1. High Velocity Maintenance Overview
Presented By:
Jerry Mobley
WR-ALC/HVM
June 2010

2. What is High Velocity Maintenance?
An AFMC-wide initiative to dramatically transform production operations in support of increasing aircraft availability, seeking to better emulate industry’s high daily rate of touch-labor maintenance
HVM examines all processes which impact aircraft programmed depot maintenance across the enterprise, including not only product flow, but also funding, requirements, infrastructure, materiel support, and information technology
The USAF is facing a confluence of factors threatening aircraft availability rates. These factors include rising operations and maintenance costs associated with a fleet averaging over 24 years in age; high operations tempo and costs due to the Global War on Terror; reduced USAF active duty end strength, and lack of fiscal resources to recapitalize the fleet in a timely fashion. The Warner Robins Air Logistics Center has begun an initiative, with Air Force wide applicability, to dramatically transform its operations in support of increasing aircraft availability, seeking to better emulate industry’s high daily rate of touch-labor maintenance.

3. Create an Ideal Process and Repeat it Every Time
HVM Concept
HVM VISION
Increase Aircraft Availability using AFSO21 tools to establish a synchronized, integrated, end-to-end process such that maintenance does not impact mission requirements
Refine Scheduled Maintenance
Correct Inefficient Processes
Low velocity compared to Industry
Airline burn rate hours/day
ALC PDM hours/day
Implement Industry Best Practices
Daily Standard Work
Point-of-Use Task Kitting
Mechanic-Centric Focus
Know tail number condition
Maintain Enterprise Approach
Scalable and Transportable Processes
Single Maintenance Concept
1000
Industry Velocity
High Velocity Maintenance is the term we coined to convey the idea that depot maintenance would transform from its current state as long duration, infrequent maintenance intervals to much shorter duration, more frequent maintenance, much like the commercial aviation community has used for years.
We have incorporated many industry best practices into HVM processes. Examples include disciplined adherence to daily standard work and the introduction of point of use task kits to support the mechanic at the plane in the same way a surgeon is supported in the OR. This requires knowing the condition of the aircraft prior to induction, and much more detailed planning and orchestration of the work when it arrives.
While HVM includes the term “maintenance”, this effort is really about making all processes supporting maintenance more efficient – from requirements determination, engineering, materiel support, IT support, to funding.
Velocity (hrs/day)
500
USAF Depot
Velocity
PDM
ISO
HSC
Maintenance Cycle
Create an Ideal Process and Repeat it Every Time

4. Attributes Current State Future State
Limited Knowledge of Aircraft Condition
Two Mx systems; creates knowledge barriers
5+ Year PDM cycle (C-130)
Damage accumulates
Promotes a “must fix now” mentality
Job Shop Environment
Mechanic gets own tools; searches for parts; accomplishes own set up
Inadequate Planning – req’ts, Mx work, parts, materiel, equipment
Lacks information – complete BOM, planned work, support
Stove-piped Processes and Execution
Unsynchronized, inefficient, encourages work arounds (non-compliance)
Future State
Known Aircraft/End Item Condition
Lead Time Ahead of Induction – Parts, Training, Infrastructure, Equipment, Data, etc.
Mechanic-Centric Focus (Surgeon)
Parts, Tools, Data, Equipment Pre-Positioned at Point of Use
Maximum Use of Kitting
Expand Standard Work & Processes
Choreograph Repair Operations
Synchronize work
Single Maintenance Concept
Integrated Planning, Decision-making, & Data Collection

5. HVM Future State Process
Data analysis critical to defining requirement
MRSR develops fully supportable , sequenced, executable work package
4 Cycles – 18 Month Interval to integrate/replace current 15 Month Isochronal Inspection
Standard Work Cards drive out Process variability
Actual requirements drive material purchases rather than historical probability
AMT provides continuous real time support
Integrator delivers POU task kits to mechanic

6. HVM Future State “Swim Lane” View
Defines Right Requirement
Builds Daily Std Work Package
Accomplishes supportability
Tailors package to tail number
Defines sequence
Feed Financial process
Executes tailored work package
Point of Use Task Kits
Man-loads a/c- High Burn Rate

7. High Velocity Maintenance Life Cycle Comparison
Current State
ISO
HSC
1000
500
hrs/day
160 Flow Days
PDM & ISO not synchronized
PDM scheduled every 5-6 yrs
Velocity (hrs/day)
Improved AA
Less A/C on ground
Reduced O&S Cost
Efficient MX Process
HVM State
This slide graphically shows the change that HVM creates for the C-130 operator.
Current practice distributes scheduled maintenance between the operator and the depot. The operator accomplishes ISO and Home Station Checks (HSC) between depot visits. All of these maintenance events are done with delays and interruptions due to parts, manpower and other factors.
HVM absorbs the ISO requirements and produces the aircraft much faster – by doing much more each day, with our target being about 500 man-hours per day.
Once you achieve approx. 500 hrs/day burn rate, the flow days for each cycle would be around days. Commercial industry has proven this can be accomplished.
The result is improved availability and higher quality repair.
Goal: hrs/day
Integrated Scheduled Mx (PDM & ISO)
High velocity, multiple cycles over 5-6 yrs
1000
Velocity (hrs/day)
C-130
500
18 month interval
HSC
HSC
HSC
Cycle 1
Cycle 2
Cycle 3
Cycle 4 7

8. Implementation Strategy
Concept development: Summer 07 – Spring 08
Process development: Spring 2009
Creation of daily standard work: Ongoing
Creating supporting data: Ongoing
Process validation: Summer 2009-Spring 2011
9 validations
Pilot Program: Fall
AFSOC C-130 aircraft: 18 – 21 months post PDM
Fleet-wide deployment:
Remaining C-130 fleet transitioned by MAJCOM
Val #4
Val #5
Val #1
Val #2
Val #3 8

9. Benefits of SLIM to HVM Aircraft Availability HVM
SLIM focuses on overall weapon system performance assessments
Efficient & effective data collection and analysis
Proactive action using the analysis results
Integrating CBM+, RAM, RCM/MSG-3, WSIP, MFOQA, and EAVI efforts
Benefits
Enables Optimized MX Requirements
Facilitates increased
knowledge of aircraft condition
Aircraft
Availability
Overarching enterprise initiatives
SLIM
MSG-3
HVM
Optimize the field/depot requirements
(the “what, when and where”)
High Velocity Maintenance (HVM) initiative, begun in June 2007 as an outgrowth of a WR center-wide strategic planning event, will employ the Air Force Smart Operations 21 (AFSO21) toolset to develop a scalable solution for significantly accelerating the speed and effectiveness of depot maintenance activities. Taking Lean concepts and methodologies to the next logical state of evolution, HVM examines all processes which impact aircraft programmed depot maintenance (PDM) across the enterprise, including not only product flow but funding; requirements; infrastructure; materiel support; and information and technology.
AAIP
RCM
Expands HVM to be
“scalable and transportable”
PLM
CBM+
GLSC
HVM for PDM/ISO
WR-ALC C-130 Prototype
Integrity
CAM
Programs
ECSS
Optimizes the PDM process (the “how”)
Includes all supporting processes
Std Work
Supply Chain Ops
Lifecycle Mgmt
Sourcing
Tech Development
D&SWS

10. High Velocity Maintenance
Discussion/Questions

11. HVM & MSG Relationship
HVM defines the “How” maintenance is accomplished
Optimizes Maintenance processes – “Mechanic Centric Focus”
Establishes processes to achieve “high daily touch labor rates” through detailed advanced planning with supportability; choreographed, synchronized work packages; aircraft man-loading; implementation of daily standard work; pre-positioned point-of-use task kits
Moves toward single “Maintenance System”
Incorporates ISO’s (C-130)
MSG-3: Defines the “What” needs to be done
Established the appropriate inspections and optimum interval for accomplishing the inspections
Ensures you accomplish the “Right “ maintenance at the “Right” time.
Notes:
One key point that should be noted is that it could be perceived as first glance a disparity between MSG-3 and HVM with respect to MSG-3 extending inspection intervals where as HVM advocates looking at the a/c more frequently. However in fact they are very complimentary. The MSG-3 program defines the appropriate inspection intervals to make sure you are neither over or under accomplishing inspections. Under HVM from an execution stand point of accomplishing the required maintenance, it is much more effective to bring in the aircraft into a heavy maintenance facility for more shorter, frequent intervals. Under HVM, the typical C-130 5/6 year PDM cycle has been broken down into 4 smaller cycles (approx 5,000 hours for each cycle versus one large 20,000 hour work package) with the a/c coming in every 18 months. However for the C-5 under MSG-3, the PDM cycle is being extended to 8 years with a package size being approx 60,000 hours. Now that the appropriate intervals and requirements are established, HVM would brake the 60,000 hour work package into multiple smaller packages and bring the a/c into the depot every 2 years with each package being 15,000 hours. You are still accomplishing the same 8 year interval, but inspecting sections every two years. Looking at it more often allows you to more proactively catch and limit damage early.
The optimum MX solution would employ the MSG-3 methodology as the foundation for HVM processes to be applied to achieve the most effective scheduled maintenance program

12. What Maintenance to Perform How Maintenance is Performed
CBM
- Real-time assessment of condition
- Embedded sensors
- External tests and measurements
- Maintenance only upon evidence of need
HVM & SLIM
RCM
- Assess system functionality
- Identify failure modes and effects
- Determines consequence of failure
- Logical process to determine actions
and insure mission success
Feedback
CBM+ What
Diagnostics
Prognostics
- Data Analysis
- RCM
MSG-3
Overall system level approach
Hierarchical zonal inspections
Structures: Logical process for
determining Mx requirements
Safe life vs Damage Tolerant
Accidental, Environmental or
Fatigue Damage Considerations
Mechanical Systems/Engines
- Uses RCM Approach
CBM+ How
- Interactive Training
- Portable Maintenance Aids
- Interactive Electronic Technical Manuals
- Integrated Information Systems
- Automatic Identification Technology
Maintenance tasks and intervals
ASIP
Inspection Reqts for
tracked zones
High Velocity Maintenance
Improving “How Mx is Done” – standard processes
and synchronized to optimize flow time
Pre-planned support, Point of Use task kitting,
mechanic centric focus to increase velocity
How Maintenance is Performed
Feedback 12