1. TWV CBM Return On Investment

2. TWV CBM Return On Investment
Response to AMC CBM Summit Tasker
Purpose:
Provide AMC G-3 with the amount of time and resources required to conduct a valid test to determine a Return on Investment (ROI) for Tactical Wheeled Vehicles
BLUF:
Modest CBM data collection and analysis for trucks currently underway.
Can augment and enhance those activities in support of a CBA/ROI study.
Added Hardware estimates included
Need CLOE Enablers in place to realize CBM “Plus”

3. TWV CBM Return On Investment
The Tactical Wheeled Vehicle CBM Challenge: High Density, High Production Rates, Substantial Aging Legacy Fleet
On-Hand 1st Production Last Production Current Production
HMMWV 141, Funded thru FY /month
HMMWV RECAP /Month
FMTV 40, Funded thru FY15 800/month
M939 FOV 26, N/A
M800 FOV N/A
HEMTT 13, Funded thru FY *
HET Tractor 2, NA
PLS Funded thru FY 13 *
M915 FOV Funded thru FY /month
HEWATT/TFFT Funded thru /month
Combined monthly production 400
Total of Key fleets 209,347 (less M939, M800 FOV)

4. TWV CBM Return On Investment
“ Ballpark” Business Case Example
Baseline Costs for Maintaining Today’s Truck Fleet
How much do we currently spend to maintain our trucks?
Based on averaging 2006 & 2007 worldwide OSMIS data:
Vehicle Quantity *O&S Costs/yr
HMMWV ~119k ~$583 M/yr
FMTV ~ 26k ~$145 M/yr
HEMTT ~ 12k ~$119 M/yr
PLS ~ 5K
M915 ~ 8K
*Incl POL
Hypothetically, how much could we save?
Vehicle % % 2% %
HMMWV $2.8M $5.8M $11.7M $29.2M
FMTV $.75M $1.5M $ 2.9M $ 7.3M
HEMTT $.60M $1.2M $ 2.4M $ 6.0M
PLS
M915

5. TWV CBM Return On Investment
ROM Estimate of CBM TV Fleet (FMTV, HEMTT, PLS, HETS, M915 and HMMWV)
Option 1
Collect only existing vehicle data with simple data logger $500/ea = $104.67M
Option 2
“Smart” data logger to collect and preprocess existing data $1500/ea = $314.02M
Option 3
“Smart” data logger plus low cost “motion pack” chassis sensor suite $3500/ea = $732.71M
Option 4
Full vehicle computer to log, process, and link (IETM & SAMS-E) existing data $5000/ea = $1,046.73M
Option 5
Vehicle computer plus low cost “motion pack” chassis sensor suite $7000/ea = $1, M
Option 6
Vehicle computer, low cost “motion pack”, plus GPS $9000/ea = $1,884.12M
Option 7
“High end” engineering level computer, “motion pack”, GPS $20,000/ea = $4,186.94M

6. TWV CBM Return On Investment
Simple ROI Calculation for TWV Fleet
Based on the following:
Fleet of 209,347 TWVs
Sustainment costs of $1,007M/yr
Option (smart data logger and low cost motion pack)
CBM savings rate of 2%
Yearly savings - 2%/yr x $1,007M = $20.12M/yr
Hardware costs ,347 x $3500 = $732.71M
ROI period - $732.71M / 20.12M/yr = 36.4 yr
ROI period can increase or decrease significantly based on percent savings applied.
This example does not include many other CBM enabling costs so the ROI period will definitely be longer or shorter when all costs are factored in.

7. TWV CBM Return On Investment
ROM Estimate of CBM HW Costs Only for OIF/OEF FMTV Fleet
~ 4300 MTV/LMTVs in theatre
Option 1
Collect only existing vehicle data with simple data logger $500/ea = $ 2.15M
Option 2
“Smart” data logger to collect and preprocess existing data $1500/ea = $ 6.45M
Option 3
“Smart” data logger plus low cost “motion pack” chassis sensor suite $3500/ea = $ 15.05M
Option 4
Full vehicle computer to log, process, and link (IETM & SAMS-E) existing data $5000/ea = $ 21.50M
Option 5
Vehicle computer plus low cost “motion pack” $7000/ea = $ 30.10M
Option 6
Vehicle computer, low cost “motion pack”, plus GPS $9000/ea = $ 38.70M
Option 7
“High end” engineering level computer, “motion pack”, and GPS $20,000/ea = $ 86.00M

8. TWV CBM Return On Investment
Simple ROI Calculation for OIF/OEF FMTV Fleet
Based on the following:
Fleet of 4300 MTVs
Sustainment costs of $52M/yr
Option (smart data logger and low cost motion pack)
CBM savings rate of 5%
Yearly savings - 2%/yr x $52M = $1.04M/yr
Hardware costs x $3500 = $15.05M
ROI period - $15.05M / $1.04M/yr = yr
ROI period can increase or decrease significantly based on percent savings applied
This example does not include many other CBM enabling costs so the
ROI period will definitely be longer when all costs are factored in.

9. TWV CBM Return On Investment
Current Efforts Supporting CBM Return on Investment Analysis
AMSAA Data Collection and Study Efforts
TACOM Failure Analysis in support of Delayed Desert Damage and Degradation Studies (4D)
TARDEC Studies
PD-TMDE Activities
PM-TV Activities
SBCT Proof of Enablers (PoE) Cost Benefit Analysis
Note: Review of AMSAA data collection to date has not yet provided PM-TV data that would result in changes in maintenance planning and support

10. TWV CBM Return On Investment
How Can AMC Help?
Funding support for AMSAA
More & varied data acquisition suites
Expanded data analysis
Failure mode/PoF investigations
Diagnostic/prognostic algorithm development
Funding support for TACOM ILSC
Improving data/record keeping interfaces
Data processing & storage
Funding support for TARDEC
Sensor selection & placement
Platform HW optimization
Funding support for PD TMDE
Smart Wireless Diagnostic Sensor development
Vehicle Integrated Diagnostic Software development
Assistance and funding support for IT/Comms Definitions & Solutions
Spur User Involvement for
Interpretation/quantification of benefits/usefulness
Requirements generation

11. TWV Supporting Common Logistics Operating Environment (CLOE) & CBM
LOGSA
LIW
SAMS-2E
SAMS-1E
SARSS
Operator
Maintainer
CAISI
SAMS-IE
SAMS-DLB
Army development and doctrine changes required
Embedded
At-Platform
Army development and doctrine changes required
Maintenance Data Collection - entire troubleshooting, maintenance and parts ordering session logged and time/date stamped:
Maintainer ID
Vehicle ID
DODAAC
Symptoms
Tests & Test Results
Diagnostic Path
Isolated Faults
Maintenance Action
Parts Consumed
SAMS-E
- Usage of information once received
PM Can Provide:
- Ability to interface
Translation of sensor data
CBM Data Warehouse
Digital Logbook
Digital PMCS
FBCB2
SBCT Proof of Enablers (PoE) Cost Benefit Analysis supports the goodness of TWVs participating in a common logistics operating environment
MTS
VHMS

12. TWV CBM Return On Investment
TWV CBM CBA/ROI Phased Approach
Phase 1:
Identify candidate platform cost drivers and component targets
Identify benefit drivers (Availability, parts ordering, automation, etc)
Develop FMEA/FMECA and other system models from existing field and design data.
Generate CBA/ROI model, identify inputs, and formulate assumptions
Phase 2:
Component level testing in test cells (engines, transmissions, alternators, etc)
Identify fault modes in controlled environment
Develop diagnostic/prognostic algorithms
Identify benefits and savings/avoidance potential
Design field trial for proof of enablers with FMTV Truck Fleet SDC
Feed CBA/ROI model with test cell experiment results
Phase 3:
Equip FMTV Fleet for tiered Sample Data Collection
Conduct FMTV Truck Fleet tiered SDC
Feed CBA/ROI model with Fleet tiered SDC results

13. TWV CBM Return On Investment
Business Case Analysis Timelines and Costs
FY09 FY10
$4.5M $4.5M
AMSAA
OMA/RDTE
POM requests for FYs of $4.5M/yr
Instrumentation & sensor improvements
Data analysis, failure mode analysis
Diagnostic and prognostic algorithm development
Data management and organization
Failure type analysis for 1 year for 4 TWV fleets with failure mode analysis for “top 5” cost and readiness drivers
Project support & execution, data analysis
Component testing and modeling
Unfunded requests for FY09 - $4.2M, FY10 - $1.1M
WDS-A, WDS-D, Smart WDS integration & test
SAMS-E, DLB, VIDS Interface Development
TACOM
OMA
$1.5M
TARDEC
RDTE
$6.2M
PD TMDE
OMA/RDTE
$4.2M $1.1M
$16.4M $5.6M

14. TWV CBM Return On Investment
Highlights from “Business Case Template for CBM+ Enablers”
Two year timeline of fleet maintenance events, dates, resources, downtimes, etc.
Maintenance related events for each enabler eligible component: inspections, parts removals, parts shipping, scheduled & unscheduled maintenance, time waiting for parts, actual repairs.
One time costs:
Purchase and installation of enablers
Development costs of enablers
Recurring costs:
Repair & replacement of enablers
Software updates
Cost savings:
Reduced parts orders
Lower transportation costs for parts
Correct parts ordered
Reduced fleet size due to higher vehicle availability
Cost avoidance:
Minimized inspections due to better vehicle health visibility
Reduced repairs by avoiding collateral damage equipment failures
Fewer recovery missions for field failures
Reduced “exposure” time & resulting injuries for users and maintainers

15. TWV CBM Return On Investment
Business Case Analysis Timelines and Costs
Although existing investments in technology development and data analysis are being leveraged, help is needed in securing requested, and new funding. This will support additional data gathering and analysis, algorithm development and validation, and cost analysis for savings or avoidance projections. This is estimated to be an month effort.
This investment will leverage ~ $20M spent in this area in the last two years.

16. BACKUP Charts

17. TWV CBM Return On Investment
Current Efforts Supporting CBM Return on Investment Analysis - AMSAA
Sample Data Collection
System Health and Reliability Computer (SHARC) data acquisition suite collects GPS, vehicle databus, and chassis sensor data
Multiple vehicle types, locations, terrains, climates
Developing usage profiles, severity indices, damage accumulation parameters
Miniaturization and improvement of data acquisition suite
Lower cost with more installation flexibility
Development of diagnostic and prognostic algorithms
Seeded fault testing and teardown analysis
Oil conditioning monitoring
Data management and correlation techniques
Linking of component parametric and maintenance data

18. TWV CBM Return On Investment
Current Efforts Supporting CBM Return on Investment Analysis - TACOM ILSC
Delayed Desert Damage & Degradation (4D) Analysis
Data mining and failure mode analysis for “Top 50” readiness drivers from SWA across all ground fleets
LIW & ILAP – Demand and cost data
OSMIS – OPTEMPO/miles & densities
Maintenance & deadline info/activity
AMSAA SDC – Parametric data
TARDEC - Deficiencies database
C-REPS - LAR database
FMEA – Root causes for failures

19. TWV CBM Return On Investment
Current Efforts Supporting CBM Return on Investment Analysis - TARDEC
MSU & nCode – Improved Techniques for Vehicle Prognostic/Diagnostic
Data Acquisition, Analysis, and Storage
On-vehicle HW & SW for chassis monitoring
Analysis, comparison, and correlation of new data with existing databases at multiple echelons
Study effects of re-configuration and compression of new data for storage in data warehouse/repository
Global Electronics – Advanced Diagnostics for Diesel Engines
Statistical analysis methods for data sets
Neural network analysis methods for data sets
Learning system behaviors and development of models
Supporting informed maintenance decisions

20. TWV CBM Return On Investment
Current Efforts Supporting CBM Return on Investment Analysis - PD TMDE
Wireless Diagnostic Sensor (WDS)
On-vehicle data logging for diagnostic and parametric data
Supports digital databus and/or analog vehicle data feeds
Vehicle Integrated Diagnostic Software (VIDS)
VIDS-Embedded. On-board data collector and analyzer that interfaces to an off-board controller such as the MSD
VIDS-Field. Expert database resides off-board and provides linear regression analysis and failure predictions (Currently hosted on an MSD)

21. TWV CBM Return On Investment
Current Efforts Supporting CBM Return on Investment Analysis – PM-TV
PM-TV – AMRDEC effort to reduce troubleshooting/diagnostic time of critical non-sensored Starting and fuel circuits. Automating diagnostics of critical systems
PM-HTV - Penn State effort to add automated diagnostics to vehicle Hydraulic systems

22. TWV CBM Return On Investment
How Can We Augment and Enhance Current Activities in Support of a CBA/ROI study?
AMSAA activities
Expand Sample Data Collection efforts
More vehicles, vehicle types, and locations
Tiered data acquisition suites
Low budget – No new sensors, databus logging, “virtual” sensing
Medium budget – “Motion Pack” chassis sensors, data logging, preprocessing of data
High budget – “Motion Pack”, data logging, full computing, links to IETMs and logistic interfaces, GPS
Support failure mode characterizations w/vehicles & components
Seeded/induced fault testing
Component teardown and analysis
Investigate advanced analysis techniques & methods
Continue component model & algorithm development

23. TWV CBM Return On Investment
How Can We Augment and Enhance Current Activities in Support of a CBA/ROI study?
TACOM ILSC activities
Create new effort to
Target TWVs for data analysis
Expand beyond SWA theater of operation
Leverage database correlation tools
Investigate modifying current maintenance action record keeping
Help develop interfaces between CBM data, IETMs, and SAMS-E

24. TWV CBM Return On Investment
How Can We Augment and Enhance Current Activities in Support of a CBA/ROI study?
PD TMDE activities
Smart Wireless Diagnostic Sensor
Develop cost effective on-board data logger/processor that complements off-board TMDE and works with Log C2 SW
Vehicle Integrated Diagnostic Software
Mature and expand VIDS-E and VIDS-F analysis and reporting capabilities
Allow porting of third party algorithms into VIDS
* Test PM-TV efforts on selected vehicles

25. TWV CBM Return On Investment
How Can We Augment and Enhance Current Activities in Support of a CBA/ROI study?
TARDEC activities
MSU & nCode – Improved Techniques for Vehicle Prognostic/Diagnostic Data Acquisition, Analysis, and Storage
Leverage 4-D Analysis or 4-D follow-on effort
Global Electronics – Advanced Diagnostics for Diesel Engines
Coordinate with AMSAA SDC, failure mode, and algorithm development activities
Correlate RAM testing data and analyses with CBM activities