2016 Tanker WWR KC-46 Program Col John Newberry

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Presentation transcript:

2016 Tanker WWR KC-46 Program Col John Newberry KC-46 System Program Manager 22 April 2016

KC-46 Program of Record KC-46 begins replacement of aging tanker fleet Acquires 179 aircraft; delivery of first 18 tankers by 2017 Production ramps up to 15 tankers per year through 2027 Missions Air refueling Cargo/passenger transport Aeromedical evacuation Implements Better Buying Power concepts Fixed-Price-Incentive-Firm contract awarded 24 Feb 11 Success depends on stable funding and requirements KC-46 program team KC-46 built in the Boeing Everett, WA factory Boeing Program Office located at Everett, WA Air Force System Program Office located at WPAFB, OH

Short-Term Milestones Top Level Schedule CY2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 Milestone B Approval + Contract Award (2/24/11) Short-Term Milestones EMD-2 – Power-On—Feb 15 EMD-2 T-30 FFRR—Jul 15 EMD-2 – KC-46 Tanker First Flight—Sep 15 Military Flight Releases (MFRs)—Jan 16 MS C—2QCY16 LRIP 1 award—Jun 16 LRIP 2 award—Jun 16 LRIP 3 award—Jan 17 * Engineering and Manufacturing Development (EMD) Systems Requirements Review (6/6/11) Integrated Baseline Review (8/24/11) Systems Functional Review (11/8/11) Preliminary Design Review (PDR) (4/25/12) Critical Design Review (CDR) (8/21/13) OA (Nov 14 – Apr 16) UPDATED AS OF: 4 Mar 16 at 0945 (Maj Logan-from PEO Immersion Brief) KC-46 (1st Flt) 767-2C (1st Flt) DT&E Milestone C (MS C) IOT&E Low Rate Initial Production (LRIP) Required Assets Available (18 AC) Full Rate Production thru 2027

Warfighter Key Performance Parameters (KPP) KPP #4: Cargo & PAX KPP #3: Worldwide Airspace Access (CNS/ATM) KPP #2: Range/Offload KPP #1: Same Sortie Boom & Drogue Worldwide Operations Aeromedical Evacuation The Joint Requirements Oversight Council approved the following 9 Key Performance Parameters (KPPs). The CDD that contained the 9 KPPs & 5 KSAs translated in 387 warfighter requirements to be delivered in every aircraft. Boeing will deliver an aircraft that could be deployed for combat the day of delivery Successful CDR reconfirmed--Boeing currently meets or will meet all contractual requirements Based on the on-going Development progress: ON-TRACK to meet all KPPs/KSAs Anecdote : July-Aug 2-14 early integration testing in wet fuels lab has burned down risk for 1200 GPM off-load KPP/KSA definitions from Capabilities Development Document (Threshold Description) KPP #1: Tanker Air Refueling Capability: The aircraft shall be capable of accomplishing air refueling of all current and programmed fixed-wing (THRESHOLD, KPP) receiver aircraft in accordance with technical guidance and standard agreements (STANAGs) using current procedures and refueling airspeeds with no modification to existing receiver air refueling equipment and no restrictions to the refueling envelope (THRESHOLD, KPP). The aircraft shall be able to effectively conduct (non-simultaneously) both boom and drogue air refuelings on the same mission (THRESHOLD, KPP). KPP#2: Fuel Offload versus radius: The aircraft shall be capable, as a minimum, of an offload versus radius as depicted in Figure 6.1 (current KC-135 capability is Threshold) KPP #3: Civil/Military CNS/ATM: Aircraft shall be capable of worldwide flight operations at all times in all civil and military airspace at time of aircraft delivery, including known future CNS/ATM requirements, with redundant systems (THRESHOLD, KPP). Capability to inhibit CNS/ATM emissions and prohibit transmission of CNS/ATM-related data accumulated during the inhibited portion of the mission (THRESHOLD, KPP). Civil ATC data link media for LOS and BLOS communications (THRESHOLD, KPP). KPP #4: Airlift Capability: The aircraft shall be capable of efficiently transporting equipment and personnel and fit seamlessly into the Defense Transportation System (THRESHOLD, KPP). The aircraft’s entire main cargo deck must be convertible to an all cargo configuration that accommodates 463L pallets (THRESHOLD, KPP), an all passenger configuration (plus baggage) (or equivalent AE capability to include ambulatory and /or patient support pallets) (THRESHOLD, KPP), and must optimize a full range of palletized cargo, passengers, and AE configurations that fully and efficiently utilize all available main deck space (THRESHOLD, KPP). KPP#5: Receiver air Refueling Capability: The aircraft must be capable of receiver air refueling (IAW current technical directives) (THRESHOLD, KPP) from any compatible tanker aircraft using current air refueling procedures (THRESHOLD, KPP). KPP#6: Force Protection: Aircraft shall be able to operate in chemical and biological environments (THRESHOLD, KPP). KPP#7: Net-ready KPP: The NR-KPP is detailed in Appendix A—Definition: Net-Ready: The system must support Net-Centric military operations. The system must be able to enter and be managed in the network, and exchange data in a secure manner to enhance mission effectiveness. The system must continuously provide survivable, interoperable, secure, and operationally effective information exchanges to enable a Net-Centric military capability.------------Threshold Def: The system must fully support execution of joint critical operational activities identified in the applicable joint and system integrated architectures and the system must satisfy the technical requirements for transition to Net-Centric military operations to include: 1) DISR-mandated GIG IT standards and profiles identified in the TV-1, DISR mandated GIG KIPs identified in the KIP declaration table, KPP#8: Survivability: Aircraft Self-Protection Measures (SPM). Tanker aircraft shall be able to operate in hostile environments (THRESHOLD, KPP) as discussed in Section 4 and AFTTP 3-3.22B KPP #9: Simultaneous multipoint refueling: The aircraft shall be provisioned (including structural modifications, plumbing, electrical, etc.) for simultaneous multi-point drogue refueling (THRESHOLD, KPP) KSA#1: Formation capability: The aircraft shall be capable of day and night formation flight in Instrument Meteorological Conditions (IMC) or Visual Meteorological Conditions (VMC) in all phases of flight (THRESHOLD, KSA). KSA#2: Aeronautical evacuation: Capability to provide air transport and care in the air, using existing Patient Support Pallets (PSP), for 50 patients total, either 16 litter/34 ambulatory patients for up to 14 hours (THRESHOLD, KSA). KSA#3: Reliability and Maintainability: R&M shall be sufficient to generate, deploy, operate, sustain and recover the tanker in the conduct of operations to levels and degrees of readiness and performance as prescribed herein (THRESHOLD, KSA). KSA#4: Operational Availability: Operational availability shall be not less than 80% KSA#5: Treaty Compliance Support: The aircraft shall have a dedicated serial cable (RS-422 or better) or a dedicated Ethernet cable (Cat5E or equivalent) running from each multi-point hard point to the main cargo compartment (THRESHOLD, KSA). The aircraft shall have 28V DC to each multi-point hard point (THRESHOLD, KSA). KPP #9: Multi-Point AR KPP #5: Receiver AR KPP #8: Survivability-- Defensive Systems & Night Ops KPP #7: Net-Ready KPP #6: Chem/Bio 4

1,200 gpm Refueling Receptacle Key Features Multi-role Capabilities Air Refueling, cargo, passengers, patients Roll-On Beyond-Line-of-Sight (ROBE) capability Aircraft Equipment Storage Self Protection Electromagnetic Pulse hardening Chemical / Biological operations LAIRCM & Radar Warning Receiver Cockpit armor Up to 54 Aeromedical Evacuation Patients Up to 58 Passengers ( 114 for Contingency Operations) 400 gpm Centerline Drogue System Up to 18 463L Pallets 1,200 gpm Refueling Receptacle Crew Bunks Galley Digital Glass Cockpit 1,200 gpm Modernized fly-by-wire KC-10 Boom Usual key points: 400 gpm Centerline Drogue System 1,200 gpm Modernized fly-by-wire KC-10 Boom 400 gpm Wing Air Refueling Pods; Aerial Refueling Operator Station July-Aug 14 early integration testing in wet fuels lab has burned down risk for 1200 GPM off-load For Aerial Refueling Missions only: the basic crew is 3—pilot, co-pilot and boomer/loadmaster For mix missions and/or cargo/pax or med evac—the basic crew will be dependent on quantity and/or what is being transported Fuel tanks—3 in back and 1 in front Aft Door High Resolution Stereoscopic Camera System Overwing Hatch Aerial Refueling Operator Station Additional Crew Seats (8) Provides Simultaneous Refueling Capability Main Cargo Door Pratt & Whitney Engines 62K Thrust 120 kVA Generators 400 gpm Wing Air Refueling Pods Forward Entry Door

Worldwide operations in all civil/military airspace Digital Glass Cockpit Large 787 15” diagonal pilot displays Flight and weather data VHF, HF, SATCOM radios capable of voice or data, Aircraft Communication Addressing & Reporting System (ACARS), and ATC comm Tactical Situation Awareness System (TSAS) w/Link 16, threat, and warning systems Air refueling operations viewable from pilot display ACARS—Aircraft Communication Addressing & Reporting System Digital Glass Cockpit Large 787 15” diagonal pilot displays Flight and weather data on both displays VHF, HF, SATCOM radios capable of voice or data, ACARS and ATC comm TSAS w/Link 16, threat and warning systems Air refueling operations viewable from pilot display Worldwide operations in all civil/military airspace

Air Refueling Operator Station Dual interconnected control sticks Instructor station with override capability 24” displays with 3D refueling picture Touchscreen capability Panoramic 185 degree field-of-view Recordable AR data and camera system Offload, rate, and boom limits automatically set Offload and receiver data automatically captured Special glasses required to see in 3D Preferred term is “Boom Operators” not “Aerial Refuelers”

Multi-Role Capabilities 56 Contingency 56 Contingency 44 9 Litter / 22 Ambulatory 182.0” KC-10 165’6” KC-46A KC-46A 165’6” 136’3” KC-135 7000 ft runway (minimum) Tail Height KC-135 – 41’9” KC-46 - 52’10” Tail Height KC-10 – 58’1” KC-46 - 52’10” 156’1” 156’1”’ 136’10”’ 165’0”’

Development Status Design is mature and requirements are stable System Integration Labs (SILs) burning off design and performance risk Accomplished 45 of 48 lab verification tests — ECD Jun 16 Completed Phase 1 of Cooperative Vulnerability Assessment; cyber risk mitigator Certification and performance verification test plans built and being executed 100% traceability from FAA and spec requirements to test plans Flight tests for FAA type and military type certifications underway Incremental System Verification Review (SVR) and audit underway Tanker-receiver pair (19) full envelope certification flight test planned CVA partners: F-16 Viewed from AROS F-18 Contact View from Cockpit Fuel Dock Testing of WARP On track to meet program KPPs and KSAs 9

767-2C Provisioned Freighter (Everett Modification Center) Production Strategy 767-2C Provisioned Freighter (BCA Facility, Bldg 40-32) Baseline Non-Military Aircraft Enhanced Flight Deck Freighter (Cargo Door & Floor) Body Tanks Tanker System Provisions Amended Type Certificate (ATC) KC-46A Tanker (Everett Modification Center) Refueling Systems Military Avionics Supplemental Type Certificate (STC) Military Certification 767 Family of Aircraft (BCA Facility, Bldg 40-32) Commercial Passenger Airplane Type Certificate (TC) The KC-46 is a derivative of the Boeing 767-200 Extended range commercial aircraft. The commercial baseline for the KC-46 Tanker is designated the 767-2C which the FAA will issue an amended type clearance (ATC). The FAA will issue supplemental type certification (STC). There is be a Military Certification issued for those items not covered by the STC (i.e., tanker operations). 767-2C (Boeing Commercial Aircraft) Procure an existing commercial FAA-certified transport aircraft modified to meet USAF requirements Utilize 767 family of aircraft and other Boeing commercial systems KC-46A Tanker (Boeing Defense Systems) Integrate military equipment on to the 767-2C to define the baseline military aircraft designated as the KC-46A Tanker

KC-46 “Test Once” Strategy Leverage One Test Event Timeline For Multiple Certs 4 LRIP KC-46 2 EMD KC-46 Key Milestones: 767-2C and KC-46 First Flights Milestone C Specification Verification Review Operational Test Readiness Review Overall scope of DT&E includes comprehensive test objectives from Boeing, and the FAA, as well as, the DT, OT, and LFT&E communities. To the maximum extent possible, test objectives from all agencies will be factored into the design of all DT&E events during EMD. This approach accents data compatibility, information sharing, and test schedule efficiency. It is also intended to reduce redundancy and program cost. 70% of our ground and flight test program leverages FAA certification activities (ATC & STC hours) 2374 total flight test hours = 820 ATC + 877 STC + 677 MTC * Doesn’t count 1,150 Phase III flight hours at Edwards AFB or 2,000 OT flight & ground hours * 3215 total flight test hours = 1,244 ATC + 959 STC + 1, 012 MTC Test aircraft status as of 7 Mar 16: 453 total flight test hours and 1,785 ground hours EMD-1 = 93 sorties, 264 total flight hours; aircraft is in a layup period to bring the fuel system up to a type-design configuration with the next flight is scheduled for early Mar 16 EMD-2 = 43 sorties, 189 total flight hours, after fuel dock is complete focus will be on completing free air stability testing required for contact demos EMD-4 = 1 sortie, 55 min Total Test Program Hours = 8,739 (2374 + 3215 + 1150 + 2000) Our 270 lab, ground, and flight test plans are “bucketed” into categories as depicted in the middle-right graphic Flight test phases: Phase I = MS C demos Phase II AR cert of F-16, C-17, F-18, KC-46x2, A-10, F-15, B-52 (287 hours) Phase III AR cert for OT of B-2A, B-1B, AV-8B, C-5M, KC-10A, E-3D, Typhoon, Tornado, F-22A, EC-130H, and KC-135R and ARASQ for KC-46 – KC-46, C-17A, F-22A, EC-130H, KC-10 – KC-46, F-16D, B-2A, C-5M and KC-46 – KC-10 plus as much add’l AR cert as possible with 17 aircraft (1,150 hours) 4 LRIP aircraft (1-1, 1-2, 1-3, 1-4) will be used at McConnell AFB for IOT&E 2 EMD aircraft will be used at Edwards AFB for the AR cert and simulator data collection (ARASQ) effort Bumper sticker mantra is how we focus to pull together 34 agencies and over 300 players into a team Aggressive Test Schedule Requires Leadership, Teamwork, Communication, And Optimized Processes/Procedures 11

EMD-2 Aerial Refueling Demo with F/A-18 Test Status EMD-1: 109 flights, 302 flight test hours Executing FAA flights for Amended Type Cert (ATC) EMD-2: 55 flights, 236 flight test hours MS C Aerial Refueling demonstration status Completed F-16C, F/A-18, AV-8B, and KC-46A as a receiver C-17A and A-10C up next following boom axial loads fix EMD-3: Installing test data collection system racks EMD-4: 6 flights, 18 flight test hours Executing free air stability and non-AR mission systems flights Completed final Live Fire Test & Evaluation ballistic test series in Dec 15 Conducted 1,094 total shots (Nov 11 – Dec 15) Survivability analysis, plus five vulnerability studies, are on-going through this year EMD-2 Aerial Refueling Demo with F-16C As of 23 March: EMD-1 Same as above (98 flights, 284 hours) EMD-2 50 flights, 216 hours EMD-4 Same as above (4 flights, 8 hours) EMD-2 Aerial Refueling Demo with F/A-18 Data as of 12 Apr 16

Milestone C (MS C) Flight Plan (Based on “KCR-0700” schedule) 2015 2016 J A S O N D F M 2015 MS C Documentation Prep MS C OSD Review MS C LRIP 1 Award (7 A/C) LRIP 2 Award (12 A/C)  Mission Systems Verification / Demo   IAW / Flutter Airlift Ground Demo  Now FD 1  Fuel Dock KC-46 First Flight     Joint AF/USN/Boeing team remain committed to completing required lab, ground, and flight tests prior to MS C; dry-run activities will provide smoother ops tempo Test procedures and Government resources on-track to support AR demo schedule Monitoring flight test efficiency These actions will complete all MS C Aerial Refueling Operations Demos. Rendezvous, contact, and fuel transfer using the boom, CDS and WARP to representative receivers … and as a receiver behind a certified tanker. 11 Jan: Complete Free Air Stability Testing 13 Jan: Conduct T-minus-5 First Contact Readiness Review 18 Jan: Complete Installation and check-out of classified components 19 Jan: Complete F-16 MS C required tests 20 Jan: Complete C-17 MS C required tests 4 Feb: Complete F-18 MS C required tests 5 Feb: Complete A-10 MS C required tests 10 Feb: Complete AV-8B MS C required tests 12 Feb: Complete KC-46A MS C Receiver onload testing (with a KC-10 tanker) 22 Feb: Receive Boeing's Initial Test Report --- delivered 60 days in advance of DAB to support ADM Technical Performance Measure (TPM) compliance statements TEMP action officers agreed to a coord cycle to produce a final, fully signed TEMP prior to the DAB F-16 C-17 F/A-18 A-10 AV-8B Light Fast Boom Heavy Drogue Slow KC-46A As Receiver  IAW/ FAS  EMD-1 EMD-2 EMD-4 Non-aircraft reliant  Complete FD 2  AR FAS ARD Aerial Refueling Demo

Sustainment Status Tenets: 100% AF organic mgt, 2 levels of mx, FAA “Meet the Intent,” use of commercial manuals, OMIT data rights, and ICS for up to 5 yrs Beddown activities at McConnell, Altus, and Pease on-track MILCON projects in-work and facility work-arounds identified Joint Technical Order certification/verification in-work (40% complete) Supply support strategy focused on deliberate transition from contractor Inventory Control Point (ICP) to Government ICP SE acceptance on-going at McConnell and Altus (about 2,000 items to date) First depot C-check postured for activation at OC-ALC (Mar 19) Beddown activities at McConnell, Altus, and Pease on-track MILCON projects in-work and facility work-arounds identified Altus Fuel Cell expansion project behind schedule, Hangar 509 C-17 Fuel Cell is the work-around facility Support Equipment accepted at McConnell (left) and Altus (center) Pictured is the KC-46 and KC-135 Tail enclosures—notice the considerable size difference Joint Technical Order certification/verification in-work (40 % complete) 2,368 tasks (950 complete) Supply support strategy focused on deliberated transition from Contractor Inventory Control Point (ICP) to Govt. ICP Cataloging INW Common Spares Procurement (three RFPs released in support of Lots 1, 2, and 3) Logistics Reassignment (448 SCMW) will be the Government ICP—KC-46 Supply Support Cell standup on-going - Overall number of SE delivered (includes EMD (McConnell Only) + CCP-008 (both McConnell and Altus): 6,457 (broken down below)   EMD: 1510 CCP-008 Altus: 2065 McConnell: 2882 Current DD250 Status as of today (21 Mar): 1418 total DD250's (broken down by:) EMD McConnell: 819 DD250'd Altus: 315 DD250'd McConnell: 284 DD250'd

Summary KC-46 is first phase of tanker recapitalization KC-46 continued strong stakeholder support hinges on delivering to program commitments KC-46 program driving to complete Milestone C KC-46 executing a comprehensive flight test program leading up to aircraft certifications and IOT&E