(Fighter Avionics Upgrade) An Example of Performance Based Logistics (Fighter Avionics Upgrade) Dale Waldo 314-705-1865 Last Rev. 5/10/99 by DFW

Requirements Implement F3I Guaranteed mission capability rate Support peace and war time scenarios USAF/Contractor forms partnership for sustainment over the system life cycle Affordable cost to USAF Note, 90% mission capability (MC) is for 5 LRU portion of radar only. As of Aug. ‘96 F-15 A/C currently had 76% mission capability. APG-63 radar was not on top 10 impact list driving MC. It was when we started the program, but reactive planning temporarily has fixed problems and so it has moved further down the list.

Implements F3I Requirements Performance based specifications Form, Fit, Function Interface (F3I) ‘How to’ responsibility given to Contractor Contractor Depot Maintenance Helps mitigate the risk of short lived technologies Contractor has configuration control internal to LRU Facilitates technology insertion Utilizes Trigger Based Item Management (TBIM) Process Provides for trends and targets actions that provide high payoff ‘Proactive’ rather than ‘reactive’ management How FFFI solves parts obsolescence. FFFI does provide the contractor with configuration control internal to the LRU. Therefore the contractor is allowed to make configuration control changes that are required to solve parts/technology obsolescence in a roadmap driven environment. The roadmap has opportunistic points at which technology, either internally developed or commercial, can be inserted into the hardware to not only solve future parts obsolescence, but also to maintain MTBMA (mitigate the bathtub effect). Improvement of MTBMA allows the Contractor an incentive for increase profits when technology is inserted wisely. Ref. PBBE Flexible Sustainment Guide https://acc.dau.mil/GetAttachment.aspx?id=19314&pname=file&lang=en-US&aid=980 -

Elements of PBL (Continued) Proper O level maintainer training and technical information Tech Pubs (plane side repair data) updated during EMD CFR/CFI system update; deployment during OT&E All technical information evaluated vs “as designed” Inclusive Diagnostic System at all levels of assembly Automated configuration management required For tracking: Base Aircraft LRU SRU Critical Component Manage parts inventory Tracking of bad actor hardware, remove when necessary PBL Implements F3I Criterion 5

Availability: When you need it you will have it! Actual On-Aircraft Mean Repair Time (MRT)< 45 Minutes BASE SUPPLY Base X Flightline Shipping & Receiving 5 Hrs 5 1 Removal Defective LRU - Receives Bad LRU - Generates DIFM via CAMS 3 Install Good LRU 4 - Issues Spare - Picks Up Bad LRU - Sends Bad LRU to Shipping 0 Hrs 2 Maint. Tech Exchanges Bad LRU for Spare 8 Hrs AMU Support Section

Shared Responsibility is Key to Success Contractor - Provide adequate spares based upon MTBMA USAF and Contractor - Minimize Mean Down Time (MDT) USAF - 45 Minute MTTR Contractor - 5 Hour stores replenishment time (for spares) USAF - 8 Hours for local transportation, preparation of maintenance action and requisition forms, pack and ship Technical Performance Measurands will be implemented to help manage the program, minimize MDT 21

Maintenance Concept Organizational Level Tasks a DTM is similar to a thumb drive Serial Numbers & BIT Matrices DTM Transfer Remove/Replace Failed LRU Perform Additional Troubleshooting Procedure and Repair System Perform System Verification Skill LvL 3 Technician CFRS/CFI 1) CFRS - Determine existence of fault. 2) CFI - Determine most likely cause of fault. Identify corrective action to be performed. PMA Maintainer Always Receives Positive Action From Technical Data (e.g. Next Action). 10

Wiring Diagram on the Fly CFR/CFI System Proposed Process (Eliminates need for Fault Isolation Tech manual) CFR / CFI Identify Corrective Action Required How is this Done? Job Guide Is the Fault Corrected? If “How To” instructions are not required DTM Job Guide PMA CFR/CFI System Wiring Diagram on the Fly CFRS/CFI 14

Functional Requirements Automated Fault Detection Provided by on-aircraft system BIT and supplemented with CFRS Accomplished via updates to WIN-95 CFRS Automated Fault Isolation capability Provides “POSITIVE ACTION” to maintainer Electronic automated tool implementation includes Digital Wire Diagrams Currently done with paper manuals today Automated data collection Enables collection and manipulation of data collected Includes maintenance corrective action and parametric information 11

Advantages CFI data base can readily be updated in 1-2 weeks time frame Not Tech Pubs update dependent (months/years time frame for paper update) Maintainer now gets real time data to help isolate failures Portable Maintenance Aid (PMA) compatible Deletes paper Fault Isolation/Wiring Diagram (FI/WD) manuals 12

REPAIR DEPOT PROCESS LRU REPAIR 7 DAYS AVERAGE SRU REPAIR 60 DAYS * BAD LRU RETURNED FOR REPAIR CFRS/CFI 2 DAYS FROM Air Base BAD SRU SRU REPAIR ASSET MANAGEMENT •PREPARE TASK ORDER PACKAGE •TRACK REPAIR • OBTAIN SHIPPING INSTRUCTIONS • PROCESS GFP DOC. •CONFIRM FAILURE •REPLACE BAD SRU •LRU TEST •CONFIRM FIX •INSPECT LRU REPAIR 7 DAYS AVERAGE SHIPPING & RECEIVING SRU SPARES SPARE PARTS 2 DAYSTO Air Base SRU REPAIR 60 DAYS RFI LRU SHIPPED PER ASSET MANAGEMENT INSTRUCTIONS REPAIRED SRU 29

Asset Manager (Middleware Merge Engine) CFR/CFI/DWDS Database Core Automated Maintenance System (CAMS) Federal Express Asset Manager Supplier Depot SPO WPAFB Middleware Merge Engine Asset Management Data Information Screens Elmendorf AFB Lakenheath RAF Nellis AFB Mountain AFB Langley AFB Edwards AFB Eglin AFB Base Supply / Trans. Databases Airborne USAFE PACAF Growth FRACAS Property Management LRU / SRU Field Configuration Database Base Supply / Transportation Program Office Field Operations Contractor DEPOT WRALC

Asset Manager Field Level Metrics System Readiness or Availability Rate System MTBMA (less -120 Antenna) Mean Down Time per Maintenance Action LRU Demand Rates System CND Rate Average Duration from JCN Issue to Part Received by Commercial Shipper Percent JCNs Awaiting Parts - Off Station Average Active Maintenance Time for Troubleshooting and Repair Average Repair Turn-Around Time Base Dock to Base Dock

Depot Metrics LRU Repair Rates Number of broken warranty seals on returns Number of Units in Pipeline Average Duration of LRUs in Transit Average Turn-Around Time by Facility BCS/RTOK Rates Depot Test Voids/Total Test Required Number of Parts Produced by Single Source Technology Obsolescence Projections Number of Obsolete Part Types in Field Percent JCNs Awaiting Parts Current Value of Repair Inventory Repair Station Availability Rates & Excess Capacity Number of Open Engineering Investigations Number of Outstanding BIT ECRAs and Time Outstanding

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