1. AMCOM Update DAU-South Acquisition Conference
Gary Nenninger
G-3 Operations Aviation & Missile Life Cycle Management Command
18 February 2009

2. Agenda Support to the Aviation Warfighter
Aviation Field Maintenance Transformation
Reset
Condition Based Maintenance (CBM)

3. AMCOM Support to the Warfighter
2,456,568 Total Hours:
01 Feb 03 – 15 Jan 09
Army Fleet in OIF
Support To The Warfighter
AH-64
479,959 Hours
MC: 82.0%
OPTEMPO: 58.0
UH-60
726,335 Hours
MC: 84.0%
OPTEMPO: 45.0
~ 3000 Aircraft Preset/Reset
Aviation Field Maintenance
Condition Based Maintenance
Supply Support
Provisioning
Worldwide Onsite Technical Assistance (LARs / CFSRs)
Fwd Deployed Repair/ Sustainment Activities: TAMP, TASM
TMDE Calibration and Repair
MWO Applications
Depot Maintenance
Technical Publications
Airworthiness & Safety of Use
CH-47
123,070 Hours
MC: 73.0%
OPTEMPO: 44.7
Fixed Wing
140,381 Hours
MC: 91.0%
OPTEMPO: 59.9
OH-58
416,903 Hours
MC: 84.0%
OPTEMPO: 72.2
UAS
569,920 Hours
Shadow 323,342 hrs
Hunter 38,244 hrs
Sky Warrior 75,001 hrs
Raven 133,309 hrs
gMAV 23 hrs
OEF Plus Up
389,768 Total Hours: 01 Feb 03 – 15 Jan 09
Army Fleet in OEF
AH-64
94,947 Hours
MC: 87.0%
OPTEMPO: 50.0
UH-60
114,928 Hours
MC: 85.0%
OPTEMPO: 42.0
CH-47
77,946 Hours
MC: 78.0%
OPTEMPO: 51.6
Fixed Wing
19,926 Hours
MC: 87.0%
OPTEMPO: 51.4
UAS
43,496 Hours
Shadow 19,529 hrs
Hunter 910 hrs
Sky Warrior 4,953 hrs
Raven 18,104 hrs
OH-58
38,525 Hours
MC: 85.0%
OPTEMPO: 80.4

4. Support to the Warfighter
Aviation Field Maintenance Transformation
Reset
Condition Based Maintenance (CBM)

5. Aviation Field Maintenance Transformation
What We Did?
Realigned All AMCOM Aviation Field Maintenance Responsibilities Into One Organization
Established Aviation Field Maintenance Directorate (AFMD)
Why We Did This?
Fragmented Aviation Maintenance Responsibilities Highlighted in Recent Aviation Maintenance Issues
Mission Explosion for OLRs (Beyond MWO Application) Required Readjustment of Management Structure
Need to Go Back to the Basics With Aviation Field Maintenance

6. Aviation Maintenance Hierarchy
Commander’s Intent:
“Establish Unity of Command for AMCOM Below Depot Aviation Maintenance Activities”
Depot
Airframe
Component
Special Projects
AMCOM Managed
Organic
Contracted
Consolidate AMCOM Structure
Standardize Processes and Business Rules
Common Metrics & Oversight
Transform How The Army Operates
SINGLE ARMY AVIATION MAINTENANCE MANAGER
Below Depot / Above Unit
Unit Overflow
Limited Depot Repair
MWO Application
Reset
Multiple Managers
AMCOM
NGB
DOL/ALMD
User
AVUM
AVIM
Scheduled Services & Inspections
Authorized Repairs
Unit Managed
Organic Military
CFT Augmentation

7. Support to the Warfighter
Aviation Field Maintenance Transformation
Reset
Condition Based Maintenance (CBM)

8. The Reset Process Reset Is NOT: Reset IS:
Routine Scheduled Maintenance
Depot Overhaul
Reset IS:
100% Disassembly of the Aircraft and Dynamic Components (Engines, Rotor Systems, Drive Trains, Flight Control Systems)
100% Cleaning of All Airframe and Component Elements
100% Serviceability Inspection of All Airframe and Component Elements
Application of DA Directed Modifications
100% Review and Correction of Historical Records
Refurbishment and Replacement of All Components to Serviceability Standards
Correction of Outstanding Deferred Maintenance Actions
Returns An Immediately Deployable Aircraft To The Unit With Significantly Improved Operational Availability And Safety Characteristics

9. Reset Sites AFMD/ALMD*
Drum (DOL)
UH-60 
Ft Campbell
UH-60, CH-47, AH-64
Germany
Ft Lewis
UH-60 and CH47
Hawaii
USAREUR
(Non-Enduring)
Ft Hood
UH-60, AH-64, OH-58
Ft Bragg
UH-60 and OH-58
Ft Stewart
UH-60 and CH-47
Ft Drum
Where
Installations with AFMD and ALMD Activities
Installations with ALMD Only
Installations with AFMD Only
* Aviation Field Maintenance Directorate / Aviation Logistics Management Division 9

10. Deployment Critical Timeline
Aviation Reset Status
Various Stakeholders
Deployment Critical Timeline
-10
POE In
Transit
-35
POD
-45
Load To
-55
ALD
Home
-85
Pre-deploy
Staging
Leave time
-120
LAD
RESET
MREs
Offload
RSOI
BOG
+30
To Include Mods
-ARFORGEN-
Reset Summary Status
Completed 2,906 Aircraft (Includes SOA – 353 A/C)
OIF1 – 923 (Includes 75 SOA)
OIF2 – 426 (Includes 62 SOA)
OIF – 561 (Includes 53 SOA)
OIF – 446 (Includes 74 SOA)
OIF – 452 (Includes 73 SOA)
OIF – 98 (Includes 16 SOA)
Aircraft In Reset Or Scheduled For Induction
OIF – 10 In Reset; 0 Scheduled
OIF – 112 In Reset; 228 Scheduled
Reset Mission: Return aircraft to an FMC (Fully Mission Capable) condition IAW AR using a special technical inspection and repair program that includes inspection, cleaning, repair, and select mandatory replacement of parts
Data as of 13 Jan 09

11. Support to the Warfighter
Aviation Field Maintenance Transformation
Reset
Condition Based Maintenance (CBM)

12. Condition Based Maintenance (CBM)
Digital Source Collector Installation
Knowledge Development
Fault Diagnosis
Remaining Useful Life Calculation
Inspection Targeting
Reactive Maintenance
Time Based Inspection/Overhaul
Proactive Maintenance
‘On Condition’ Inspection/Overhaul
CBM Program Objectives:
Decrease Maintenance Burden on the Soldier
Increase Platform Availability and Readiness
Enhance Safety
Reduce Operations & Support (O&S) Costs
Monitored Master Parts List – UH-60A/L (56 Parts)
T/R Blade
T/R Pitch Change Horn
PC Links
Main Rotor Hub
Main Rotor Shaft
Bifilars
Swashplate ASSY
Swashplate Guide
Swashplate Bearing**
PC Links
M/R Spindle
Spherical Bearing
M/R Spindle Tie Rod
Control Horn
M/R Shaft Extender
M/R Damper
T/R Pitch Change Shaft
T/R Pitch Change Bearing
M/R Blade
M/R Blade Tip Cap
M/R Blade Expandable Pin
M/R Blade Cuff
Tail Rotor GB**
Retention Plates (2)
Gearshaft
Viscous Bearings (4)**
T/R Driveshafts (7)**
Vibration
Absorbers (2)
Intermediate GB**
Key CBM Enablers
Digital Source Collectors
Flight Line Diagnostics
Data Fusion/Analysis
Main Transmission Module
Accessory Module
Generators (2)
Hydraulic Pumps (2)
Planetary Carrier
Engine (No. 1 & 2)
Driveshafts (2)**
Input Modules (2)
Oil Cooler Axial Fan
Oil Cooler Fan Bearing**
APU
Currently Monitored by Vibration
Structural Part, Possible Addition for Monitoring

13. Digital Source Collector Fieldings Through Jan 09
Aircraft Type
Total # of Aircraft
DSC Equipped
Percent Complete
AH-64A
690
333
48%
AH-64D
CH-47D
513 61 71
14%
CH-47F
MH-47E/G 10
UH-60A
1732
105
364
21%
UH-60L
180
UH-60M 79
MH-60K/L
MH-6 51 16
31%
OH-58D
339 9
TOTAL
3325
793
24%
* Includes Active, Reserve, and National Guard Units 13

14. CBM Demonstrated Benefits
Increased Readiness
Decreased Mission Aborts
4-101 Avn Flew 26,000 Hours on 38 UH-60 During 12 Month OIF Deployment With 87% FMC
57 Hrs/Acft/Month = 3.8 Times Peacetime OPTEMPO
7,260 Launches With No Missions Dropped for Maintenance
3,417 Hours in Highest Month (~110 Hours/Day With Aircraft)
Impact of Equipping Deployed UH-60s Battalions With DSCs
03-04 OIF Rotation (30 Aircraft )
Non-equipped (Bn 1)
Non-equipped (Bn 2)
FMC*
65%
77%
Total Flt Hours
10,331
11,844
OPTEMPO (Hours/Year/Aircraft)
334
395
Both Units Completed Reset
05-06 OIF Rotation (30 Aircraft)
DSC Equipped (Bn 1)
FMC
87%
82%
21,819
20,388
OPTEMPO (Hours/Year/Aircraft)
727
680
CBM Will Enhance Pilot Training by Providing Insight Not Previously Available (e.g., Fatigue Damage Due to Maneuver Severity)
Expect Increased Readiness in Deployed. Real Comparison Is Deployed CBM vs Non-CBM Deployed Aircraft
CBM Already Changing the Way Aviation Operations Are Planned & Conducted
CBM = Increased Warfighting Capability

15. Cost Savings/Avoidance of ~$112M (26 Month Period) Due to CBM
CBM Benefits to Army Aviation Increased Readiness/Reduced O&S Costs/Reduced Soldier Burden
Impact of Equipping Aircraft With DSCs
Cost Savings/Avoidance
 2007/2008
AH-64
UH-60
CH-47
# of Aircraft
319 71
MMH Avoided
16,369
7,274
2,957
Hrs Reduction in MTF hours
2,005
722
166
$24M: 51 T700 Engines not Replaced on UH-60/AH-64 for Overspeed/Overtorque
~$30M: Additional AH-64/UH-60 Flight Hours Available Due to Increased Readiness/Availability + MTF Hours Saved
~$49M: Three Class A Accidents Avoided
~$6.6M: Components not Replaced, Returned to Service, and Overhaul Savings Due to Early Failure Detection
~ $2.8M: AH-64 Tail Gearbox Scheduled Maintenance
~$112.4M
Reduced NMC Due to Maintenance
Cost Savings/Avoidance of ~$112M (26 Month Period) Due to CBM
(Accidents Avoided, Components Not Replaced Unnecessarily, MTF Hours Saved,… )

16. HELLFIRE Captive Carry Health Monitor
Methodology – Automatically Measure and Record
Captive Carry Hours / Number of Cycles
Temperature Exposure
Battery Life
Data Histogram
Drop Shock/Humidity
Payoff
Reduced Maintenance Burden
Increased Reliability and Enhanced Safety
Positive Impact to Stockpile Readiness and Shelf Life
CCHM
Captive Carry Exposure Data Will Optimize Reset Maintenance, Improve Reliability, and Reduce Reset Costs
Hellfire II (AGM-114K) Guidance Section

17. Challenges Reset Increased OEF Support OIF Retrograde Funding
ARFORGEN Synchronization
Increased OEF Support
OIF Retrograde
CBM success stories should be annotated in the commanders comments on the backside of the monthly 1352 reports.
They should include, but not be limited to, aircraft accidents prevented, major component non-replacements such as engines and gearboxes, maintenance troubleshooting and maintenance man-hour savings as a result of having CBM maintenance processes and procedures.

18. Our Customers
We Are Here…
BECAUSE THEY ARE THERE !!!