1. (Fighter Avionics Upgrade)
An Example of Performance Based Logistics
(Fighter Avionics Upgrade)
Dale Waldo
Last Rev. 5/10/99 by DFW

2. Requirements Implement F3I Guaranteed mission capability rate
Support peace and war time scenarios
USAF/Contractor forms partnership for sustainment over the system life cycle
Affordable cost to USAF
Note, 90% mission capability (MC) is for 5 LRU portion
of radar only. As of Aug. ‘96 F-15 A/C currently had 76% mission capability. APG-63 radar was not on top 10 impact list driving MC. It was when we started the program, but reactive planning temporarily has fixed problems and so it has moved further down the list.

3. Implements F3I Requirements
Performance based specifications
Form, Fit, Function Interface (F3I)
‘How to’ responsibility given to Contractor
Contractor Depot Maintenance
Helps mitigate the risk of short lived technologies
Contractor has configuration control internal to LRU
Facilitates technology insertion
Utilizes Trigger Based Item Management (TBIM) Process
Provides for trends and targets actions that provide high payoff
‘Proactive’ rather than ‘reactive’ management
How FFFI solves parts obsolescence. FFFI does provide the contractor with configuration control internal to the LRU. Therefore the contractor is allowed to make configuration control changes that are required to solve parts/technology obsolescence in a roadmap driven environment. The roadmap has opportunistic points at which technology, either internally developed or commercial, can be inserted into the hardware to not only solve future parts obsolescence, but also to maintain MTBMA (mitigate the bathtub effect). Improvement of MTBMA allows the Contractor an incentive for increase profits when technology is inserted wisely.
Ref. PBBE Flexible Sustainment Guide -

4. Elements of PBL (Continued)
Proper O level maintainer training and technical information
Tech Pubs (plane side repair data) updated during EMD
CFR/CFI system update; deployment during OT&E
All technical information evaluated vs “as designed”
Inclusive Diagnostic System at all levels of assembly
Automated configuration management required
For tracking:
Base Aircraft LRU SRU Critical Component
Manage parts inventory
Tracking of bad actor hardware, remove when necessary
PBL Implements F3I Criterion 5

5. Availability: When you need it you will have it!
Actual On-Aircraft Mean Repair
Time (MRT)< 45 Minutes
BASE SUPPLY
Base X Flightline
Shipping
& Receiving
5 Hrs 5 1
Removal
Defective
LRU
- Receives Bad LRU
- Generates DIFM via CAMS 3
Install
Good
LRU 4
- Issues Spare
- Picks Up Bad LRU
- Sends Bad LRU to
Shipping
0 Hrs 2
Maint. Tech
Exchanges Bad
LRU for Spare
8 Hrs
AMU Support Section

6. Shared Responsibility is Key to Success
Contractor - Provide adequate spares based upon MTBMA
USAF and Contractor - Minimize Mean Down Time (MDT)
USAF Minute MTTR
Contractor - 5 Hour stores replenishment time (for spares)
USAF - 8 Hours for local transportation, preparation of
maintenance action and requisition forms,
pack and ship
Technical Performance Measurands will be implemented to help manage the program, minimize MDT 21

7. Maintenance Concept Organizational Level Tasks
a DTM is similar to a thumb drive
Serial Numbers & BIT Matrices
DTM Transfer
Remove/Replace
Failed LRU
Perform Additional
Troubleshooting Procedure
and Repair System
Perform System Verification
Skill LvL 3
Technician
CFRS/CFI
1) CFRS - Determine existence of fault.
2) CFI - Determine most likely cause of fault. Identify corrective action to be performed.
PMA
Maintainer Always Receives Positive
Action From Technical Data (e.g. Next
Action). 10

8. Wiring Diagram on the Fly
CFR/CFI System
Proposed Process (Eliminates need for Fault Isolation Tech manual)
CFR / CFI
Identify Corrective
Action Required
How is this Done?
Job Guide
Is the Fault Corrected?
If “How To” instructions are not required
DTM
Job Guide
PMA
CFR/CFI System
Wiring Diagram on the Fly
CFRS/CFI 14

9. Functional Requirements
Automated Fault Detection
Provided by on-aircraft system BIT and supplemented with CFRS
Accomplished via updates to WIN-95 CFRS
Automated Fault Isolation capability
Provides “POSITIVE ACTION” to maintainer
Electronic automated tool implementation includes Digital Wire Diagrams
Currently done with paper manuals today
Automated data collection
Enables collection and manipulation of data collected
Includes maintenance corrective action and parametric information 11

10. Advantages
CFI data base can readily be updated in 1-2 weeks time frame
Not Tech Pubs update dependent (months/years time frame for paper update)
Maintainer now gets real time data to help isolate failures
Portable Maintenance Aid (PMA) compatible
Deletes paper Fault Isolation/Wiring Diagram (FI/WD) manuals 12

11. REPAIR DEPOT PROCESS LRU REPAIR 7 DAYS AVERAGE SRU REPAIR 60 DAYS
* BAD LRU RETURNED
FOR REPAIR
CFRS/CFI
2 DAYS FROM Air Base
BAD SRU
SRU REPAIR
ASSET MANAGEMENT
•PREPARE TASK
ORDER PACKAGE
•TRACK REPAIR
• OBTAIN SHIPPING
INSTRUCTIONS
• PROCESS GFP DOC.
•CONFIRM FAILURE
•REPLACE BAD SRU
•LRU TEST
•CONFIRM FIX
•INSPECT
LRU REPAIR
7 DAYS AVERAGE
SHIPPING
& RECEIVING
SRU SPARES
SPARE PARTS
2 DAYSTO Air Base
SRU REPAIR
60 DAYS
RFI LRU SHIPPED
PER ASSET MANAGEMENT
INSTRUCTIONS
REPAIRED SRU 29

12. Asset Manager (Middleware Merge Engine)
CFR/CFI/DWDS
Database
Core Automated Maintenance System (CAMS)
Federal Express
Asset Manager
Supplier Depot
SPO
WPAFB
Middleware
Merge Engine
Asset Management Data Information Screens
Elmendorf AFB
Lakenheath RAF
Nellis AFB
Mountain AFB
Langley AFB
Edwards AFB
Eglin AFB
Base Supply / Trans. Databases
Airborne
USAFE
PACAF
Growth
FRACAS
Property Management
LRU / SRU Field Configuration Database
Base Supply / Transportation
Program Office
Field Operations
Contractor
DEPOT
WRALC

13. Asset Manager Field Level Metrics
System Readiness or Availability Rate
System MTBMA (less -120 Antenna)
Mean Down Time per Maintenance Action
LRU Demand Rates
System CND Rate
Average Duration from JCN Issue to Part Received by Commercial Shipper
Percent JCNs Awaiting Parts - Off Station
Average Active Maintenance Time for Troubleshooting and Repair
Average Repair Turn-Around Time Base Dock to Base Dock

14. Depot Metrics LRU Repair Rates
Number of broken warranty seals on returns
Number of Units in Pipeline
Average Duration of LRUs in Transit
Average Turn-Around Time by Facility
BCS/RTOK Rates
Depot Test Voids/Total Test Required
Number of Parts Produced by Single Source
Technology Obsolescence Projections
Number of Obsolete Part Types in Field
Percent JCNs Awaiting Parts
Current Value of Repair Inventory
Repair Station Availability Rates & Excess Capacity
Number of Open Engineering Investigations
Number of Outstanding BIT ECRAs and Time Outstanding

15. Questions?