depot Contributions to Weapon Systems Readiness Slide 13

14 Component Repair AS IS FLEET Bad Parts I Bad Parts D Good Parts Inventory Good Parts Good Parts FRC TO BE FLEET Bad Parts I Artisans LESS Bad Parts D Good Parts Inventory MORE Good Parts Good Parts Reduced Cost Decreased Turn-Around Time 26 OCT 2006 NAVAIR Depot Contributions to Weapon Systems Readiness Slide 14

15 FRC s Creating Value -Expected Enterprise Benefits- Improved readiness through: Reduced turn-around times Less WIP Improved reliability/increased time on wing Increased Type/Model/Series focus and visibility Lower enterprise cost through: Focused D at I that maximizes readiness at reduced cost Reduction of duplicate/repeated maintenance activity Reduced manpower requirement Reduced materiel cost Potentially fewer repair sites 26 OCT 2006 NAVAIR Depot Contributions to Weapon Systems Readiness Slide 15

16 Leadership Of course it s hard! It s the hard that makes the game great! Be Visibly Committed & Engaged Establish Burning Platform Advanced Leadership, not management Change management vs. change leadership Manage within resources or go to the next level Path of discovery Refresh education, engage and train leaders & influencers first Work Top Down Include the customers & suppliers Coach, Cheer, Celebrate Implementation progress will be measured Can t just talk the talk 26 OCT 2006 NAVAIR Depot Contributions to Weapon Systems Readiness Slide 16

17 Senior Leadership FROZEN MIDDLE Civilian Artisans & Uniformed Technicians How do you become a part of the CHOCOLATE? 26 OCT 2006 NAVAIR Depot Contributions to Weapon Systems Readiness Slide 17

18 Status Basic organization and operation fixed Funding alignment fixed HQ and Area Commands standing up provisionally in Oct Staffing of key HQ and Area Command positions in process Fleet Implementation Team deployed to: Introduce concepts to Area Commands and Subordinate Sites Facilitate workload movement from Depot to IMA Functional IT requirements in development MOA s with Fleet leaders (Commodores) in work 26 OCT 2006 NAVAIR Depot Contributions to Weapon Systems Readiness Slide 18

19 Lessons Learned Senior leadership must be aligned with basic intent and organization Beware of Miracles Move fast Establish basic governance structure early Chapter 3 of Good to Great is critical CONOPS must flow: Intent and operational objectives Structured application of design criteria Stakeholder involvement and buy-in Communication is never what you think it is BRAC is a good foundation, but not sufficient Navy: Readiness and Cost Congress: Jobs, Oversight, and Control 26 OCT 2006 NAVAIR Depot Contributions to Weapon Systems Readiness Slide 19

20 Take Aways Depot and Intermediate operations provide strong legacy of excellence Naval Aviation Maintenance is transforming with FRC Depot capability placed forward BRAC driven Cost-wise readiness focused This transformation is highly complex Synchronization required across the enterprise Savings and readiness are dependent variables We are moving fast Initial Operating Capability Oct06 Full Operating Capability Oct08 CONOPS and Organizational definition by Aug06 26 OCT 2006 NAVAIR Depot Contributions to Weapon Systems Readiness Slide 20