AMCOM Update DAU-South Acquisition Conference Gary Nenninger G-3 Operations Aviation & Missile Life Cycle Management Command 18 February 2009

Agenda Support to the Aviation Warfighter Aviation Field Maintenance Transformation Reset Condition Based Maintenance (CBM)

AMCOM Support to the Warfighter 2,456,568 Total Hours: 01 Feb 03 – 15 Jan 09 Army Fleet in OIF Support To The Warfighter AH-64 479,959 Hours MC: 82.0% OPTEMPO: 58.0 UH-60 726,335 Hours MC: 84.0% OPTEMPO: 45.0 ~ 3000 Aircraft Preset/Reset Aviation Field Maintenance Condition Based Maintenance Supply Support Provisioning Worldwide Onsite Technical Assistance (LARs / CFSRs) Fwd Deployed Repair/ Sustainment Activities: TAMP, TASM TMDE Calibration and Repair MWO Applications Depot Maintenance Technical Publications Airworthiness & Safety of Use CH-47 123,070 Hours MC: 73.0% OPTEMPO: 44.7 Fixed Wing 140,381 Hours MC: 91.0% OPTEMPO: 59.9 OH-58 416,903 Hours MC: 84.0% OPTEMPO: 72.2 UAS 569,920 Hours Shadow 323,342 hrs Hunter 38,244 hrs Sky Warrior 75,001 hrs Raven 133,309 hrs gMAV 23 hrs OEF Plus Up 389,768 Total Hours: 01 Feb 03 – 15 Jan 09 Army Fleet in OEF AH-64 94,947 Hours MC: 87.0% OPTEMPO: 50.0 UH-60 114,928 Hours MC: 85.0% OPTEMPO: 42.0 CH-47 77,946 Hours MC: 78.0% OPTEMPO: 51.6 Fixed Wing 19,926 Hours MC: 87.0% OPTEMPO: 51.4 UAS 43,496 Hours Shadow 19,529 hrs Hunter 910 hrs Sky Warrior 4,953 hrs Raven 18,104 hrs OH-58 38,525 Hours MC: 85.0% OPTEMPO: 80.4

Support to the Warfighter Aviation Field Maintenance Transformation Reset Condition Based Maintenance (CBM)

Aviation Field Maintenance Transformation What We Did? Realigned All AMCOM Aviation Field Maintenance Responsibilities Into One Organization Established Aviation Field Maintenance Directorate (AFMD) Why We Did This? Fragmented Aviation Maintenance Responsibilities Highlighted in Recent Aviation Maintenance Issues Mission Explosion for OLRs (Beyond MWO Application) Required Readjustment of Management Structure Need to Go Back to the Basics With Aviation Field Maintenance

Aviation Maintenance Hierarchy Commander’s Intent: “Establish Unity of Command for AMCOM Below Depot Aviation Maintenance Activities” Depot Airframe Component Special Projects AMCOM Managed Organic Contracted Consolidate AMCOM Structure Standardize Processes and Business Rules Common Metrics & Oversight Transform How The Army Operates SINGLE ARMY AVIATION MAINTENANCE MANAGER Below Depot / Above Unit Unit Overflow Limited Depot Repair MWO Application Reset Multiple Managers AMCOM NGB DOL/ALMD User AVUM AVIM Scheduled Services & Inspections Authorized Repairs Unit Managed Organic Military CFT Augmentation

Support to the Warfighter Aviation Field Maintenance Transformation Reset Condition Based Maintenance (CBM)

The Reset Process Reset Is NOT: Reset IS: Routine Scheduled Maintenance Depot Overhaul Reset IS: 100% Disassembly of the Aircraft and Dynamic Components (Engines, Rotor Systems, Drive Trains, Flight Control Systems) 100% Cleaning of All Airframe and Component Elements 100% Serviceability Inspection of All Airframe and Component Elements Application of DA Directed Modifications 100% Review and Correction of Historical Records Refurbishment and Replacement of All Components to Serviceability Standards Correction of Outstanding Deferred Maintenance Actions Returns An Immediately Deployable Aircraft To The Unit With Significantly Improved Operational Availability And Safety Characteristics

Reset Sites AFMD/ALMD* Drum (DOL) UH-60  Ft Campbell UH-60, CH-47, AH-64 Germany Ft Lewis UH-60 and CH47 Hawaii USAREUR (Non-Enduring) Ft Hood UH-60, AH-64, OH-58 Ft Bragg UH-60 and OH-58 Ft Stewart UH-60 and CH-47 Ft Drum Where Installations with AFMD and ALMD Activities Installations with ALMD Only Installations with AFMD Only * Aviation Field Maintenance Directorate / Aviation Logistics Management Division 9

Deployment Critical Timeline Aviation Reset Status Various Stakeholders Deployment Critical Timeline -10 POE In Transit -35 POD -45 Load To -55 ALD Home -85 Pre-deploy Staging Leave time -120 LAD RESET MREs Offload RSOI BOG +30 To Include Mods -ARFORGEN- Reset Summary Status Completed 2,906 Aircraft (Includes SOA – 353 A/C) OIF1 – 923 (Includes 75 SOA) OIF2 – 426 (Includes 62 SOA) OIF 04-06 – 561 (Includes 53 SOA) OIF 05-07 – 446 (Includes 74 SOA) OIF 06-08 – 452 (Includes 73 SOA) OIF 07-09 – 98 (Includes 16 SOA) Aircraft In Reset Or Scheduled For Induction OIF 06-08 – 10 In Reset; 0 Scheduled OIF 07-09 – 112 In Reset; 228 Scheduled Reset Mission: Return aircraft to an FMC (Fully Mission Capable) condition IAW AR 700-138 using a special technical inspection and repair program that includes inspection, cleaning, repair, and select mandatory replacement of parts Data as of 13 Jan 09

Support to the Warfighter Aviation Field Maintenance Transformation Reset Condition Based Maintenance (CBM)

Condition Based Maintenance (CBM) Digital Source Collector Installation Knowledge Development Fault Diagnosis Remaining Useful Life Calculation Inspection Targeting Reactive Maintenance Time Based Inspection/Overhaul Proactive Maintenance ‘On Condition’ Inspection/Overhaul CBM Program Objectives: Decrease Maintenance Burden on the Soldier Increase Platform Availability and Readiness Enhance Safety Reduce Operations & Support (O&S) Costs Monitored Master Parts List – UH-60A/L (56 Parts) T/R Blade T/R Pitch Change Horn PC Links Main Rotor Hub Main Rotor Shaft Bifilars Swashplate ASSY Swashplate Guide Swashplate Bearing** PC Links M/R Spindle Spherical Bearing M/R Spindle Tie Rod Control Horn M/R Shaft Extender M/R Damper T/R Pitch Change Shaft T/R Pitch Change Bearing M/R Blade M/R Blade Tip Cap M/R Blade Expandable Pin M/R Blade Cuff Tail Rotor GB** Retention Plates (2) Gearshaft Viscous Bearings (4)** T/R Driveshafts (7)** Vibration Absorbers (2) Intermediate GB** Key CBM Enablers Digital Source Collectors Flight Line Diagnostics Data Fusion/Analysis Main Transmission Module Accessory Module Generators (2) Hydraulic Pumps (2) Planetary Carrier Engine (No. 1 & 2) Driveshafts (2)** Input Modules (2) Oil Cooler Axial Fan Oil Cooler Fan Bearing** APU Currently Monitored by Vibration Structural Part, Possible Addition for Monitoring

Digital Source Collector Fieldings Through Jan 09 Aircraft Type Total # of Aircraft DSC Equipped Percent Complete AH-64A 690 333 48% AH-64D CH-47D 513 61 71 14% CH-47F MH-47E/G 10 UH-60A 1732 105 364 21% UH-60L 180 UH-60M 79 MH-60K/L MH-6 51 16 31% OH-58D 339 9 TOTAL 3325 793 24% * Includes Active, Reserve, and National Guard Units 13

CBM Demonstrated Benefits Increased Readiness Decreased Mission Aborts 4-101 Avn Flew 26,000 Hours on 38 UH-60 During 12 Month OIF Deployment With 87% FMC 57 Hrs/Acft/Month = 3.8 Times Peacetime OPTEMPO 7,260 Launches With No Missions Dropped for Maintenance 3,417 Hours in Highest Month (~110 Hours/Day With 20-25 Aircraft) Impact of Equipping Deployed UH-60s Battalions With DSCs 03-04 OIF Rotation (30 Aircraft ) Non-equipped (Bn 1) Non-equipped (Bn 2) FMC* 65% 77% Total Flt Hours 10,331 11,844 OPTEMPO (Hours/Year/Aircraft) 334 395 Both Units Completed Reset 05-06 OIF Rotation (30 Aircraft) DSC Equipped (Bn 1) FMC 87% 82% 21,819 20,388 OPTEMPO (Hours/Year/Aircraft) 727 680 CBM Will Enhance Pilot Training by Providing Insight Not Previously Available (e.g., Fatigue Damage Due to Maneuver Severity) Expect Increased Readiness in Deployed. Real Comparison Is Deployed CBM vs Non-CBM Deployed Aircraft CBM Already Changing the Way Aviation Operations Are Planned & Conducted CBM = Increased Warfighting Capability

Cost Savings/Avoidance of ~$112M (26 Month Period) Due to CBM CBM Benefits to Army Aviation Increased Readiness/Reduced O&S Costs/Reduced Soldier Burden Impact of Equipping Aircraft With DSCs Cost Savings/Avoidance  2007/2008 AH-64 UH-60 CH-47 # of Aircraft 319 71 MMH Avoided 16,369 7,274 2,957 Hrs Reduction in MTF hours 2,005 722 166 $24M: 51 T700 Engines not Replaced on UH-60/AH-64 for Overspeed/Overtorque ~$30M: Additional AH-64/UH-60 Flight Hours Available Due to Increased Readiness/Availability + MTF Hours Saved ~$49M: Three Class A Accidents Avoided ~$6.6M: Components not Replaced, Returned to Service, and Overhaul Savings Due to Early Failure Detection ~ $2.8M: AH-64 Tail Gearbox Scheduled Maintenance ~$112.4M Reduced NMC Due to Maintenance Cost Savings/Avoidance of ~$112M (26 Month Period) Due to CBM (Accidents Avoided, Components Not Replaced Unnecessarily, MTF Hours Saved,… )

HELLFIRE Captive Carry Health Monitor Methodology – Automatically Measure and Record Captive Carry Hours / Number of Cycles Temperature Exposure Battery Life Data Histogram Drop Shock/Humidity Payoff Reduced Maintenance Burden Increased Reliability and Enhanced Safety Positive Impact to Stockpile Readiness and Shelf Life CCHM Captive Carry Exposure Data Will Optimize Reset Maintenance, Improve Reliability, and Reduce Reset Costs Hellfire II (AGM-114K) Guidance Section

Challenges Reset Increased OEF Support OIF Retrograde Funding ARFORGEN Synchronization Increased OEF Support OIF Retrograde CBM success stories should be annotated in the commanders comments on the backside of the monthly 1352 reports.   They should include, but not be limited to, aircraft accidents prevented, major component non-replacements such as engines and gearboxes, maintenance troubleshooting and maintenance man-hour savings as a result of having CBM maintenance processes and procedures.

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