High Velocity Maintenance Overview Presented By: Jerry Mobley WR-ALC/HVM June 2010

What is High Velocity Maintenance? An AFMC-wide initiative to dramatically transform production operations in support of increasing aircraft availability, seeking to better emulate industry’s high daily rate of touch-labor maintenance HVM examines all processes which impact aircraft programmed depot maintenance across the enterprise, including not only product flow, but also funding, requirements, infrastructure, materiel support, and information technology The USAF is facing a confluence of factors threatening aircraft availability rates. These factors include rising operations and maintenance costs associated with a fleet averaging over 24 years in age; high operations tempo and costs due to the Global War on Terror; reduced USAF active duty end strength, and lack of fiscal resources to recapitalize the fleet in a timely fashion. The Warner Robins Air Logistics Center has begun an initiative, with Air Force wide applicability, to dramatically transform its operations in support of increasing aircraft availability, seeking to better emulate industry’s high daily rate of touch-labor maintenance.

Create an Ideal Process and Repeat it Every Time HVM Concept HVM VISION Increase Aircraft Availability using AFSO21 tools to establish a synchronized, integrated, end-to-end process such that maintenance does not impact mission requirements Refine Scheduled Maintenance Correct Inefficient Processes Low velocity compared to Industry Airline burn rate 500-900 hours/day ALC PDM 145-220 hours/day Implement Industry Best Practices Daily Standard Work Point-of-Use Task Kitting Mechanic-Centric Focus Know tail number condition Maintain Enterprise Approach Scalable and Transportable Processes Single Maintenance Concept 1000 Industry Velocity High Velocity Maintenance is the term we coined to convey the idea that depot maintenance would transform from its current state as long duration, infrequent maintenance intervals to much shorter duration, more frequent maintenance, much like the commercial aviation community has used for years. We have incorporated many industry best practices into HVM processes. Examples include disciplined adherence to daily standard work and the introduction of point of use task kits to support the mechanic at the plane in the same way a surgeon is supported in the OR. This requires knowing the condition of the aircraft prior to induction, and much more detailed planning and orchestration of the work when it arrives. While HVM includes the term “maintenance”, this effort is really about making all processes supporting maintenance more efficient – from requirements determination, engineering, materiel support, IT support, to funding. Velocity (hrs/day) 500 USAF Depot Velocity PDM ISO HSC Maintenance Cycle Create an Ideal Process and Repeat it Every Time

Attributes Current State Future State Limited Knowledge of Aircraft Condition Two Mx systems; creates knowledge barriers 5+ Year PDM cycle (C-130) Damage accumulates Promotes a “must fix now” mentality Job Shop Environment Mechanic gets own tools; searches for parts; accomplishes own set up Inadequate Planning – req’ts, Mx work, parts, materiel, equipment Lacks information – complete BOM, planned work, support Stove-piped Processes and Execution Unsynchronized, inefficient, encourages work arounds (non-compliance) Future State Known Aircraft/End Item Condition Lead Time Ahead of Induction – Parts, Training, Infrastructure, Equipment, Data, etc. Mechanic-Centric Focus (Surgeon) Parts, Tools, Data, Equipment Pre-Positioned at Point of Use Maximum Use of Kitting Expand Standard Work & Processes Choreograph Repair Operations Synchronize work Single Maintenance Concept Integrated Planning, Decision-making, & Data Collection

HVM Future State Process Data analysis critical to defining requirement MRSR develops fully supportable , sequenced, executable work package 4 Cycles – 18 Month Interval to integrate/replace current 15 Month Isochronal Inspection Standard Work Cards drive out Process variability Actual requirements drive material purchases rather than historical probability AMT provides continuous real time support Integrator delivers POU task kits to mechanic

HVM Future State “Swim Lane” View Defines Right Requirement Builds Daily Std Work Package Accomplishes supportability Tailors package to tail number Defines sequence Feed Financial process Executes tailored work package Point of Use Task Kits Man-loads a/c- High Burn Rate

High Velocity Maintenance Life Cycle Comparison Current State ISO HSC 1000 500 145-220 hrs/day 160 Flow Days PDM & ISO not synchronized PDM scheduled every 5-6 yrs Velocity (hrs/day) Improved AA Less A/C on ground Reduced O&S Cost Efficient MX Process HVM State This slide graphically shows the change that HVM creates for the C-130 operator. Current practice distributes scheduled maintenance between the operator and the depot. The operator accomplishes ISO and Home Station Checks (HSC) between depot visits. All of these maintenance events are done with delays and interruptions due to parts, manpower and other factors. HVM absorbs the ISO requirements and produces the aircraft much faster – by doing much more each day, with our target being about 500 man-hours per day. Once you achieve approx. 500 hrs/day burn rate, the flow days for each cycle would be around 12-15 days. Commercial industry has proven this can be accomplished. The result is improved availability and higher quality repair. Goal: 500 + hrs/day Integrated Scheduled Mx (PDM & ISO) High velocity, multiple cycles over 5-6 yrs 1000 Velocity (hrs/day) C-130 500 18 month interval HSC HSC HSC Cycle 1 Cycle 2 Cycle 3 Cycle 4 7

Implementation Strategy Concept development: Summer 07 – Spring 08 Process development: Spring 2009 Creation of daily standard work: Ongoing Creating supporting data: Ongoing Process validation: Summer 2009-Spring 2011 9 validations Pilot Program: Fall 2011-2012 AFSOC C-130 aircraft: 18 – 21 months post PDM Fleet-wide deployment: 2013+ Remaining C-130 fleet transitioned by MAJCOM Val #4 Val #5 Val #1 Val #2 Val #3 8

Benefits of SLIM to HVM Aircraft Availability HVM SLIM focuses on overall weapon system performance assessments Efficient & effective data collection and analysis Proactive action using the analysis results Integrating CBM+, RAM, RCM/MSG-3, WSIP, MFOQA, and EAVI efforts Benefits Enables Optimized MX Requirements Facilitates increased knowledge of aircraft condition Aircraft Availability Overarching enterprise initiatives SLIM MSG-3 HVM Optimize the field/depot requirements (the “what, when and where”) High Velocity Maintenance (HVM) initiative, begun in June 2007 as an outgrowth of a WR center-wide strategic planning event, will employ the Air Force Smart Operations 21 (AFSO21) toolset to develop a scalable solution for significantly accelerating the speed and effectiveness of depot maintenance activities. Taking Lean concepts and methodologies to the next logical state of evolution, HVM examines all processes which impact aircraft programmed depot maintenance (PDM) across the enterprise, including not only product flow but funding; requirements; infrastructure; materiel support; and information and technology. AAIP RCM Expands HVM to be “scalable and transportable” PLM CBM+ GLSC HVM for PDM/ISO WR-ALC C-130 Prototype Integrity CAM Programs ECSS Optimizes the PDM process (the “how”) Includes all supporting processes Std Work Supply Chain Ops Lifecycle Mgmt Sourcing Tech Development D&SWS

High Velocity Maintenance Discussion/Questions

HVM & MSG Relationship HVM defines the “How” maintenance is accomplished Optimizes Maintenance processes – “Mechanic Centric Focus” Establishes processes to achieve “high daily touch labor rates” through detailed advanced planning with supportability; choreographed, synchronized work packages; aircraft man-loading; implementation of daily standard work; pre-positioned point-of-use task kits Moves toward single “Maintenance System” Incorporates ISO’s (C-130) MSG-3: Defines the “What” needs to be done Established the appropriate inspections and optimum interval for accomplishing the inspections Ensures you accomplish the “Right “ maintenance at the “Right” time. Notes: One key point that should be noted is that it could be perceived as first glance a disparity between MSG-3 and HVM with respect to MSG-3 extending inspection intervals where as HVM advocates looking at the a/c more frequently. However in fact they are very complimentary. The MSG-3 program defines the appropriate inspection intervals to make sure you are neither over or under accomplishing inspections. Under HVM from an execution stand point of accomplishing the required maintenance, it is much more effective to bring in the aircraft into a heavy maintenance facility for more shorter, frequent intervals. Under HVM, the typical C-130 5/6 year PDM cycle has been broken down into 4 smaller cycles (approx 5,000 hours for each cycle versus one large 20,000 hour work package) with the a/c coming in every 18 months. However for the C-5 under MSG-3, the PDM cycle is being extended to 8 years with a package size being approx 60,000 hours. Now that the appropriate intervals and requirements are established, HVM would brake the 60,000 hour work package into multiple smaller packages and bring the a/c into the depot every 2 years with each package being 15,000 hours. You are still accomplishing the same 8 year interval, but inspecting sections every two years. Looking at it more often allows you to more proactively catch and limit damage early. The optimum MX solution would employ the MSG-3 methodology as the foundation for HVM processes to be applied to achieve the most effective scheduled maintenance program

What Maintenance to Perform How Maintenance is Performed CBM - Real-time assessment of condition - Embedded sensors - External tests and measurements - Maintenance only upon evidence of need HVM & SLIM RCM - Assess system functionality - Identify failure modes and effects - Determines consequence of failure - Logical process to determine actions and insure mission success Feedback CBM+ What Diagnostics Prognostics - Data Analysis - RCM MSG-3 Overall system level approach Hierarchical zonal inspections Structures: Logical process for determining Mx requirements Safe life vs Damage Tolerant Accidental, Environmental or Fatigue Damage Considerations Mechanical Systems/Engines - Uses RCM Approach CBM+ How - Interactive Training - Portable Maintenance Aids - Interactive Electronic Technical Manuals - Integrated Information Systems - Automatic Identification Technology Maintenance tasks and intervals ASIP Inspection Reqts for tracked zones High Velocity Maintenance Improving “How Mx is Done” – standard processes and synchronized to optimize flow time Pre-planned support, Point of Use task kitting, mechanic centric focus to increase velocity How Maintenance is Performed Feedback 12