Equipping the American Forces with a Reliable and Robust Condition Based Maintenance Plus Capability Colonel Sarah J. Smith, USAF Military Deputy to ADUSD Materiel Readiness & Maintenance Policy

How do I monitor what is going on inside these components? CBM+ Origin “I check everything because I don’t know Anything!” Reactive How do I monitor what is going on inside these components? Predictive LUBE ORDER M1A2 TANK AOAP 1961 OBD-II To Predict Failure I need… Sensors Management Unit Decision Mechanism Refinement OBD-I White Truck 1900 1917 1941 1955 1982 1988 2004 2015 2025 2050 PREVENTIVE CONDITION MONITORING PROGNOSTICS

Overview The need for effective policy and doctrine to underpin the emerging capabilities of integrated mechanical diagnostics/ prognostics and advanced maintenance systems • Optimizing platform readiness, safety and reliability to ensure maximum capability • The challenges in creating and implementing policy for new and emerging maintenance technologies and systems • The US DoD requirements for effective maintenance systems • The impact of HUMS/future maintenance systems within the operational and logistical command chains • The effects on future logistic and maintenance based policy and doctrine

Condition Based Maintenance Plus Why? Decrease maintenance burden on the warfighter Increase platform availability and readiness Reduce Operations & Sustainment costs What? Maintenance capabilities: Enhancing diagnostics… Evolving to predicting remaining component life… Then to proactive supply transactions Derived from near real-time assessment and analysis of data from: Embedded sensors Platform maintenance environments Weapon system and supply historical data How? Interactive electronic technical manuals, portable maintenance aids, other enabling tools and technologies Diagnostics, sensors and prognostic algorithms & techniques Reliability-centered maintenance concepts and practices Statistical and engineering analysis processes Condition-driven maintenance plans Integrated maintenance and logistics processes & reporting systems “Note that without prognostics, the CBM+ initiative looks a whole lot like RCM.” USAF Aircraft Maintenance Officer 19

Overview The need for effective policy and doctrine to underpin the emerging capabilities of integrated mechanical diagnostics/ prognostics and advanced maintenance systems • Optimizing platform readiness, safety and reliability to ensure maximum capability • The challenges in creating and implementing policy for new and emerging maintenance technologies and systems • The US DoD requirements for effective maintenance systems • The impact of HUMS/future maintenance systems within the operational and logistical command chains • The effects on future logistic and maintenance based policy and doctrine

Current CBM+ System “The best current CBM+ system is a well-trained, well equipped, very experienced maintenance technician who has the time and inclination to correspond in meaningful terms with the AFETS and Engineering people. Don't take that wrong. What I mean is that the closest thing we have to a system that can predict when a system will fail is the dedicated, expert technician.” USAF Aircraft Maintenance Officer

Air Force Initiative: Instrumentation of Critical Life Areas in Aircraft One of the lessons we learned,…is that we do not have sufficient reliability and structural integrity information to determine the correct course of action relative to the future of our aging fleet. …the uncertainty in reliability and structural integrity in that fleet We have the means and methods for achieving a data driven analysis across our fleet. We have extraordinary fleet reliability experts…, extraordinary data analyzers….the Fleet Viability Board…. What is needed now is to provide [them]…the right information….

Overview The need for effective policy and doctrine to underpin the emerging capabilities of integrated mechanical diagnostics/ prognostics and advanced maintenance systems • Optimizing platform readiness, safety and reliability to ensure maximum capability • The challenges in creating and implementing policy for new and emerging maintenance technologies and systems • The US DoD requirements for effective maintenance systems • The impact of HUMS/future maintenance systems within the operational and logistical command chains • The effects on future logistic and maintenance based policy and doctrine

CBM+ Elements and Enablers Sensors and algorithms Condition status reporting Data collection techniques Automated Information Technology Serialized Item Management Troubleshooting Unique Identification Diagnostics Radio Frequency Identification (RFID) Prognostics Fault Isolation Health monitoring & management Systems integration Interactive training Reliability Centered Maintenance (RCM) Analog condition extenders Built In Test (BIT) Asset visibility Integrated information tools & systems Portable maintenance aids (PMA) Interactive electronic technical manuals [Systems & Sustaining] Engineering analysis

Legacy and Aging Weapon Systems Can CBM+ be implemented on legacy and aging weapon systems, and… is it cost-effective to do so?

Overview The need for effective policy and doctrine to underpin the emerging capabilities of integrated mechanical diagnostics/ prognostics and advanced maintenance systems • Optimizing platform readiness, safety and reliability to ensure maximum capability • The challenges in creating and implementing policy for new and emerging maintenance technologies and systems • The US DoD requirements for effective maintenance systems • The impact of HUMS/future maintenance systems within the operational and logistical command chains • The effects on future logistic and maintenance based policy and doctrine

Weapon Systems Supported by DoD Maintenance Maintained by: 678,000 DoD personnel Private sector companies 100,000+ Ground Combat/ Tactical Vehicles  900 Strategic Missiles Marine Corps Depot Marine Corps Field 0.9 (<1%) 49.9 (7%) Navy Depot 20.9 (3%) Army Field 220.8 (33%) Navy Field  280 Ships 14,000 Aircraft/Helicopters 173.6 (26%) + 250K+ Wheeled Vehicles + Comm/Electronics Equipment + Support Equipment + ... Army Depot 7.2 (1%) Air Force Depot 15.1 (2%) Air Force Field National Defense PP&E is valued at  $700 Billion 186.8 (28%) 1 1 Maintenance cost: ~$63B per year

Improving Materiel Readiness: Reliability, Cycle-Time, Cost Life-cycle cost (acquisition + O&S) More Drive reliability up to optimum level reliability Sustainment cycle-time Less Drive sustainment cycle time down to optimum level (O&S only) Higher $ Lower $ Cost of Readiness R&D/ACQ Only R&D/ACQ/O&S Lowest $

Sustained Materiel Readiness ISSUE: WAY AHEAD: Concentrate on achieving and sustaining SPG/CPG readiness Balance safety, reliability, and maintenance activities to achieve readiness at best cost. Optimize TIME-ON-WEAPON SYSTEM 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 Translate SPG/CPG capabilities to weapon system/materiel requirements Foster and promote Continuous Process Improvements (CPI) Reliability Condition Based Maintenance Plus (CBM+)/Reliability Centered Maintenance (RCM) Cycle process discipline Lean, Six Sigma, Theory of Constraints, etc Develop cause and effect predictive models Institute integrated budgets (engineering, logistics, industrial) 7

CBM+ Policy CBM+ key policy tenets… Need-driven, reliability centered maintenance Embedded diagnostics and prognostics Automated maintenance information generation Trend-based reliability and sustainability process improvements Integrated information systems providing logistics response based equipment condition and tasking Smaller maintenance and support footprints Improved Operational availability US Army Policy 17 AUG 05

CBM+ Select Programs Army Navy Air Force Marine Corps Future Combat System (FCS) Apache Stryker Navy Maintenance Effective Reviews (MER) Engineering for Reduced Maintenance (ERM) Integrated Condition Assessment System (ICAS) Smart Ship Air Force C-17 JSF Marine Corps Expeditionary Fighting Vehicle (formerly AAAV) Light Armored Vehicle (LAV) Defense Logistics Agency Service Parts Ordering Tool (SPOT) – AWACS DLA Reliability Initiative

CBM+ Implementation Phases IOC 2011 FOC 2015 FOC 2015 FY 05-07 FY 08-15 FY 16+ Phase 1 – Concept Development Proof of Principle Develop Data Warehouse Develop Prognostics Assess Impacts to DOTMLPF Assure Interoperability With: GCSS-A CLOE LMP PLM+ Phase 2 - Implementation CAB Pilot Fielding Continuous Data Analysis Refinement of Prognostics Changes to DOTMLPF Examine New Technologies Phase 3 - Operations Sustain CBM+ Continuous Data Analysis Refine Prognostics DOTMLPF Improvements

Overview The need for effective policy and doctrine to underpin the emerging capabilities of integrated mechanical diagnostics/ prognostics and advanced maintenance systems • Optimizing platform readiness, safety and reliability to ensure maximum capability • The challenges in creating and implementing policy for new and emerging maintenance technologies and systems • The US DoD requirements for effective maintenance systems • The impact of HUMS/future maintenance systems within the operational and logistical command chains • The effects on future logistic and maintenance based policy and doctrine

CBM+ Program Focus: Benefits for Warfighters To Battlefield Commanders, CBM+ Is: Ability to Meet Mission Requirements With Proactively Driven Maintenance Ability to Optimize Competing Demands of Warfighting & Planned Maintenance To The Warfighter, CBM+ Is: Maintenance Instructions Based on Actual Condition and Usage Greatly Enhanced Diagnostics and Troubleshooting Fewer Maintenance Manhours Physical Inspections Are Reduced or Eliminated

Potential Benefits to Warfighters AH-64 Block III Fleet 10 Parts Readiness +4.9% Maintenance Burden reduced by 41,000 Maintenance Manhours (MMHs) Equates to an additional AH64 Battalion UH-60 M Model Fleet 9 Parts Readiness +3.4% Maintenance Burden Reduced by 26,000 MMHs Annually

CBM Enabled Army Aircraft South Carolina National Guard 2 AH - 64A Korea US Army 15 UH 60A/L Kentucky Ft Campbell 160 th SOAR 6 MH 60K Alabama 8 UH 3 CH 47D (P) Missouri 1 AH 17 AH 64A (P) 12 UH 60A/L (P) California NASA Ames 1 UH 60 Test Aircraft ATTC 1UH 60A/L, 1 AH 64A, 64D, 1 CH 47D Arizona WAATS 5 AH 15 AH Iraq 8 AH 64D North Carolina 60A/L(P) Tennessee IRAQ/Kuwait 60 • Over 33 Systems supporting the war fighter In IRAQ Over 40,000 Flight Hours Experience 60A/L, 16 AH 30 UH 60L 4 AH PA National Guard/EAATS 1 CH

Overview The need for effective policy and doctrine to underpin the emerging capabilities of integrated mechanical diagnostics/ prognostics and advanced maintenance systems • Optimizing platform readiness, safety and reliability to ensure maximum capability • The challenges in creating and implementing policy for new and emerging maintenance technologies and systems • The US DoD requirements for effective maintenance systems • The impact of HUMS/future maintenance systems within the operational and logistical command chains • The effects on future logistic and maintenance based policy and doctrine

CBM+ Related Efforts Defense Advanced Research Projects Agency (DARPA) Advanced Concept Technology Demonstrations (ACTD) Commercial Technologies for Maintenance Activities (CTMA) Joint Oil Analysis Program Technical Service Center (JOAP-TSC) Military Flight Operations Quality Assurance (MFOQA) Modeling and Simulation Industry Academia Sports and Entertainment Corrosion Control Allied Military Services

CBM+ Future & Summary Reality Check #2 When do you reach a critical Mass? CBM+ is a long term commitment! Reality Check #3 Need some low hanging fruit…or bridging strategy Reality Check #1 Technology is here…but…facing real constraints CBM+ is proactive maintenance based on evidence of need performed by maintainers with the right knowledge, tools and support at the optimal time.

Contact Information Colonel Sarah J. Smith OSD-ATL (MR&MP) 3500 Defense Pentagon, Room 5A712A Washington DC 20301-3500 (703) 695-0338 Email: Sarah.Smith@osd.mil OSD CBM+ Website: http://www.acq.osd.mil/log/mppr/CBM%2B.htm