1. Commercial Technologies for Maintenance Activities
The
Commercial Technologies
for Maintenance Activities
Program
a joint NCMS/DoD Partnership

2. CTMA is the only DoD-wide program focused on improving maintenance efficiency and effectiveness for current weapon systems.
Resourced Since
1998
Industry to Government Cost Share
2:1
Congressionally Directed DoD Project Funds $45M
Industry Cost Share Committed
$116M
Program Focus : Technology Demonstration
Program Focus 2005-Present: Technology Transition
Proven results warrant ongoing DoD commitment
Congressional patience for CTMA is waning
DoD decision required
DoD-wide transition
Current project completion
Continued CTMA funding 2

3. CTMA Basics CTMA Focus Industry Partners Army / CTMA Activities
Cooperative agreement between NCMS & ADUSD (MP&P)
Requires 2:1 industry/government cost match
DoD-wide; produces joint service results
Requires commitment by at least two services
Provides an estimated ROI of 20 to 1
Average technology transition is 12 months to IOC and 24 months to benefit realization
35 DoD facilities participated on projects
Rapid and relevant response to GWOT
Transition commercially available technology (TRL Level 6+) versus inventing new technology
Reduce cost of sustaining weapons systems
65-80% of Life Cycle Cost in O&S
Maintenance cost ~ $84B in FY07
Sustain readiness via
Maintenance avoidance via CBM+ technologies
Enabling expeditionary maintenance
Reducing repair cycle time
Industry Partners
Army / CTMA Activities
CECOM
New Jersey
TACOM
Michigan
SIAD 1
California
TACOM
Illinois
TYAD 12
Pennsylvania
LEAD 2
Pennsylvania
ARL 1
Maryland
AMCOM
Alabama
ANAD 8
Alabama
RRAD 5
Texas
# indicates projects
CCAD 5
Texas 3

4. 1. 2. 3. 4. Army Resourcing Options Resourced by PMs/PEOs
PM/PEO directed 2.
Resourced in Working Capital Fund rate
Materiel Command/Depot directed 3.
Resourced by Sustainment Accounts
“4” code directed 4.
Combinations of above

5. LENS™ direct metal deposition technology provides a solution to reduce repair costs and provide higher quality parts when compared to traditional repair methods.
Ability to repair critical components that would be scrapped resulting in reduction of supply chain logistics and enhanced readiness of M1 Abram
The LENS™ machine builds up material on the surface of an existing component, restoring the original material that has been lost due to wear and corrosion
Since the process does not apply heat to critical areas, LENS™ can affect repairs without strength loss or distortion. Formerly irreparable parts can now be repaired
Enables repair of long lead time, critical components traditionally scrapped – reduces logistics supply chain, improves readiness, reduces sustainment costs and cycle times
DoD ROI to Date:
$31M
DoD Investment - $2.4M
Industry Cost Share - $4.9M
Laser Engineered Net Shaping (LENSTM) DoD Potential Cost Benefits $600M/yr assuming deployment to all appropriate weapon system components
Army Realized Benefits
Application by the Armed Services
$30 M
Reduced maintenance cost
2-3 years
Acquisition lead time reduction
LENS™ big player in critical path to M1A1 Abrams readiness
Two LENS™ units reside at Anniston Army Depot (ANAD)
Abrams consistently meeting readiness targets in GWOT
Improved readiness at less cost. Result – repair parts that were previously scrapped
Capable of metal deposition repairs to virtually any part that fits within the machine
Significant cycle time reduction for repair of end item
Navy Realized Benefits
$500k/year
Aft fuel tanks repair
$150K/year
Compressor crankshaft buildup
$110k/year
Submarine connector rods
Source: Keyport - projected by Keyport engineers
ANAD – Actual savings as measured the first year
WINNER 2004 Defense Manufacturing Excellence Award

6. EWIS technology is reliable, user-friendly menu-driven equipment that detects and locates wiring defects on a variety of cable and wire types.
Conservatively 1000x faster than old method (pin to pin)
Provides exact location of wire fault
Reduces unscheduled maintenance
Portability enables expeditionary maintenance and rapid response to GWOT
Technology milestone on the path to wiring system prognostics
Ensures early detection of faulty repair processes
Reduces LRU “Re-Test OK” rate approximately 50%
Increases system availability
~50% reduction in troubleshooting time
Increased readiness and fewer mission aborts due to wiring incidents
9,336 man-hours saved in F-16 repair in the first six months
DoD ROI to Date:
$50M
DoD Investment - $837K
Industry Cost Share – $1.8M
F-15 realized $3M cost avoidance to date
Enhanced Wiring Integrity Systems (EWIS) DoD Potential Cost Benefits $2.4B/yr assuming full DoD deployment (based on $10M savings per weapons system extended to Navy and Army)
Army Realized Benefits
Application by the Armed Services
$1,400/shelter
Maintenance cost avoidance
F-15 realized approximately $3M cost avoidance
to date.
EA-6B circuit breaker panels test and repair
resulted in $824K cost savings.
F-16 wing tests prior to retrofit has an estimated annual savings of $63K.
Shelter wiring repair resulted in approximately $1400/shelter cost avoidance.
$240, annual savings per EWIS equipment set when analyzing typical electrical problems on Portsmouth Cranes, days reduced to hours.
At Tobyhanna Army Depot, the location of faults in complex mobile shelters was reduced to minutes versus days resulting in a projected annual savings of $840,
C-2 rewire verified engineering data and the electrical integrity of wiring prior to flight test and clearly improved mission readiness of rewired aircraft.
$840K/year
Annual cost savings
50% Reduction
in troubleshooting time
(10-17 man hours)
Air Force Realized Benefits
F-15 wiring faults -
$49M/year cost avoidance
120 lost a/c days recouped
Navy Realized Benefits
EA-6B Circuit Breaker - $2.4M overall
$137K/aircraft - $824K cost avoidance
WINNER Defense Manufacturing Excellence Award
-Seymour Johnson AFB Chief of Staff Award
Source: NCMS Project Team

7. Field Level Fluid Analysis
Rapid Manufacturing fabrication methods for replacement and repair of legacy parts are case studied to:
Evaluate and define materials and process factors,
Address part qualification, and specification approval for ADF-RP technologies, and
Create CAD, stl or STEP files for future use.
ADF-RP processes include laser sintering (LS), electron beam melting (EBM), stereo-lithography (SLA), fused deposition modeling (FDM), direct metal deposition (DMD), and ultrasonic consolidation.
DoD Investment - $1.4M
Industry Cost Share - $4.2M
Field Level Fluid Analysis
Rapid Manufacturing and Repair DoD Potential Cost Benefits $25M/yr assuming extending technology to similar DoD components and castings
Realized Benefits
Application by the Armed Services
Total Annual Cost Avoidance
Of $3.5 M
Technology Transfer:
Inserted 12 pieces of ADF-FP equipment into DoD Maintenance facilities and 12 pieces of ADF-RP equipment for initial piloting at industrial partners – conducted >70 case studies to date.
Rapid manufacturing technologies are being quickly deployed in European and Asian manufacturing communities.
310 weeks
Saved on non-availability of parts per year
50% 75%
Raw material and labor cost avoidance
50% - 70%
Cycle time reduction for part repair and replacement
Source: Based on commercial industrial
experience and over 36 conducted case
studies to date
Greatly reduces repair turnaround time and
directly effects diminishing mfg. sources and
material shortages (DMSMS)
WINNER 2005 Defense Manufacturing Excellence Award

8. Field Level Fluid Analysis
DoD has issued a requirement that all weapons system parts of value greater than $5,000 be permanently marked with a unique identifier. The 2D data matrix as specified in ISO is the required marking but as this project was launched, little work had been done to develop processes and technology for meeting the DoD requirement on post procurement parts. This project piloted appropriate solutions.
Total asset visibility providing the ability to mark, verify, and read current inventories with one system.
Removal of data entry errors, real-time capture of data, and the ability of the DoD to track items for operational, logistical, and financial accountability purposes.
Identification of all critical components within an engine.
A General Accounting Office (GAO) study estimated the DoD could have saved $2 billion in Desert Storm inventory, from a $2.7 billion total inventory through better information about available inventory.
DoD Investment - $1.4M
Industry Cost Share - $3M
Field Level Fluid Analysis
Parts Identification through Permanent Marking Techniques
DoD Potential Cost Benefits $2B by accelerating IUID deployment by 1 year
Application by the Armed Services
Potential Benefits
Tested and applied a variety of IUID marking and reading applications to overcome environmental and material challenges facing DoD weapons system.
Fully integrated mobile 2D marking cart deployed in field:
Ogden Air Logistics Center
Fleet Readiness Center East
Letterkenny Army Depot
All DoD depots are now purchasing similar equipment for marking parts.
Handheld laser to mark products deployed in field.
Color additives in conjunction with deep electrochemical etch and laser coating removal processes to improve marking contrast.
ALL FIRST TIME APPLICATIONS!
$2 Billion
The CTMA project has accelerated the implementation of IUID throughout DoD by at least 1 year. The DoD IUID program projects an average annualized benefit through 2020 of $2B
$800K/ Monthly
Cost savings at LEAD on two programs
Source: DoD data

9. Hard chromium plating provides superior wear resistance for a wide variety of surface geometries. While considerable effort has been expended over the past several years to develop alternative processes to hard chrome plating that can match its performance and flexibility, itis not likely to be superseded in the foreseeable future for many critical applications. This project piloted a new “no mask” process in which a customized rack and anode fixture replaces masking, resulting in reduced labor for masking, faster plating times and more uniform chromium deposits. CH-47 horizontal pin and cover support were targeted in the pilot.
DoD Investment - $455K
Industry Cost Share - $888K
No-Mask Hard Chrome Plating DoD Potential Cost Benefits $15M/yr assuming deployment at the 7 organic plating facilities.
Realized Benefits
Application by the Armed Services
Enables maintainers to respond to >200% surge in demand
Technology Transfer:
Widely adopted by CCAD in production use. NAVAIR-North Island has identified eight additional parts. Adoption of no-mask tooling will result in potential cost avoidance of $15 million per year.
Similar savings possible for all DoD plating facilities that plate hard chrome.
Project currently underway to apply this technology to nickel plating.
$5M to date at CCAD and FRCSW
$4.8M/year throughout Dod
Annual labor savings / 83% decreased labor cost / part
200%
Increase in plating equipment capacity
60%
Reduction in component cycle time
Source: benefit data provided by CCAD

10. Application by the Armed Services Realized Benefits of $2.6M to date
Material State Management optimizes the processing of composite parts to improve product quality and throughput.
Previous projects addressed material and process substitution focused on improved materials utilization and process flexibility for producing composite parts.
Current effort furthers quality and throughput by classifying the tooling to manage heat transfer in ovens and autoclaves used in the production and repair of composites.
Cost to government is millions of dollars each year in scrapped parts, lost time, delays in returning weapon systems to service and lost opportunity to improve performance and reduce production costs.
DoD Investment - $744K
Industry Cost Share - $4.4M
Heat Transfer Classification for Production Tooling and Composite Repairs - DoD Potential Cost Benefits $13M/yr assuming similar per part savings for helicopter blades and radomes as being realized in private industry
Application by the Armed Services
Realized Benefits of $2.6M to date
Control system software platforms has been installed or updated at CCAD and OO-ALC to permit the incorporation of the heat transfer characterization tools.
This system is improving the quality of composite helicopter blades manufactured at CCAD.
Ogden ALC uses control system for manufacturing of F-16 leading edge repair parts and is laying the foundation for improved composite fabrication methods to be used on the F-22.
With the rapidly growing use of composites on DoD weapon systems, efficient composite repair will enable DoD repair facilities to prepare for future workload
$13M Potential Short Term Annual Cost Savings
Due to improved process throughput (35% in private industry) and reduced scrap
20%
Reduced cycle times using optimized composite material processing
Availability
Weapon systems increased due to efficient material usage. Raw materials property shifts and cure interruptions requires10% of engineering resources in the composites shop.
Source: NCMS Project Team, Air Force Advanced Composites Office and CCAD 10

11. Field Level Fluid Analysis
Freedom eLog® enabling technology is a web-based, interactive, on-demand, electronic log that makes visible and tracks all critical production performance criteria.
Shop floor status board
Machine daily view details
Multi-year summaries
Developed and implemented Freedom eLog® system at RRAD to legacy production
equipment in order to reduce the cycle time and improve the repeatability or organically
manufactured treads.
Document production patterns
Log equipment utilization and downtime verification
Actual vs. theoretical labor hours
DoD Investment - $831K
Industry Cost Share - $1919K
Field Level Fluid Analysis
Smart Machine Pilot Project
DoD-Wide Potential Cost Benefits $57M assuming 1% savings on current DoD depot maintenance cost of $5.7B
Potential Benefits
Application by the Armed Services
Depots currently lack Total Asset Visibility for organic manufacturing assets. This technology provides unbiased, real time view of factory status and health.
Industry realizes up to 40% improvement in machine utilization, yielding as much as 5% improvement in production efficiency. Helped RRAD Rubber Products respond to large, war-driven workload increase
25x6 Roadwheel - Abrams Tank - 200% average increase
26x6 Roadwheel - M88 - greater than 200% increase
24x3.75 steel Roadwheel - BFV - 80% / 100% increase
T-157I Track Shoe - BFV and MLRS - 60% / 100% increase
T-107 Track Shoe - M % / 250% increase
DoD wide deployment could conservatively yield 1% savings on current $5.7B depot maintenance cost.
Technology Transfer:
Planning underway for a commercial deployment in the Rubber Products building at Red River Army Depot. Potential there for expanded deployment.
Pilots installed at WR-ALC and PHNSY
Source: Based on commercial industrial
experience of Mag Industries and data from RRAD

12. Field Level Fluid Analysis
Cold Spray technology – investigate several technologies and processes for high velocity spray of metal particles to apply corrosion protective coatings and also as a repair technology through build-up of metal surfaces.
Corrosion protection is a $2B problem to DoD. Cold Spray technology could reduce cost by 1% or $20M
DoD Investment - $451K
Industry Cost Share - $978K
Field Level Fluid Analysis
Kinetic Spray Metal Deposition DoD Potential Cost Benefits $100M/yr assuming full DoD deployment addressing 1% of $10B/yr cost of corrosion
Potential Benefits
Application by the Armed Services
Fleet Readiness Center (FRC) East, N. Carolina, reports a H-53 helicopter gearbox repair cost avoidance of approximately $80K per year (average of four housings per year). FRC has received Kinetic Spray equipment, a Cold Gas Technology CGT 4000/17
USMC Maintenance Depot at Albany reports that the Marine Corps Light Armored Vehicle (LAV), fleet on Okinawa cost avoidance of one 1010 steel bulkhead component is estimated to be approximately $100K per year.
Vandenberg Air Force Base, CA, US Space Command, to repair corrosion of missile silos.
US Army Fort Hood, TX to repair mast support of radar pod on Apache helicopters.
Patrick Air Force Base, FL to repair IVD Aluminum coating on F-15 landing gear.
8.5%
Cost reduction per part
60%
Overall process cycle time improvement
Metal deposition coatings are far superior to painted coatings, and this project developed the first fieldable technology for applying metal coatings
WINNER 2007 Defense Manufacturing Excellence Award
Source: Centerline Limited

13. Field Level Fluid Analysis
3FAST technology is focused on delivering a tool that maintainers can use to assess their fluids (lubricant, hydraulics, transmission) in near real-time.
Initial needs statement provided by Army ground maintainers in Iraq
Provides an expeditionary fluid analysis capability
Supplements AOAP lab analysis by developing same capability for in-field use
Increase the capabilities of maintainers in the field (expeditionary maintenance)
Condition based maintenance for fluids supported with on-demand testing, rather than on hard-time or hard-mileage intervals.
Speed up and streamline the maintenance of fluid-wetted components
Portable 3FAST tools revitalize the way our military maintains its equipment
DoD Investment - $1M
Industry Cost Share - $2.2M
Field Level Fluid Analysis
Fast Field Fluid Assessment Tools (3FAST) DoD Potential Cost Benefits $15M/yr (assuming broad cross service adoption)
Application by the Armed Services
Potential Benefits
Projected Applications for project technology in development
DoD Aviation equipment
Rotary and fixed wing aircraft
Tug, tractor, AGPU
Ground equipment
All tactical vehicles
HMMWV, HEMTT
Hauled 10 ton tractor trailer
PLS – palletized loading system
LAV 25, EFV
Power generation equipment (15 – 60 kilowatts)
All engineering equipment
M9 ACE, backhoe, bulldozer
$3M/year
Centralized oil testing curtailed
$4-6M/year
Saved in waste oil reduction
$6M/year
Ensure correct fluid type in components
$3M/year
Reduced logistics/supply chain in theater
Source: Numbers were developed
by Dr. Ed Urbansky, JOAP-TSC

14. Field Level Fluid Analysis
Laser coating removal technology: This project delivers an automated, robotic system for stripping helicopter blade coatings.
automated system for blade stripping which will remove the operator from this demanding repair environment
improves refurbishment lead times
reduces repair cost
reduces scrap rate
DoD Investment - $1.2M
Industry Cost Share - $1.3M
Field Level Fluid Analysis
Laser Coating Removal for Helicopter Blades
DoD Potential Cost Benefits $7.4M/yr assuming adoption for helicopter blades and propellers
Projected Benefits
Application by the Armed Services
Annual Repair Cost Reduced
From $1,188/blade to $223/blade
Penn State Technical Report “Integration of Laser Coating Removal for Helicopter Blade Refurbishment Phase I Final Test Report,” has resulted in a conditional approval of the laser coating removal process for the H-53E helicopter blade application.
2X Faster than traditional stripping methods
Technology Transfer:
The system in the photo above is targeted for delivery to FRC East for production use.
Helo blade scrap rate reduced by 60%
Potential Annual Cost Savings
$1M at FRC East
$2.6M at CCAD
Source: Cost analysis conducted by Penn State based on data provided by FRC East.

15. Contact Greg Kilchenstein ADUSD (MP&P) greg.kilchenstein@osd.mil
(703)
Chuck Ryan
VP Technology, NCMS
(734)