2006 DOD Maintenance Symposium Reno, Nevada
Fleet Readiness Center Southwest “Move Your Cheese Now!” Captain Fred Cleveland, USN Commanding Officer
Who We Are---FRC Southwest
• Fix it once • Fix it right • Fix it on time
Sec SecNav NavPriorities Priorities
What We’re Doing
Optimize Optimizethe theWorkforce Workforce Prosecute the Prosecute theGWOT GWOT Build Buildthe theNavy-Marine Navy-MarineCorps Corpsfor forTomorrow Tomorrow Emphasize Safety, Manage Risk Emphasize Safety, Manage Risk Reinforce ReinforceEthics Ethics Lean/Six Sigma Lean/Six Sigma
Alignment
CNO CNOPriorities Priorities Mission MissionAccomplishment Accomplishment
Sustain SustainCombat CombatReadiness Readiness
Build BuildaaFleet Fleetfor forthe theFuture Future
st Develop Develop21 21stCentury CenturyLeaders Leaders
Focus on Innovation That amplifies by leveraging aligned goals NAE/NAVAIR NAE/NAVAIRGoals Goals
Balance BalanceCurrent Currentand andFuture FutureReadiness Readiness Reduce the Cost of Doing Business Reduce the Cost of Doing Business Enhance Enhance Agility Agility Improve Alignment Improve Alignment Implement ImplementFleet-Driven Fleet-DrivenMetrics Metrics
EEnn tteer rpprris isee A Alliig gnnm mee nntt Fleet Fleet Support Support
Depot DepotPriorities Priorities
Alignment Alignment Cycle-Time Cycle-TimeReduction Reduction Reliability Reliability I2D I2DIntegration Integration Material MaterialManagement Management Reduce ReduceCost CostofofDoing DoingBusiness Business
FY-06 Production Results Plan / Actual * Helo-line:
* E-2/C-2:
* F/A-18:
* Field Service:
(46) / (44)
H-60 IMC aircraft
(59) / (59) (9) / (8)
H-1 IMC aircraft, H53 IMC aircraft
(9) / (7)
E-2 aircraft
(9) / (8)
C-2 aircraft
(53) / (47)
PMI-1s
(32) / (32) (13) / (11) (13) / (7)
PMI-2s Crash Damaged aircraft CBR+ aircraft
(3) / (3)
"E/F" AEPD aircraft
(25) / (23) (6) / (6)
•Components:
Aircraft (247) - approx 94% of FY2006 plan
EA-6B IMC aircraft AV-8 IMC aircraft
39,159 / 34,279 Units 3,813 / 3,460 PBL units 3,591 / 3,000 DMISA units 1,235 / 829 FMS units 28,164 / 24,990 FE units 154 / 126 4Z units 2,202 / 1,874 Concurrent units
* LM2500 Engines: (10) / (13) * Mobile Facilities: (57) / (56) * Calibration: (14,218) / (12,850) units * Manufacturing: (1,822) / (1,644) items
Components (34,279) - 88% of FY2006 plan
Ensured Commander, Naval Air Forces “Ready For Tasking” Aircraft Goals
THIS MONTH! FLEET READINESS CENTERS (FRC) NORTHWEST
MID ATLANTIC
AIMD WHIDBEY ISLAND (Crane ALQ-99 workload)
Site Patuxent River
WEST
Site Fallon NADEP NI Det Fallon
AIMD LEMOORE NADEP NI Det Lemoore
AIMD OCEANA AIMD Norfolk AIMD NAS Corpus Christi NADEP CP Det Oceana NADEP JAX Det Norfolk NADEP JAX Det Oceana X Det Norfolk NAWC Lakehurst
Site N. Orleans AIMD Atlanta (E-2C Support) NAVAIRES New Orleans
NADEP CHERRY POINT MALS-14 Cherry Point AIMD Willow Grove FRC East Det Lakehurst
Site Fort Worth AIMD Atlanta (FA-18 Support) NAVAIRES Fort Worth
Site New River Site Beaufort
Site Pendleton
MALS-26 & 29 New River NADEP CP Det New River
MALS-39 Pendleton NADEP NI Det Pendleton
Site Pt. Mugu
SOUTHWEST MALS-11 & 16 Miramar NADEP NI Det Miramar AIMD North Island NADEP North Island NADEP North Island DET NI
EAST
Site Yuma MALS-13 Yuma NADEP NI Det Yuma
SOUTHEAST NADEP JACKSONVILLE NADEP JAX Det Cecil Field AIMD Brunswick AIMD JAX
MALS-31 Beaufort NADEP JAX Det Beaufort
Site Mayport AIMD Mayport NADEP JAX Det Mayport NAWCAD LKE Det Mayport
Site Key West
A MAJOR TRANSFORMATION IN DELIVERY OF AVIATION MAINTENANCE!
FRC Southwest A Presence Far Beyond San Diego Whidbey Island
Fallon NAPRA, Atsugi, Japan Guam Kaneohe
Patuxent River
Lemoore Pt Mugu
China Lake Camp Pendleton Miramar NADEP North Island Yuma
Atlanta Dallas
FRCSW regularly supports 6 pacific fleet Aircraft Carriers while in-port or at sea. We also resource numerous long and short-term detachments at many sites around the country and the globe. The FRCSW team provides immediate worldwide Warfighter support wherever and whenever needed!
The Naval Aviation Enterprise. . . Transforming into Fleet Readiness Centers FRC “I2D” AIMD DEPOT
DEPOT
Inventory Control Point
Satellite
N– INTEGRATIO nd Off” st a “Ha More than ju On site Artisan skills allows for increased capability by leveraging infrastructure and technology.
AIMD
Stovepipe processes
Facilitates positive upstream impacts that transcend the NAE
More “Move your cheese now!”
Center Of Excellence (COE)
Satellite Satellite
COE: Jewelry Store Satellite: Wal-Mart
A Simple FRC Principle Don’t Do Stupid Stuff! Remove at squadron
Unwrap Screen at IMA
BCM at IMA Pack/Wrap/Ship At ASD
Stow/Unstow at DDDC
Order/Wrap Detrash/Induct at D Condemn!
Pickup by ASD
I2D Lemoore
FRC Planning Whidbey Island Whidbey Island
• Radar BCM Interdiction Team
•Canopies, EA-6B Flight Controls, P-3 Components •Number to Date: 188
•Number to Date: 1
9 Value to FHP; $7,462,727
• APG-65 Pwr Supply Converter
MALS 11
9 Value to FHP: $4,601
•Composites, Hyd, Avionics Interdictions
•RFTF Bench Round Robin: 1
•Number to Date: 59
•Composites, Hydraulic, Avionics Interdictions •Number to Date: 44
9 Value to FHP: $ 2,422,917
9 Value to FHP: $ 383,179 YUMA • Finalizing BCM Analysis
Pt. Mugu • Finalizing BCM Analysis • 3-artisans planned for support
NORIS Petri Dish: •AirsSeed Plans in Final (Avionics) •BCA with Reserves week of June 6 •BCM Interdictions •Number to Date: 51
9 Value to FHP: $159,597
FY06 BCM Interdictions:
up
41% from FY2005
9 Value to Flying Hour Program: $10,433,021 9 To date 344 items (51% more units)
AIRSpeed/LEAN Success Stories F/A-18 PMI 1TAT SOLD & INFLOW ACFT 450 400 350 300 250 200 150 100 50 0
3
0
J9 R
J9
86
R
83
RJ
80
RJ
77
RJ
74
RJ
69
RJ
62
RJ
9
R
R
RJ
6
J5
2
J5
9
J5 R
J4
46
R
42
RJ
39
RJ
RJ
RJ
28
Phase 2 Cut over-
F/A-18 HOURS Paid vs Actual Phase 1 Cut over12,000
•Phase 1, Visual Synchronization provided reduction in cost by 18 % down by 1744 man-hours
10,000 8,000
•Phase 2, Single Piece Flow reducing TAT by 33% to 120 Days
6,000 4,000
Paid WLS HRs
43 RJ 46 RJ 51 RJ 54 RJ 57 RJ 60 RJ 63 RJ 68 RJ 71 RJ 75
RJ
40
RJ
37
34
RJ
31
RJ
RJ
25 28 RJ
RJ
22
RJ
19
RJ
14
RJ
07
RJ
RJ
01
RJ
RH
97
0
11
$1.9M in FY-06 AIRSpeed Labor Efficiencies
2,000
Actual Expended HRs
•Quality Reduction in MAF per manhour down by 29% from first half of year
E-2/C-2 - Single Piece Flow Synchronized Pull system based on Fleet Flightline Requirement C 2 S L E P E L E C TR IC A L B U IL D U P
8 5'
52 '
40 '
85 '
85 '
E2 AS SE M BLY
C2 AS S E M BL Y
41 '
4 1'
37'
E2 E 2 / C 2 D IS A S S E M B L Y
E &E
E2
M E TA L
E &E
ELECT
M ETAL
D IT M C O
ELECT
C2 S LE P
C 2 S LE P
C2 SLEP
E LE CT
M E TA L
M E TA L
1 4'
1 7'
C 2 S L E P K IT C A G E
75 '
E-2/C-2 Local Mfg BB Project Touches All Areas of NAVAIR NI
I s it C S I b a s e d o n D o c um en tation? NO
NO
Is N IN A v a i la b l e ?
F o r w a rd e d B O M t o F ISC D e v e lo p s B ill o f M a t e r ia l f o r R a w Sto c k
FISC Engineering
FISC Engineering
S t re n g t h te s t f or m a t e r ia l s
P rep a re Q V TR
Pass Te s t(s )?
NO
In f orm e d t ha t M a t e r ia l F a ils
Y ES
G e n e ra t e s / 3 R e p o rt a n d s en d s t o P & E
Tech Library
Y ES NO Y ES
Y ES
S u b m it 3R ?
R e le a s e E n t ir e W o rk P a c k a g e T o P r o d u c t io n C o n t r o l
I n f o rm e d t h a t M a t e r ia l F a i ls
Y E S G e m e ra t e 3 R t o s e e if t h e F a ilu r e is a c c ep t a ble
I n f o rm e d t h a t M a t e r ia l F a ils R e q u ir e L a b Te s t?
NO
P l a n n in g R e c ie v e s E n g in e e r in g D is p o s it io n
M a t e ri a l D e t e r m in e d A c c e pta ble
NO
P & E C re a t e s N e w W o rk O r d e r a n d B O M in M R P I I
P & E F o r w a rd s N e w W o rk O rd e r a n d B O M to F I SC
Y ES
Tooling
M a r e r ia l C u t / C ou p o n w ith E x c es s re t u rn e d t o F IS C If G G /G F
M aterials and
F o rw ard A ll M a t e ri a l T o C ut
Accumulate All
M a t e ri a l A v a il. G G / GF
R e q u e s t a ll G G /G F M a t e ri a l f ro m F I S C
Tooling
W o rk P a c k ag e R e c e iv ed b y P r o d u c t io n C o n t r o l
E n g in e e r in g P ro v id e s D is p o s it io n
QA
A p p r o v e s A ll M a t e r ia l C e r t s
M a t e r ia l & D o c u m e n t a t io n A c c e p t a b le ?
E n g in e e rin g R e s e arc h es th e F a i lu r e
Materials Lab
Materials Lab
E n g i n e e r in g R e c e iv es 3 R R e q u es t
C h e m ic a l Tes t m a t e r ia ls NO
Materials and
MFG Planning Process / Approval MFG 6.0 GB JB Thurmond JR CT Reduction from 8 days to 3 days with Savings in Man Hrs/Wk Years
Y es
Ex ces s r e c ie v e d b y F IS C
F IS C M o v e s in M R P II
MFG Pro. Cont. MFG Planning
P la n n e r P ic k s U p w o rk f ro m Q u eue
R e v is e W o r k O r d e r b as e d o n f e edb ac k f ro m Q A , M a t L a b a nd F ST Eng F ee dba c k
F I S C P u l ls A v a il a b l e M a t e r ia l, I s s u e s B u lk C u t
D e liv e ry o f t h e M a n u f a c t u r in g P la n t o t h e S h o p F lo o r
10.0
R e q ie s t N I N f ro m F I S C V ia M e m o
R e q u es t V e n d e r P ro v i d e R ep lac e m e n t M a t e ri a l a n d C e r t i f i c a t io n s
QA
FISC Engineering Materials Lab QA Y ES
Tech Library
C o l le c t iv e l y A p p ro v e d ?
M a t e r ia l R e c e i v e d f ro m o u t s id e s o u r c e By F ISC
R e t u rn B O M t o P la n n i n g
MFG Pro. Cont. MFG Planning
C re a t e s S u p p o rt W o r k O rd e r (S W O )
R e v ie w F in a l W o r k O rd e r P a c k a g e f o r A p p ro v a l
NO Y es
Y ES
3 R G en e rat e d
D e t e r m i n e d U n a c c e p t a b le
Accumulate All
NAVSUP GB LCDR Ken Flaherty CT reduction from 16 days to 4 days with Savings in Transaction fees
L o g in t o MR P II by S c re e n e r
R e v ie w F in a l W o r k O rd e r P a c k a g e f o r A p p ro v a l
R e v ie w R o u g h D r a f t o f W o rk O rd e r P a c k a g e & P r o v id e C om m ents
P la n n e r P r e p a r e s t h e W o rk O rd e r w it h R o u t e r , a n y S u b -R o u t e rs , M a t e r ia l N e e d s a n d S e r v ic e s N e e d e d
NO
is
Aircraft Line
< P ro c e s s N a m e >
P ro c u re m e n t M e th o d N AVC OM PT 2276
E n g in e e r in g R e v ie w B o a r e R e v ie w s f o r F in a l A p p r o v a l a n d S ig n a t u r e o f P a c k a g e
R e v ie w R o u g h D r a f t o f W o rk O rd e r P a c k a g e & P r o v id e C o m m ents
B a s e d o n "P ic k U p " t h e jo b is a s s igne d to a P la n n e r a n d L o g e d in t o M R P I I
G o v t C o n tra c t in p la c e ?
Y ES P ro c u r e , F il e C o p y a n d P ro v i d e D o c N u m b er an d B O M t o P la n n e r
Input R e q u it it io n i n t o M R P II
Tooling
E2/C2 6.0 GB Denise Brent Ct Reduction from 5 days to 1 day with Savings in Prod work/hrs
while
Local Mfg Request Devel.
W o rk O rd e r J O N E s t a b li s h e d a n d A c t iv a t e d in T A A
W o rk O rd e r J O N A c t iv a t e d in T A A
activating
ID & Approve Needed AC Part
W o rk O r d e r J O N A s s ig n e d b y S c re e n e r
R e v ie w F in a l W o r k O rd e r P a c k a g e f o r A p p ro v a l
P r o c u re V ia G o v t . P u rc h a s e C a rd
10.0
YES
Y ES Y ES I n f o rm s P l a n n in g o f A v a i la b il it y o n t h e B O M a n d s e n d s it back
NO
MFG Pro. Cont. MFG Planning
Te c h D a t a P ac k age C o m p le t e ?
W o rk O r d e r m ov ed t o to Tr a d e Q u e u e F or "F IF O " P ic k u p
S end N IN bac k to P& E V ia M em o
C ost ov er $2500
10.0
FISC Materials Lab QA Tech Library
S c re e n e r S c re e n s Te c h D a t a P a c k a g e f o r C o m p le t e n e s s
I d e n t i f ie s C a t e g o r ie s f o r D a tab as e (C u s t o m e r, T ra d e , C S I or N o t, N ew or R epe at)
MFG Pro. Cont. MFG Planning
P rod u c es H a rd C o py D ra win g s f o r FISC
C re a t e N I N & Inp ut I nto D a taba s e
R e v ie w R o u g h D r a f t o f W o r k O rd e r P a c k a g e & P r o v id e C o m m en ts
10.0
A s s e m b le s H a rd C o p y D ra win g s f o r Te c h D a t a P ac k a g e
QA
NO
R e c e iv e s R e q ue s t t o A s s e m b le T ec h D a t a P a c k ag e
NO
Materials Lab
E n g ine e r D e t e rm in e s C rit ic a l C ha ra c te ris t ic s
R e c eiv e Mem o f ro m P & E s R e q u e s t in g N I N
Engineering
FISC Engineering
L o g -in t o L o g B o o k (H a rd C o p y ) in B L D G 4 7 2 P l a n n in g
Tech Library
Engineering Materials Lab
A s s e m ble T e c h D a ta P ac k a g e/ A t ta c h t o 4 23 5 / 1 0
R equest C ost & Lead C o m m e r c ia l
Accumulate
QA
Y ES
NO M a t e r ia l A v a il a b l e D L A / ?
Materials and
Tech Library
D ra win g s A v a ila b le in J E D MI C S ?
24 hr Delay
10.0
A s s e m b le s Te c h D a t a P a c k ag e
Queue
MFG Pro. Cont. MFG Planning
Engineering Materials Lab
P re p a re 42 3 5 / 10
Awaits
QA
Y ES
up In Trade
Tech Library
E n g in ee rin g R e s e a rc h e s t h e P a rt
I s t h e P a rt C SI
E ng in e erin g P ro v ide s D is p o s it io n
Planner Pick
MFG Pro. Cont. MFG Planning
E n g in e e ring R e c eiv e s 3R R e qu e s t
MFG Pro. Cont. MFG Planning
Y ES
Y
NO
Await M aterial
Is C S I D e t e rm in a t io n in C M P ro
M a t e r ia l A v a ila b l e G G / GF?
Replenishment
F I S C C h e c k s f or C S I D e t e r m in a t ion in C M P r o D a t a b as e
L o g in b o o k
Await
Y ES
F I S C rec e iv e s W o r k O rd e r / B O M f r o m P la n n in g
M aterial
L o c al M f g D ec is io n
Y es MFG
F I S C R e s e a rc h e s P r o c ur e m e nt M et h o d
L o c al M f g D e c is io n
NO R e w o r k L o o p i f M a t e r ia l
N O (I nc . T ec h D at a ) NO
Batch
F I S C A c c e pt s M a t e r ial R e q ue s t
P re p are a 3R for E n g in ee rin g
4.9 Green Belt Ken LaVere Ct Reduction from xx days to 2 days Savings in Prod Overhead Man Hrs
< P ro c e s s N a m e >
R e w o r k L o o p i f M a t e ri a l L a b t e s t f a il u re
Receipt
NO
N
Aircraft Line
NO
NO
< P ro c e s s N a m e >
< P ro c e s s N a m e >
Aircraft Line
C o m m e rc ial Mf g
10.0
N SN / C o m m e r c ial Mf g
E & E S e nd s M a t er ia l R eq u e s t ( t e ar d o wn a n d d is p o s it io n ) t o F I S C in M R P I I
ENG Chemical and Strength Test for Mfg Materials
Aircraft Line
< P ro c e s s N a m e >
Aircraft Line
E & E R e c e iv es A p p r o v a l f r om S u p er v is o r
FISC
Aircraft Line
4.3 Green Belt Dick Hogan Ct Reduction from 17 days to 3 days Savings in Prod Overhead Man hrs Negotiated
Delivery to
FISC
6.8 Green Belt Rebecca Buchta CT Reduction from XX days to
< P ro c e s s N a m e >
E & E I de n t if ies N e e d f or A ir c r a f t Pa rt
MFG Plan ENG Approval
Tech Library
NEED AIRCRAFT PART
Tech Data Package Assembly
Aircraft Line
Eng/Log Support
ENG CSI Determination
Procurement of Materials/Tools
Forwarding and Accumulation
NAVSUP GB LCDR Ken Flaherty reduction from 8 to 4 days with Savings in Transaction fees
MFG 6.0 GB John Rubio CT reduction from 18 days to 4 days with Savings in Man Hrs
MFG PLAN TO ARTISAN
6.0 Process
Pilot Complete – Replication on F-18, Implementation on all E-2/C-2
MFG Planning Before and After Lean/Six Sigma ProcessCapabilityof 13-0fromIDtoArtisan
ProcessCapabilityof FromE&EtoArtisan
Calculations BasedonLognormal DistributionModel
Calculations BasedonLoglogistic DistributionModel
USL
USL
Process Data LSL * Target * USL 15 Sample Mean 39.1158 Sample N 777 Location 3.37588 Scale 0.754739
Overall Capability Z.Bench -0.88 Z.LSL * Z.USL -0.17 Ppk -0.06 Exp. Overall Performance PPM USL 811880 PPM Total 811880
Observed Performance PPM USL 801802 PPM Total 801802
0
50
100
150
200
250
300
Before Lean/Six Sigma – Process was 20% capable of Meeting 15 Day TAT
Process Data LSL Target USL Sample Mean Sample N Location Scale
Overall Capability Z.Bench 1.20 Z.LSL * Z.USL 0.29 Ppk 0.10
* * 15.00000 8.47222 36 1.90643 0.39403
Exp. Overall Performance PPM USL 115637 PPM Total 115637
Observed Performance PPM USL 194444 PPM Total 194444
0.0
7.5
15.0
22.5
30.0
37.5
After Lean/Six Sigma – Process Is 80% Capable of meeting 15 Day TAT
FY-06 AIRSpeed Yield Summary Labor Hours
Flightline Inventory/Cycle Time
• F-18 PMI-1 • H-1
Down 20% - $1.9M Execution
At or Above Entitlement
Down 10% 1.8M FY-07 WLS Reductions
WIP Reduction 8 AH-1W ($8M Inv)
• E-2/C-2
C-2 SLEP APN-5 Reductions 2K Hours Re-wire, 1.5K Hours SLEP
C-2 @ F/L (Adding Re-wire for 30 Days C/T) E-2 Gap Driven by Mods
At WLS
Was over 300 days, delivered last aircraft at 218 days, driving towards 175 days over next three aircraft w/Current Staffing
Aircraft Lines
• CH-53 Manufacturing
50% Reduction in Sheet Metal Cycle Time
Components $10.4M Repair Interdiction Savings
Process Axis Product Axis
FISC Lean 6 Sigma
F/A-18 PMI-1/CBR+ Lean Effort
E2/C2 PMI-2/PMI-3 SLEP Lean Effort
F/A-18 Manufacturing BB Project
E2/C2 Manufacturing BB Project
CH-53, H-1, H-60 Lean Effort BOM Improvement Projects
Components Lean Effort Manufacturing Lean Effort
= Lean/Six Sigma Project = Product Line Lean Effort
Business Unit Material Ordering Projects
Connect the dots in the value chain!!
Focus for Innovation
• Weak Signal Management • Industrial Information Technologies • Accelerated Supply Chain • Coherent Human Capital • Relevant Technology
Fleet Readiness Center Southwest FRCSW
CNAF/COMFRC
Strategically Positioned to Support our Navy and USMC Warfighter's
A National asset, providing flexible, responsive, integrated maintenance solutions and cost-wise readiness to our nation’s Warfighters
