VSM DOD WORKSHOP MAINTENANCE SYMPOSIUM Leadership Outbrief FRC Transformation Overview 19 27 Aug Oct 2009 Presented by: Mr. Garry Newton Deputy Commander, Presented by: Fleet Mr. Garry Readiness Newton Centers Director, Industrial Operations Presented to: COMFRC Deputy Commander, LEADERSHIP Fleet Readiness Centers
NAVAL AVIATION MAINTENANCE TRANSFORMATION HISTORY 1995 Established Integrated Maintenance Concept First significant moves of depot capability closer to the flightline 2001 Implemented AIRSpeed throughout NAE Implementation of industry-proven process improvement tools 2005 Established Fleet Readiness Centers Returning ready-for-tasking aircraft back to the Fleet faster by moving maintenance closer to the flightline 2
NAVAL AVIATION INTEGRATED MAINTENANCE CONCEPT Shifted from on-condition to CALENDAR-BASED aircraft maintenance, taking Depot Maintenance to the Fleet OCONUS LOCATIONS MCAS Kaneohe Bay, HI H-60 Andersen AFB, Guam H-60 STAE Singapore C-130 NAF Atsugi Japan / NAPRA Det Okinawa E-2, F/A-18, H-60, H-46, H-1, H-53, EA-6B NAPRA S. Korea H-53 FIELD SITE DEPOT SITE FULL-TIME DEPOT MAINTENANCE AT EVERY MAJOR NAVY & MARINE CORPS AIR STATION WORLDWIDE 3
INDUSTRIAL STRATEGY FOR NAVAL AVIATION Workforce Revitalization Transformations that facilitate changes in skills, knowledge, ability, experience and organizational construct in concert with changes in weapons, technologies, and supporting processes. Optimize the Industrial Base Develop the industrial capabilities to support future Naval Aviation requirements that are of the proper size and mix between Organic, Commercial, and Inter-service. Core-Sustaining Capability Provide the most up to date industrial capability to sustain Naval Aviation s current readiness requirements with the right capability for the right cost that conforms to USC Title 10. Capital Investment Prioritization and provisioning of investment dollars in support of the above strategic objectives. Logistics Transformation Organizational realignments, process improvements, and integration across the value chain to produce aircraft ready for tasking at the right time, the right place and at the right cost. 4
OPTIMIZING THE INDUSTRIAL BASE INTEGRATE AND OPTIMIZE FRC NORTHWEST WHIDBEY ISLAND Det Everett FRC Southwest Det Northwest Whidbey Island FRC SEFAC SOLOMON S ISLAND FRC WEST LEMOORE Det Fallon Southwest Det West Lemoore Det Fort Worth Det China Lake I-LEVEL 6,000+ SAILORS & MARINES 20 IMAS 6,000 ENGINE/ MODULE/ ACCESSORY REPAIRS 580,000 COMPONENT REPAIRS $2.0 BILLION OPERATION MISSION FUNDED D-LEVEL 10,000 CIVILIANS 3 DEPOTS 1,500 ENGINE/ MODULE REPAIRS 70,000 COMPONENT REPAIRS 700 AIRCRAFT REPAIRS $2.0 BILLION OPERATION NWCF FUNDED FRC MID-ATLANTIC OCEANA Det Norfolk Det Pax River Det New Orleans Det NAF Washington Det Atlanta FRCSE Det MA Oceana Det Beaufort FRC WEST PAC NAF Atsugi, Japan Det Guam Det Okinawa Det Singapore Det Korea Det Iwakuni Det Australia FRC SOUTHWEST NORTH ISLAND Det Point Mugu Site Pendleton MALS-39 NADEP NI Det Pendleton Site Yuma MALS-13 NADEP NI Det Yuma Det NAVCAL Lab Futenma Det NAVCAL Lab Iwakuni FRC SOUTHEAST JACKSONVILLE Det Mayport Det Key West FRC EAST CHERRY POINT MALS-14 Cherry Point Site New River MALS-26 & 29 New River Site Beaufort MALS-31 Beaufort NADEP JAX Det Beaufort Site Quantico HMX-1 Quantico Site Robins AFB MALS-42 AIMD Atlanta Site McGuire AFB AIMD Willow Grove Site Stewart ANGB MALS-49 *Dets in red indicate closing activities 5
LOGISTICS TRANSFORMATION PILLARS Distribute Moving Depot Capability Forward Establishing High Velocity Repair Loops with Brokered R/R Consolidate BRAC-Related Closures Consolidating Repair Sites and Creating Centers of Excellence Optimize AIRSpeed Saturation Supply/ Maintenance Consolidation of Connectivity CHOOSING THE RIGHT APPROACH BASED ON THE SITUATION 6
DISTRIBUTED DEPOT MAINTENANCE I- Repair Assemble Non-Distributed Maintenance Example Disassemble Inspect Not Repairable Re-Assemble Transport Disassemble Inspect D-Repair Assemble I-Repair Assemble Distributed Maintenance Example Disassemble Inspect D-Repair Assemble EXAMPLE OF IMPROVEMENTS F/A 18 A-D Hydraulic Drive Unit (HDU) Repairs 44 HDUs Interdicted $1.15M in AVDLR Cost-avoidance F/A 18 A-D Horizontal Stabilizer Actuator Repair $3.31M in AVDLR Cost-avoidance to date H-53 Main rotor Blade Repairs 27 Rotor Blades Interdicted $2.05M in AVDLR Cost-avoidance to date 7
-25 Repair Sites Worldwide - Wide Performance variation - Supporting different operating environments NAS Whidbey Island, WA P-3 Prop / -14 Level 1 NAS Pt. Mugu, CA P-3, C-130, E-2, C-2 Prop -14 / -427 Level 2-425 Level 1 NAS Misawa, JA P-3 Prop / -14 Level 1 NAF Atsugi, Japan E-2/C-2 Prop / -425/-427 Pres / Depres Only MCAS Futenma, Okinawa C-130, P-3 Prop / -16 Level 1 NS Bahrain P-3 Prop BU / OTW RGB MCAS Miramar, CA C-130 Prop / -16 Level 2 Closed Sites NS Rota NAS Keflavikk NAS Adak NAS Barbers PT CONSOLIDATION EXAMPLE (AIMD / MALS / Depot / Commercial) P-3 / C-130 / E-2 / C-2 Propellers and Engines Rolls Royce -427 Depot Standard Aero -14/16/425 Depot NAS JRB Willow Grove, PA P-3, C-130 Prop / -14/ -16 Level 2 PPI P-3 Props NAS JRB Fort Worth, TX NAS New Orleans C-130 Prop / -16 Level 2 P-3, C-130 Prop / -14/-16 Level 1 NAS Sigonella, Italy MCAS Kaneohe Bay, HI P-3, C-130 Prop / -14 Level 1 Closed Sites NAS Kadena NS Diego Garcia NAS Roosevelt Roads NAS Agana NAS Moffet Field Warner Robbins C-130 Props NADEP CP P-3/E-2/C-2 Props P-3, C-130 E-2, C-2 Prop -14 / -425 Level 1-16 Level 3-427 Level 2 NAS Brunswick, ME P-3,C-130 Prop / -14 Level 1 Stuart ANGB, NY (MALS-49) C-130 Prop / -16 Level 2 NAF Washington -16 Pres / Depres NAS Pax River, MD P-3, C-130, E-2,C-2 Prop / -14 Level 1 NAS Norfolk, VA E-2/C-2 Prop / -425/-427 Level 2 MCAS Cherry Point, NC C-130 prop / -16 Level 1 (NADEP CP Propeller CFA) NAS Jacksonville, FL P-3 prop / -14 Level 1 (NADEP Jax Engine CFA) NAS Atlanta, GA E-2/C-2 Prop -425 Pres / Depres Navy Active Red Marines Navy Reserve Infrastructure Adjustments through Closure vice Optimization 8
Greatest cost savings, C130 Support Risk FY04 Constant Year $ Reg / TMS1 INVESTMENT MILCON $0 SE $0 CONTAINERS $0 INITIAL SPARES $0 PCS COST $83,322 OPERATIONS & SUPPORT MANPOWER -$32,402,654 AFM $0 AVDLR (Excl CRR) $0 1A5A (incl. Civ Manpower) $0 Commercial I-Level Repairs N/A TRAINING -$3,177,834 SPARES $0 TRANSPORTATION $3,222,135 PERSONNEL SUPPORT -$5,229,847 TEST CELL SUPPORT/YEAR $0 INVESTMENT $83,322 OPERATIONS & SUPPORT -$37,588,200 Total Cost FYDP Deltas (Negative indicates Savings) -$37,504,878 CONSOLIDATION EXAMPLE T56 Legend: / Prop Blue I-1 I Level Optimization Gray I-3 Orange: Min 20 28 / 40 NAS Whidbey Island, WA 36 / 33 NAS Pt. Mugu, 33 / 10 NAS Misawa, JA NAS JRB Willow Grove, PA(BRAC) 4 / 4 NAF Atsugi, Japan Eng Pres-Depres 9 / 0 MCAS Miramar, CA 6 / 12 25 / 8 NAS JRB Fort Worth, TX NAS New Orleans 9/ 10 MCAS Futenma, Okinawa 24 / 10 MCAS Kaneohe Bay, HI (Atlanta Sqd to NO) 3 / 6 NS Bahrain Prop BU / OTW RGB Only (Feed by Jax/ NORVA CNAF dir) Region / TMS 1 Hybrid Scenario. Combination of Capacity driven by region and TMS based (scenarios 1&2) (w/brac and flow) 19 / 8 McGuire AFB (VR-64) 47 / 4 NAS Sigonella (Feed by Jax/ NORVA CNAF dir) Note: CNAF / CNAFR direct Module / QECA Movement Current Man Total: 382 Projected Man Total:246 Reduction of 136 NAS Brunswick, ME(BRAC) 4 / 10 Stuart ANGB, NY (MALS-49) 0 / 0 NAF Washington Eng Pres-Depres (VR-53 C130Tx4) 0 / 0 NAS Pax River, MD 35 / 30 NAS Norfolk, VA 10 / 0 MCAS Cherry Point, NC 49 / 61 NAS Jacksonville, FL (Brunswick Sqd to Jax) C130 Capability established NAS Atlanta, GA(BRAC) LOCATION NEC/MOS BA COB POB 5 Reg / TMS1 NAS BRUNSWICK ME 6418 41 28 23 25 NAS WILLOW GROVE PA 6418 19 19 19 8 MALS-49 (Stuart ANG) 6226 4 4 4 10 NAF WASHINGTON 6418 0 0 0 0 NAS NORFOLK VA 6423 35 17 25 30 NAS JACKSONVILLE FL 6418 49 41 45 36 MALS-14 (Cherry Point) 6226 10 7 5 0 NAS ATLANTA GA 6423 0 0 0 0 NAS SIGONELLA IT 6418 47 47 47 4 NAS NEW ORLEANS LA 6418 25 18 14 8 MALS-41 (Fort Worth) 6418 6 6 6 12 MALS-11 (Miramar) 6226 9 9 9 0 NAF ATSUGI JA 6423 4 4 3 4 NAS MISAWA JA 6418 33 21 33 10 NAS PT MUGU CA 6418 10 3 6 3 NAS PT MUGU CA 6423 26 21 19 30 NAS WHIDBEY ISLAND WA 6418 28 15 17 40 MALS-36 (Okinawa) 6226 9 9 9 10 NS BAHRAIN 6418 3 2 2 6 MALS-24 (Kaneohe Bay) 6418 24 13 16 10 Total 382 284 302 246 RESULTS OPTIMIZED REPAIR NETWORK MORE TRANSPORTATION (WITH CLEAR PROTOCOL) OUTCOMES FASTER REPAIR CYCLES LESS MANPOWER LESS EQUIPMENT LESS OVERALL COST 9
OPTIMIZATION (BEST PRACTICE REPLICATION) Optimization Cost Avoidance EOY Trend ~ $105M 100% 95% 90% 85% BRAC APPROVAL RFI TRENDS TARGETED CPI PROJECT PLANS 80% 75% COMP PROJ 70% 65% 60% 55% 50% 06 RFI % 07 RFI % 08 RFI % 09 RFI % 10
FLEET READINESS CENTER TRANSFORMATION SUMMARY ACCOMPLISHMENTS DELIVERING COST-EFFECTIVE READINESS TO THE FLEET CHALLENGES BLENDING ORGANZIATIONAL CULTURES CREATING A CONTINUOUS PROCESS IMPROVEMENT CULTURE CREATING AN ENVIRONMENT OF SHARED RESPONSIBILITY AND MUTUAL ACCOUNTABILITY CONNECTING THE DOTS ACROSS ORGANIZATIONS AND PROCESS OVERCOMING POLICY AND PROCESS BARRIERS 11