1. Transforming Army Aviation to Condition Based Maintenance (CBM)! 1 DSS-0228 – CBM (OSD) – 11/29/2004 CBM Program Update DA & OSD Senior Leaders Robert Brown AMCOM Lead - CBM Robert Brown AMCOM Lead - CBM E-MAIL: robert.brown29@us.army.mil PHONE: (256) 842-8911 Bill Braddy Westar A&DG Bill Braddy Westar A&DG E-Mail: braddy@cobrohsv.com PHONE: (256) 430-1610 x148  OSD Policy and Army Guidance  CBM Program Objectives  Commander’s Guidance  Stakeholders/Enablers  Proof of Principle — Mission — Products — Process — CBM Data Management  CBM Transformation Milestones  Summary Topics for 30 Nov 2004

2. Transforming Army Aviation to Condition Based Maintenance (CBM)! 2 DSS-0228 – CBM (OSD) – 11/29/2004 OSD Policy and Army Guidance  DOD – Policy Letter for CBM Dtd: 25 Nov 2002 — Guidance and Directive to Services to Examine, Evaluate, and Implement CBM — CBM Shall Be Implemented to Improve Maintenance Agility, Responsiveness, and Increase Readiness With Reduced Life Cycle Ownership Cost  DOD – CBM Memorandum Dtd: 20 Nov 2003 — Develop CBM As One of Six Future Logistics Enterprise Initiatives — Created the Maintenance Technology Senior Steering Group (MTSSG)  Army CBM Plus Plan Dtd: 14 Apr 2004 — Shifts From Preventive and Reactive Maintenance to Proactive CBM — Affirms the Goal of the Common Logistics Operating Environment (CLOE) to Provide Combatant Commanders With Higher Equipment Availability Using Fewer Resources  DA, G4 – Draft Army Aviation White Paper On CBM Plan Dtd: 10 Nov 2004 — Stated That Task Force- Aviation Was One of Sixteen Army Focus Areas — Task Force Aviation Goal Is to Achieve Full CBM Within Aviation By End of FY 2015 — Identifies Responsibilities of Stakeholders Within Aviation Community

3. Transforming Army Aviation to Condition Based Maintenance (CBM)! 3 DSS-0228 – CBM (OSD) – 11/29/2004 CBM … Turning Data Into Maintenance Action! Condition Based Maintenance Defined … OSD/Army: CBM Is a Set of Maintenance Actions Based on Real-time or Near-real Time Assessment of Equipment Condition, Obtained From Embedded Sensors and/or External Measurements or Tests To the Commander: The Ability to Meet Mission Requirements With Proactively Driven Maintenance; Increasing Operational Availability -- CBM Proof of Principle Team To the Soldier: The Ability to Convert Data on Aircraft Condition and Usage Into Proactive Maintenance Action, Reducing Maintenance Workload -- CBM Proof of Principle Team

4. Transforming Army Aviation to Condition Based Maintenance (CBM)! 4 DSS-0228 – CBM (OSD) – 11/29/2004 CBM Program Objectives  Use Real-time Assessments of Material Condition Obtained From Embedded Sensors and Other Data Sources to Improve Diagnostics and Prognostics Capabilities  Increase Operational Availability for the Warfighter  Reduce the Maintainers Workload  Convert Unscheduled Maintenance to Planned Maintenance  Achieve IOC By 2011 IAW CSA Intent; FOC 2015

5. Transforming Army Aviation to Condition Based Maintenance (CBM)! 5 DSS-0228 – CBM (OSD) – 11/29/2004 AMCOM Commander’s Guidance Guidance:  CG, AMCOM Serve As the Lead to Transform Army Aviation to CBM  Identify the Stakeholders and Build Consensus  Develop a Long Range Plan  Develop Funding Requirements for FY 06 and FY 07-11 Program Change Proposal  Report Progress Monthly "This Opportunity, Has the Potential to Significantly Increase the Operational Readiness of Our Aircraft and Reduce the Maintenance Burden on Our Soldiers. You Are the Team to Make This Happen. I Thank You for Your Involvement and Dedication." MG James H. Pillsbury, Commander, Aviation/Missile Life Cycle Management Command

6. Transforming Army Aviation to Condition Based Maintenance (CBM)! 6 DSS-0228 – CBM (OSD) – 11/29/2004 The Stakeholders … PM-TMDE RDECOM - Engr Dir - AED Other Industry Logistics Transformation Agency DA G4 OSD CBM AG HQ AMC Aviation Task Force PEO AVN OEMs User Reps − USAAVNC − USAALS IMMC CDR AMCOM

7. Transforming Army Aviation to Condition Based Maintenance (CBM)! 7 DSS-0228 – CBM (OSD) – 11/29/2004 CBM Enablers 1.World Class Change Management 2.Digital Source Collectors — Open Architecture — Non Proprietary Data — Efficient Download and Transfer — Reliable, Simple Translation Into Engineering Units (Relational Data) 3.Reliable Data Warehouse — Multiple Sources and Data Types DSCs – Vibration and State Data ELAS – Maintenance Actions ELAS – Parts Tracking and Usage History — Multiple Customers Different Needs for Data Granularity Different Needs for Information 4.Closed Loop Information System — Data (for Engineers) To Information (for Analysts) –To Knowledge (for Planners) oTo Maintenance Action! (for Commander/Soldiers)

8. Transforming Army Aviation to Condition Based Maintenance (CBM)! 8 DSS-0228 – CBM (OSD) – 11/29/2004 CBM Proof of Principle  Mission: “In Support of the Transformation of Army Aviation to CBM, Demonstrate the Feasibility of Converting Condition and Usage Data Into Maintenance Action”  Products:  Sample Components From Each MDS  Data Sources for Each Component By Aircraft  Analytical Methods — Collaborated Analytical Methods (With AED) — Draft Charter in Staffing — A Proof of Principle Data Warehouse By 31 Jan 05 — Condition / Usage Data Into Maintenance Action By Jul 05

9. Transforming Army Aviation to Condition Based Maintenance (CBM)! 9 DSS-0228 – CBM (OSD) – 11/29/2004 CBM Proof of Principle Process Calculate New CIs Implement Maintenance Actions Research Existing Data & Condition Indicators (CIs) Select Part Collect Data Accuracy Of Estimate Sufficient? Yes No Build Failure Curve Collect Additional Parameters/Data Condition Based Maintenance Probability of Failure Maintenance Action “Inspect & Lubricate bearing” “Replace Bearing” “Order Part ” Time in Regime or Planned Usage Supply Action A significant volume of collected data over time, will establish the curve. Tail # specific history and component CI’s tell you where the part lays on the curve Perform Analysis: Hypothesis: Aircraft vibration & usage has a significant effect on the failure of a component. Predicted Outcome: Time remaining to component failure under planned usage. Possible Factors: Vibration, Time in Regime, Gross Weight, Torque, etc.

10. Transforming Army Aviation to Condition Based Maintenance (CBM)! 10 DSS-0228 – CBM (OSD) – 11/29/2004 AH-64 Consensus AED PMO CBM Proof ATTC DSC OEM AH-64 Parts Selected Vibration Active Monitoring (Non-vibration) Passive Monitoring (Inspection, Sampling, Data) Fatigue Life Limited M/R Swashplate,M/R Pitch Housing TBO APU Clutch, Fwd/Aft Hanger bearing On Condition Engine Assy, 701C Hydraulic Pump Motor, Hydraulic (Gun) Status: Finalized Type Component Monitoring Method

11. Transforming Army Aviation to Condition Based Maintenance (CBM)! 11 DSS-0228 – CBM (OSD) – 11/29/2004 Current Preventive Maintenance CBM Potential Potential CBM Benefit AH-64 Aft Hanger Bearing Current Maintenance Unscheduled Failure MMH = 18 Hrs Wait Time = 10 Days Not Combat Ready = 11 Days CBM Potential No Unscheduled Maintenance MMH = 5 Hrs Wait Time = 0 Days Not Combat Ready = 0 Days Assumptions: No Fault Found During 1 st Two Inspections Inspection Interval Is 250 hours MTB Repair is 537 hrs Part Time Change is 2500 Hrs Part Not on Hand CBM Potential: 13 Fewer Hours of Maintenance 11 More Days of Availability (Reactive) (Proactive)

12. Transforming Army Aviation to Condition Based Maintenance (CBM)! 12 DSS-0228 – CBM (OSD) – 11/29/2004 AH64 A&D Opportunities Data Types  Today – No Significant In-theater Data Collection Capability  CBM Progress Requires at Least 4 Data Types  Vibration – Fault Detection of Monitored Components  State and Usage Data – Maneuvers, Stress Accumulation, Conditions  Parts Tracking Info – Part ID and Usage History  Maintenance Activity – Details on Component Change Out Units  AH64D Unit Deploys to OIF With Data Collection Capability  AH64A Units With VMEP in SC NG

13. Transforming Army Aviation to Condition Based Maintenance (CBM)! 13 DSS-0228 – CBM (OSD) – 11/29/2004 UH-60 Parts Selected Vibration Active Monitoring (Non-vibration) Passive Monitoring (Inspection, Sampling, Data) Fatigue Life Limited M/R Blade, Oil Cooler Bearing TBO On Condition Engine Output Drive Shaft Pump Module Assy Engine Assy 701 Damper Assy, Main Landing Gear Strut Type Component Monitoring Method UH-60 Consensus AED PMO CBM Proof ATTC DSC OEM Status: Finalized

14. Transforming Army Aviation to Condition Based Maintenance (CBM)! 14 DSS-0228 – CBM (OSD) – 11/29/2004 UH60 A&L Opportunities  Required Data Types  Vibration – Fault Detection of Monitored Components  State and Usage Data – Maneuvers, Stress Accumulation, Conditions  Parts Tracking Info – Part ID and Usage History  Maintenance Activity – Details on Component Change Out  4th Battalion 101st AASLT Division — UH60Ls Equipped With IMD HUMS  1-52 Aviation, 8 th US Army — UH60As With VMEP  SC National Guard, — UH60As With VMEP

15. Transforming Army Aviation to Condition Based Maintenance (CBM)! 15 DSS-0228 – CBM (OSD) – 11/29/2004 Vibration Active Monitoring (Non-vibration) Passive Monitoring (Inspection, Sampling, Data) Fatigue Life Limited Shaft Assy, Engine DrivenTie Bar Assy TBO Fwd/Aft Swashplate Assy, Fwd/Aft Head Assy Engine AssyHinge Pin Assy On Condition Pump Axial PistonPower Steering Unit Type Component Monitoring Method CH-47 Consensus AED PMO CBM Proof ATTC DSC OEM CH-47 Parts Selected Status: Finalized

16. Transforming Army Aviation to Condition Based Maintenance (CBM)! 16 DSS-0228 – CBM (OSD) – 11/29/2004 CBM Data Management

17. Transforming Army Aviation to Condition Based Maintenance (CBM)! 17 DSS-0228 – CBM (OSD) – 11/29/2004 AED IMMC PEO Aviation OEMs PMs TMDE, AGSE, AS, ASE, … Commander, AMCOM We Are Vertically Challenged ApacheLUHCH47ARHUH60 How Do We Provide Horizontal Views of Data Stored in Different Places - in Different Formats - Under Different Management ? Systems of Record Responsible Agencies Aviation Data SystemsEnterprise Data Systems

18. Transforming Army Aviation to Condition Based Maintenance (CBM)! 18 DSS-0228 – CBM (OSD) – 11/29/2004 AMCOM CBM Proof of Principle Architecture IMMC UniRAM OSMIS ELAS – Sgt Dalton LOGSA PM TMDE PM Utility UH HUMS CH HUMS TBD OEMs Cost Parts Failure Mode Condition State Usage Aircraft Data Warehouse Subject Areas AH MDR AH HUMS IMMC ELAS Data SourcesCustomers PM Cargo PM Apache PEO-AV Extract, Transform, Load Meta Data and Access Layer 1.Optimal storage 2.Change mgmt 1.User interface 2.Efficient Query 3.Periodic refresh 1.Loading 2.Normalization 3.Cleansing EDRS AMSAA AED

19. Transforming Army Aviation to Condition Based Maintenance (CBM)! 19 DSS-0228 – CBM (OSD) – 11/29/2004 Proof of Principle Data Management Production Control Source ETL Station Regime Recog Failure Analysis Logistics Req’s Service Life Database 10G w/ RAC CBM Proof of Principle Information System Reports Generate Maintenance Action Satellite Internet Mail Plane Side Analysis

20. Transforming Army Aviation to Condition Based Maintenance (CBM)! 20 DSS-0228 – CBM (OSD) – 11/29/2004 CBM Milestones  21 Oct – Stakeholders Meeting  26 Oct – NCR Senior Leaders (Ms. Leiby, MG Stevenson)  09 Nov – UH60/Navy IDM HUMS Symposium  17 Nov – CLOE Ground Systems Demo  30 Nov – DA Leadership Visit (Mr. Pybus, MS Plummer, COL Smith)  30 Jan – CBM Strategy/Milestones/PCP

21. Transforming Army Aviation to Condition Based Maintenance (CBM)! 21 DSS-0228 – CBM (OSD) – 11/29/2004 Summary On Track …  Moving Forward With Proof of Principle  Long-term Strategy Is Emerging  Positive Support From Stakeholders Challenges: — CBM Data and Information Management — Automation Architecture (CLOE, LMP, PLM+, GCSS-A) — Connectivity — Long-term Commitment to CBM Transformation

22. Transforming Army Aviation to Condition Based Maintenance (CBM)! 22 DSS-0228 – CBM (OSD) – 11/29/2004 Back Ups

23. Transforming Army Aviation to Condition Based Maintenance (CBM)! 23 DSS-0228 – CBM (OSD) – 11/29/2004 NSNMTBRLIFE Cycle/Hrs Data Type Analysis Method ATTC Test 3130-01-333-8491834TC 2500 Vibration, Maintenance, State, Parts Tracking 3130-01-333-8490537TC 2500 Vibration, Maintenance, State, Parts Tracking AH-64 Forward Hangar BearingAH-64 Aft Hangar Bearing

24. Transforming Army Aviation to Condition Based Maintenance (CBM)! 24 DSS-0228 – CBM (OSD) – 11/29/2004 MDR Binary Download MDR Converted (MAST) and Ready for Load

25. Transforming Army Aviation to Condition Based Maintenance (CBM)! 25 DSS-0228 – CBM (OSD) – 11/29/2004 ELAS Database

26. Transforming Army Aviation to Condition Based Maintenance (CBM)! 26 DSS-0228 – CBM (OSD) – 11/29/2004 VMEP Binary Download VMEP Converted (PC-GBS) to Database

27. Transforming Army Aviation to Condition Based Maintenance (CBM)! 27 DSS-0228 – CBM (OSD) – 11/29/2004 Method to Access OSMIS data MDSMDS NameFY QT R TPSNDivisionActivity Basis Activ ity Densit y OPTEMPO UH-1HHUEY200 3 21900 3 3RD AIR CAV COMBAT BDEHOUR321.50 UH-60ABLACKHAWK200 3 21900 3 3RD AIR CAV COMBAT BDEHOUR7712629.65 UH-60ABLACKHAWK200 3 31900 3 3RD AIR CAV COMBAT BDEHOUR7292529.16 UH-60ABLACKHAWK200 3 41900 3 3RD AIR CAV COMBAT BDEHOUR9003030.00 UH-60LBLACKHAWK200 3 31900 3 3RD AIR CAV COMBAT BDEHOUR130526.00 UH-60LBLACKHAWK200 3 41900 3 3RD AIR CAV COMBAT BDEHOUR244548.80 9 Web Queries to get the information below Bulk Data Load

28. Transforming Army Aviation to Condition Based Maintenance (CBM)! 28 DSS-0228 – CBM (OSD) – 11/29/2004 Method to Access 2410 Data Requires a Government Representative for Access Request Assistance Send an Email Get Some Data 2410 Data