Sustaining Systems Engineering: The A-10 Example
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1 Sustaining Systems Engineering: The A-10 Example (Based on A-10 Systems Engineering Case Study) 23 Oct 08 David Jacques Air Force Institute of Technology
2 Overview Systems Engineering in Sustainment Phase A-10 Development and Operational Service Aircraft Structural Integrity Program Structural Problems on the A-10 HOG-UP/Service Life Extension Re-winging Decision and the A-10C Summary
3 SE Sustainment Activities A Partial List: Execution of strategies for operations, sustainment and, when necessary, disposal Maintain baselines, data, and supply chain Maintain Operational Suitability, Safety and Effectiveness Monitoring and comparing performance and condition to design and prediction models Re-engineering of legacy system performance requirements and designs Decision analysis support for upgrades/mods and life extension decisions May include modifications to maintenance concepts
4 Aircraft Structural Integrity Program (ASIP) ASIP Initiated in 1958 Monitor and evaluate structural health of AF aircraft AFI requires plan, MIL-HDBK 1530 provides guidelines and details During 1970 s and 80 s Damage Tolerance Assessments (DTA) Inspection and modification programs Fatigue tests on wing, fuselage, and full aircraft Used to develop individual aircraft tracking program, and tech orders for inspection, maintenance and repair actions
5 A-10: Early Struggles Within the Air Force Close Air Support (CAS) was considered less important than strategic bombing, air superiority, and interdiction Tactical force mix required less expensive aircraft, but AF still favored fast multi-role fighters F-5, A-7D were early choices for the CAS role Reluctantly agreed to pursue specialized CAS aircraft
6 A-10: Early Struggles (ctd.) Within the Army Unsatisfied with level of CAS provided by Air Force Doctrine evolving towards air mobile tactics Increased reliance on armed helicopters Initiated development of AH-56 Cheyenne Competed with AF for CAS development $ Johnson-McConnell Agreement (1966) AF retained CAS mission, but recognized role of Army helicopters for fire support Army gave up large fixed-wing transports
7 A-10: The aircraft that almost wasn t! Key sustainment features: Survivability redundancy, shielded systems, engine placement Maintainability interchangeable left/right side parts, simple skin panels, engine placement Cost Considerations lean avionics (no night/adverse weather systems), ammunition cost reduction efforts
8 A-10 Deployment, and Debate Final production aircraft delivered in 1984 No service support for continued production (F-16 factor) Army Air-Land Battle doctrine Greater reliance on Battlefield Air Interdiction (BAI) Survivability concerns associated with greater SAM threat By 1985, studies emerged suggesting an A-16 as a replacement for the A-10 Defense Authorization Act for FY88-89 Directed completion of CAS/BAI Master Plan Directed yet another CAS fly-off (A-10, F-16, A-7, AV-8, F/A-18)
9 Desert Storm Performance vindication High effectiveness, and demonstrated survivability High sortie rate, low maintenance man hours/flight hour CAS F-16 s performed poorly, reverted back to standard Post war decisions Serious proposal floated by CSAF to give CAS and A-10 to Army in exchange for ATACMS, space mission, et.al. AF decided to keep A-10, but in reduced numbers
10 A-10 Structural Configurations Retrofit WOP Configuration Production WOP Thick Skin Configuration Intended for Aircraft (not completed on all aircraft) Aircraft Aircraft 582 and subsequent Thin wing center panel, cold worked at WS 0, Retrofit thick wing outer panel. Qualified to 6,000 hours Spectrum 3. Thin wing center panel, cold worked at WS 0, Production thick wing outer panel. Qualified to 6,000 hours Spectrum 3. Production increased wing center panel and outer panel thickness. Configuration qualified to 8,000 hour service life. Notes: Original design life was 6,000 flight hours Design load spectrum changed in 1977 based on measured fleet usage Fatigue test failed at less than 60% of new spectrum service life Resulting production and retrofit changes indicated above
11 ASIP Implementation Fairchild sold A-10 rights to Grumman in 1987 Fairchild ceases to exist shortly after Grumman delivers updated DTA and associated Force Structural Maintenance Plan (FSMP) Never fully incorporated into tech orders, not accomplished Difficulty with field inspections, budget constraints cited Analytical Condition Inspection (ACI) Addressed some inspection locations, but on few aircraft Cracks found in several locations in 1995, 96 Cracks classified as minor
12 And then, the wheels started to come off! 1994 Northrop merges with Grumman Although NG still the prime, most mods competed or done organically by government Fallout funds used to task NG to incorporate design changes into configuration baseline drawings 1995 Base Realignment and Closure (BRAC) Closes McClellan AFB Maintenance and repair operations moved to Hill AFB Results in loss of 80% of experienced workforce by SPO competes prime sustainment contract Lockheed Martin Systems Integration wins NG expected to be part of team due to proposed LM-NG merger 1998 LM-NG merger called off NG reduced to supporting role
13 HOG UP 1998: Northrop Grumman delivers A-10A Aircraft Wing Center Panel Rework-Fatigue Life Improvement report Detailed changes required to support 16,000 hour service life Based on assumption that 1993 FSMP implemented 1999: SPO initiates HOG UP Repair program vice modification Allowed use of maintenance funding Did not require acquisition approval Configuration Control Board action not required HOG UP expands to catch other necessary changes No composite assessment of structural risk Cost growth from $140M to $600M, not including unprogrammed cost for WS-23 inspection and repair No full-scale fatigue test to validate HOG UP
14 HOG UP Evolution Hog Up 1999 and 2003 Forward/Aft Fuel Tank Cavity Corrosion control/inspections Wing Outer Panel (WOP) Mid-Spar Web Rework Leading Edges Center Fuselage Inspection Area Wing Center Panel (WCP) Rework N/A for USAFE Fuselage Station 365 Bulkhead Repair Paint Flight Control Rework Center Fuselage Fuel Cell Floor & Boost Pump Flange Repair ACI Inspections Additional ACI Inspections Wing Station 90 Repair 1999 Original Hog Up 2003 Current Hog Up
15 Sometimes, things have to get worse before they can get better! HOG UP delays due to WS-23 inspection and repair Number of unusable wings higher than expected Predictions that serviceable wings would run out by 2011 Back-up of aircraft in depot due to longer than expected repair times Catastrophic failure of HOG UP wing in fatigue test (2003) Well short of 16,000 hour life expectancy 2005: AF completes business case analysis Option 1: Organic sustainment of thin skinned wings, increase SLEP for all wings ($4.6B) Option 2: Buy 135 wings, increase SLEP for remaining wings ($3.16B) Option 3: Buy 242 wings and avoid cost of SLEP ($1.72B) 2006: AF competes contract for new wings! (Option 3) Boeing wins contract to build wings, to be installed on a Fairchild Republic aircraft, being maintained by Lockheed Martin!
16 Learning Principle 5* Successful design, development and production is not enough to sustain a system throughout its life cycle. A-10 sustainment efforts were severely impacted by a number of factors On-again, off-again retirement decisions Vanishing prime contractor BRAC, and general turnover of government personnel Loss of condition baseline led to initially poor decisions regarding life extension efforts A-10 sustainment has recovered, but after significant cost associated with the original HOG-UP program * 6 Learning Principles are contained in the A-10 Case Study
17 A Second Life for a Modern Day Hog Low Altitude Safety and Targeting Enhancements (1990 s) Embedded GPS/INS system added (1999) Precision Engagement (2005) Results in A-10C Designation Replacement of TF-34 Engines (Proposed)
18 Air Force Center for Systems Engineering Case Studies Hubble Space Telescope GPS (Global Positioning System) F-111 Aardvark C-5 Galaxy B-2 TBMCS (Theater Battle Management Core Systems) Website: A-10 Peacekeeper Intercontinental Ballistic Missile
19 Ongoing & Future Case Studies International Space Station MH-53J/M Helicopter E-10 Underway Global Hawk FY09 Option KC-135 Simulators FY10 Option T-6A Texan II Underway FY09 Start FY10 Start
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