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Sustained Materiel Readiness

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Title: Sustained Materiel Readiness


1
Sustained Materiel Readiness
David Pauling, ADUSD (MRMP) MRO Conferences
2
Systems Supported by DoD Maintenance
100,000 Ground Combat/Tactical Vehicles
? 900 Strategic Missiles
  • Maintained by
  • 681,000 DoD personnel
  • Private sector companies

? 300 Ships
? 15,000 Aircraft/Helicopters
Maintenance cost 59B per year
250K Wheeled Vehicles Comm/Electronics
Equipment Support Equipment ...
National Defense PPE is valued at ? 600 Billion
1
1
Source LMI
3
DoD Field- and Depot-Level Maintainers
Distribution by Service (in 000s)
Marine Corps Field
Marine Corps Depot
Maintainers
Maintainers
49.9 (7)
0.9 (lt1)
Navy Depot
Maintainers
Army Field
20.9 (3)
Maintainers
220.8 (33)

Totals
Navy Field
Field
-
Level Maintainers

631.1

93

Maintainers
Depot Maintainers

44.1

7

173.6 (26)

Army Depot
Maintainers
7.2 (1)
Air Force Depot
Air Force Field
Maintainers
Maintainers
15.1 (2)
186.8 (28)
2

4
Major DoD Intermediate-Level Activities
  • Army
  • 21 Aviation Intermediate Maintenance (AVIM)
    companies
  • 31 Direct Support/General Support (DS/GS)
    companies
  • Navy
  • 15 shore-based Aircraft Intermediate Maintenance
    Detachments (AIMDs)
  • 12 carrier-based AIMDs
  • 6 Shore Intermediate Maintenance Activities
    (SIMAs)
  • 2 Trident Refit Facilities (TRFs)
  • Air Force
  • 65 aviation maintenance groups
  • Marine Corps
  • 12 Marine Aviation Logistics Squadrons (MALS)
  • 11 Amphibious assault ship-based AIMDs
  • 3 Force Service Support Groups

4
5
OrganicCommercial Distribution of DoD Depot
Maintenance
DoD-wide 54 Organic 46 Commercial
46
48
FY03 (in billions)
Commercial Organic
44
52
54
56
85 Organic
Army
Navy
Air Force
USMC
Source USD(ATL) report Distribution of DoD
Depot Maintenance Workloads Fiscal Years 2002
and 2003, February 2004
5
6
DoD/Commercial Maintenance Structure Comparison
Depot (Centralized) vs. Field Level Percentage
of Personnel
Approximate Total Number of Maintainers
  • Field maintenance key to both DoD and commercial
    maintenance structures
  • Maintenance structure drivers include . . .
  • DoD deployable maintenance capabilities
  • Equipment differences (e.g., age, complexity,
    role)
  • Available commercial infrastructure
  • Life-cycle status (i.e., position in life cycle)
  • Business support concept (e.g., run to optimum
    age and dispose vs. continuous rebuild)

Trucking maintenance
40K
DoD maintenance
681K
Low cost air carrier
13K
Parcel trucking
15K
Railway
8.7K
Legacy airline
125K
0
20
40
60
80
100
6
Note Commercial percentages are estimated based
on available data
7
Sustained Materiel Readiness
ISSUE
  • Concentrate on achieving/sustaining SPG/CPG
    readiness
  • Balance safety, reliability, and maintenance
    activities to achieve readiness at best cost.
  • Optimize TIME-ON-WING and repair TURN
    AROUND TIME
  • Promote End-to-End (E2E) materiel readiness
    value chain perspective across DoD
  • Optimize materiel condition reliability
    sustainment
  • Optimize maintenance cost, cycle time

7
8
Sustained Materiel Readiness
WAY AHEAD
  • Translate SPG/CPG capabilities to weapon
    system/materiel requirements
  • Develop cause and effect predictive models
  • Foster and promote continuous process
    improvements
  • Reliability
  • Condition Based Maintenance (CBM)/Reliability
    Centered Maintenance (RCM)
  • Cycle process discipline
  • Lean, Six Sigma, Theory of Constraints, etc
  • Institute integrated budgets (engineering,
    logistics, industrial)

8
9
VISION - Focus Areas Materiel Readiness E2E
Planning and Process(es) Improvement
  • Update/execute policy (E2E)
  • Improve System Life Cycle Management Prediction
    Capabilities
  • Expertise, Tools and TE Facilities
  • Cause and effect predictive modeling
  • Optimize Materiel Reliability
  • Implement CBM/RCM
  • Preventive Maintenance Addresses Failure
    Characteristics
  • Optimize Repair/build specs
  • Optimize Materiel Cycle Time
  • Employ CPI (Lean, 6Sigma, Theory of Constraints)
  • Integrate Depot and Intermediate Level Best
    Practices and Processes
  • Parts forecasting
  • Integrate Materiel Readiness Budgets
  • Balance Engineering, Logistics, Industrial
    Accounts

9
10
Building the Optimum Materiel Readiness
Sustainment Plan/Budget
mission-based operational readiness requirement
mission-based materiel readiness requirement
START
SPG/CPG
Seek to reduce sustainment costs
WAR PLAN
Required Amount of RFI Materiel (installed
uninstalled)
Required Number of RFI Weapons
INTEGRATED BUDGET
INTEGRATED MANAGEMENT PLAN
RD
YES

ST
SAFETY STANDARDS
Technical PLAN

Design
READINESS BASED MATERIEL REQUIREMENTS MODEL
EQUIPMENT RELIABILITY
PROCUREMENT
INTEGRATED REPAIR/BUILD CYCLE TIME PLAN
MAINT/RCM STRATEGY
MATERIEL READINESS GOALS ACHIEVED?
OM
PIPELINE
COMMON METRICS

In Svc Eng/Log
SPARES FORECASTING PROCUREMENT PLAN
PLANNING FACTORS

DEPOT
MATERIEL TRANSPORTATION DISTRIBUTION PLAN
  • DLR

NO
WCF
Seek to increase sustainment performance
10
11
Materiel Readiness Responsibilities
11
12
VISION - Focus Areas Materiel Readiness E2E
Planning and Process(es) Improvement
  • Update/execute policy (E2E)
  • Improve System Life Cycle Management Prediction
    Capabilities
  • Expertise, Tools and TE Facilities
  • Cause and effect predictive modeling
  • Optimize Materiel Reliability
  • Implement CBM/RCM
  • Preventive Maintenance Addresses Failure
    Characteristics
  • Optimize Repair/build specs
  • Optimize Materiel Cycle Time
  • Employ CPI (Lean, 6Sigma, Theory of Constraints)
  • Integrate Depot and Intermediate Level Best
    Practices and Processes
  • Parts forecasting
  • Integrate Materiel Readiness Budgets
  • Balance Engineering, Logistics, Industrial
    Accounts

12
13
Policy MRMP Mission (1)
DoDD 4151.18 Maintenance of Military Materiel
  • A. DoD Materiel Readiness Sustainment Outcomes
  • Achieve and sustain inherent performance, safety,
    reliability
  • Invest/employ technologies
  • Meet readiness and sustainability objectives
  • Minimize total life cycle cost
  • Optimize reliability cycle time
  • B. Condition Based Reliability Centered
    Processes
  • Provide materiel design improvement data/needs as
    necessary
  • Allocate reliability centered, FMECA-based tasks
  • Utilize diagnostics and prognostics techniques
  • Employ serialized item management (SIM)
    techniques

13
14
Policy MRMP Mission (2)
DoDD 4151.18 Maintenance of Military Materiel
  • C. E2E Materiel Value Chain Agility/Continuous
    Process
  • Improvement
  • Employ Lean, Six Sigma, Theory of Constraints
  • Identify consolidation, partnership,
    opportunities
  • Maintain core capabilities
  • D. Resources/Operations Information Systems
  • Scheduling, production control, financial
    management
  • Personnel materiel performance and QA
  • Integrated budgets

14
15
VISION - Focus Areas Materiel Readiness E2E
Planning and Process(es) Improvement
  • Update/execute policy (E2E)
  • Improve System Life Cycle Management Prediction
    Capabilities
  • Expertise, Tools and TE Facilities
  • Cause and effect predictive modeling
  • Optimize Materiel Reliability
  • Implement CBM/RCM
  • Preventive Maintenance Addresses Failure
    Characteristics
  • Optimize Repair/build specs
  • Optimize Materiel Cycle Time
  • Employ CPI (Lean, 6Sigma, Theory of Constraints)
  • Integrate Depot and Intermediate Level Best
    Practices and Processes
  • Parts forecasting
  • Integrate Materiel Readiness Budgets
  • Balance Engineering, Logistics, Industrial
    Accounts

15
16
Materiel Readiness Modeling
  • Why?
  • Prescribe policies/procedures and
    monitor/review/assess materiel readiness E2E
    Value Chain operations relative to the ability of
    the Departments major weapon systems to meet
    mission requirements.
  • How?
  • Develop DoD-wide predictive modeling/analyses
    capability to determine cause and effect
    relationship to materiel readiness-based
    outcomes, e.g.,
  • Reliability improvement initiatives
  • Cycle Time Process improvements for
    Supply/Maintenance/Transportation/Distribution
  • Alternative resource strategies
    (short-term/long-term)
  • Determining life-cycle costs from an integrated
    budget perspective when materiel readiness issues
    are addressed
  • Status
  • Assessing current DoD and commercial models
  • Submitted cross-cutting proposal enhance best
    of breed model
  • Working with Services to convert status models to
    predictive models

16
17
Materiel Readiness Integrated Management (E2E)
17
18
VISION - Focus Areas Materiel Readiness E2E
Planning and Process(es) Improvement
  • Update/execute policy (E2E)
  • Improve System Life Cycle Management Prediction
    Capabilities
  • Expertise, Tools and TE Facilities
  • Cause and effect predictive modeling
  • Optimize Materiel Reliability
  • Implement CBM/RCM
  • Preventive Maintenance Addresses Failure
    Characteristics
  • Optimize Repair/build specs
  • Optimize Materiel Cycle Time
  • Employ CPI (Lean, 6Sigma, Theory of Constraints)
  • Integrate Depot and Intermediate Level Best
    Practices and Processes
  • Parts forecasting
  • Integrate Materiel Readiness Budgets
  • Balance Engineering, Logistics, Industrial
    Accounts

18
19
Condition-Based Maintenance Plus
  • Why?
  • To improve reliability centered maintenance
    effectiveness and efficiency through application
    of technology initiatives and process
    improvements
  • Sustain inherent performance, safety, reliability
    of materiel
  • How?
  • Utilize interactive electronic technical manuals,
    portable maintenance aids and other enabling
    tools and technologies
  • Implement diagnostics, sensors and prognostic
    algorithms and techniques
  • Employ reliability-centered maintenance concepts
    and practices
  • Enable statistical and engineering analysis
    processes
  • Develop condition-driven maintenance plans
  • Integrate maintenance and logistics processes and
    reporting systems
  • Status?
  • Completed survey of Service CBM Select Programs
  • Establishing the DoD CBM baseline
  • CBM website on-line and regularly updated
  • OSD/Service CBM Advisory Group meets weekly

19
20
OCM vs RCM On-condition Maintenance
vsReliability-centered Maintenance
OCM
RCM
Maintenance Is Unplanned
Focus is Planned Maintenance Facilitates
Resource Requirements Predications
Maintenance Based on LCC Value
Maintenance Driven by Equipment Conditioner or
Lowest /Shop Visit
(What's Best for the Long Term)
(What's Easiest Today)
20
21
Engine Life RecoveredAfter Repair
RCM Reliability Centered Maintenance
21
22
Engine Repair/Time on Wing Tradeoffs
297K/repair
380/flt hr
240K/repair
700/flt hr
165K/repair
22
23
Cost Per RFI System Sensitivity
Reliability Investment
Optimal Reliability Invest
23
24
VISION - Focus Areas Materiel Readiness E2E
Planning and Process(es) Improvement
  • Update/execute policy (E2E)
  • Improve System Life Cycle Management Prediction
    Capabilities
  • Expertise, Tools and TE Facilities
  • Cause and effect predictive modeling
  • Optimize Materiel Reliability
  • Implement CBM/RCM
  • Preventive Maintenance Addresses Failure
    Characteristics
  • Optimize Repair/build specs
  • Optimize Materiel Cycle Time
  • Employ CPI (Lean, 6Sigma, Theory of Constraints)
  • Integrate Depot and Intermediate Level Best
    Practices and Processes
  • Parts forecasting
  • Integrate Materiel Readiness Budgets
  • Balance Engineering, Logistics, Industrial
    Accounts

24
25
Continuous Process Improvement
  • Why?
  • Maximize weapon system readiness while minimizing
    materiel flows and in-process inventories
  • Goal Optimize reliability and cycle time while
    striking a reasonable balance with costs across
    the total life cycle value chain
  • How?
  • Employ
  • Lean for eliminating all types of waste
  • Six Sigma (6s ) for minimizing process variation
  • Theory of Constraints (TOC) for alleviating
    process bottlenecks
  • CBM (Condition Based Maintenance Plus)
  • Status?
  • DOD CPI Transformation Review initiated
  • DOD CPI Policy in coordination
  • OSD-led CPI Working Group (O-6 level) meets
    weekly, updates OSD-led GO/SES Group monthly

25
26
Focus on Continuous Improvement(Maintenance
Cycle Time)
Oct-03
Apr-04
Apr-03
Oct-02
Apr-02
Oct-01
AIMD Lemoore Power Plants Shop Engine Repair
Cycle Time
26
27
CCAD Engine Turn Around Time Run Chart
Reduction in Mean Variation Continue In 2004!
27
28
Initial Lean Results Encouraging
Employment of techniques fragmented, incomplete
needs policy)
28
29
When Should We Partner?


MIX
GOAL Leverage Innovative Concepts of the Private
and Public Sectors to Support the Warfighter at
the Best Value for the Department of Defense and
the Taxpayer
29
30
Growth Trend in Public-Private Partnerships
30
Source DoD reports, Public-Private Partnerships
for Depot Maintenance, July 2003 and July 2004
31
Benefits Are Being Realized fromDepot
Maintenance Partnerships
31
32
VISION - Focus Areas Materiel Readiness E2E
Planning and Process(es) Improvement
  • Update/execute policy (E2E)
  • Improve System Life Cycle Management Prediction
    Capabilities
  • Expertise, Tools and TE Facilities
  • Cause and effect predictive modeling
  • Optimize Materiel Reliability
  • Implement CBM/RCM
  • Preventive Maintenance Addresses Failure
    Characteristics
  • Optimize Repair/build specs
  • Optimize Materiel Cycle Time
  • Employ CPI (Lean, 6Sigma, Theory of Constraints)
  • Integrate Depot and Intermediate Level Best
    Practices and Processes
  • Parts forecasting
  • Integrate Materiel Readiness Budgets
  • Balance Engineering, Logistics, Industrial
    Accounts

32
33
Improving Materiel ReadinessReliability,
Cycle-Time, Cost
Life-cycle cost (acquisition OS)
more
Drive reliability up to optimum level
reliability
Sustainment cycle-time
less
Drive sustainment cycle time down to optimum level
Cost of Readiness
Lower
Higher
(OS only)
RD/ACQ Only
Higher
Lower
33
RD/ACQ/OS Lowest
Higher
Higher
34
Engine Integrated RecoveryApproach
34
35
VISION - Focus Areas Materiel Readiness E2E
Planning and Process(es) Improvement
  • Update/execute policy (E2E)
  • Improve System Life Cycle Management Prediction
    Capabilities
  • Expertise, Tools and TE Facilities
  • Cause and effect predictive modeling
  • Optimize Materiel Reliability
  • Implement CBM/RCM
  • Preventive Maintenance Addresses Failure
    Characteristics
  • Optimize Repair/build specs
  • Optimize Materiel Cycle Time
  • Employ CPI (Lean, 6Sigma, Theory of Constraints)
  • Integrate Depot and Intermediate Level Best
    Practices and Processes
  • Parts forecasting
  • Integrate Materiel Readiness Budgets
  • Balance Engineering, Logistics, Industrial
    Accounts

35
36
Responsibility
  • Warfighter Combat Capability
  • Ensure a ready and controlled source capable of
    providing combat ready weapon systems anytime and
    anywhere efficiently and effectively.

Program Manager
Partnering
Government Team (Engr, Log, Ind)
Private Sector
36
37
2004 Maintenance Award Winners Awarded to the
Most Outstanding Field-Level Units in the DoD
  • Marine Heavy Helicopter Squadron 462Marine Corps
    Air Station Miramar, California, USMC
  • 509th Munitions SquadronWhiteman Air Force Base,
    Missouri, USAF
  • 3rd Military Intelligence Battalion (Aerial
    Exploitation)Camp Humphreys, Republic of Korea,
    USA
  • Combat Service Support Battalion 10Marine Corps
    Air Ground Combat Center, Twentynine Palms,
    California, USMC
  • USS ABRAHAM LINCOLN (CVN 72)Naval Station
    Everett, Washington, USN
  • 27th Maintenance GroupCannon Air Force Base, New
    Mexico, USAF

37
38
2005DoD Maintenance Symposium
ExhibitionBirmingham, Alabama
  • Prognostics/Diagnostics
  • Integrated Information
  • Common Logistics Operating Environment
  • UID/Serialized Item Management
  • Lean, Theory of Constraints, Six Sigma in
    Maintenance
  • Cycle Time Optimization
  • Responsive Logistics Support
  • Reliability-centered Maintenance

Operations
Technology
Sustaining Weapon System Readiness through
Reliability, Cycle Time, and Continuous Process
Improvements
Management
Special Events
  • Transformation Initiatives
  • Maintenance-centric Readiness Roadmap
  • Public/private-sector Integration
  • Materiel Readiness Modeling
  • . . .
  • Senior Logisticians Roundtable
  • SecDef Maintenance Awards
  • Industry Tours
  • Over 180 Exhibits
  • Lessons learned
  • Knowledge sharing
  • Training opportunities

October 24 - 27, 2005
More info Chuck Field, (703) 697-9067chuck.fiel
d_at_osd.mil or www.sae.org/dod
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