FSIP LC Quarterly Brief, 12 Dec 01

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CORAL REACH FSIP
The C/KC-135 Aging Aircraft Program
FSIP PROGRAM OVERVIEW
3 - 6 NOVEMBER 2003
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OBJECTIVES

• Introduce CORAL REACH
• Understand the FSIP Process
• Understand Identifying and Mitigating Findings

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AGENDA

• CORAL REACH
• FSIP GENESIS
• FSIP PURPOSE
• FSIP PROCESS
• FSIP ORGANIZATION
• PROJECT PLANNING STATUS
• FINDINGS
• SUMMARY

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CORAL REACH
PROGRAM DESCRIPTION

• The Coral Reach IPT Purpose is to manage all
  aging aircraft activities under one umbrella
• The Goal of the Coral Reach IPT is to identify
  actions required to ensure a logical,
  comprehensive, and proactive aging aircraft
  program that will sustain the KC-135 until
  retirement
• Three Objectives - Program Metrics - were
  established for Coral Reach
• Maintain an acceptable Margin of Safety
• Minimize the Cost of Ownership
• Improve Aircraft Availability

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CORAL REACH
PROGRAM DESCRIPTION (cont.)

• Aircraft Strategic Master Plan - ASMP
• Strategic Guide for Investment, Repair, and
  Modification
• Detailed Action Plans Responsive to the Air
  Mobility Master Plan
• Aging Aircraft Issues - Program Metrics
• Structural Margin of Safety
• Systems Margin of Safety
• Aircraft Availability
• Cost of Ownership/Cost per flying hour
• Drivers noted from each Program Metric
• Lists combined, prioritized coordinated
• Engineering Assignments (EA) identified and
  work begins

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FSIP - GENESIS

• Fuel Pump Accidents
• KC-135, C-141
• AMC/CC - Whats my next fuel pump

• Initial Activities
• HQ AMC
• SAF/AQ Involvement
• POM initiative intended
• Airplane generic - a goal
• Address safety and durability objectives
• Interest waned support did not materialize
• -135 Board of Directors validated need for -135
  FSIP
• OC-ALC/LC moved to develop a generic FSIP process

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FSIP - GENESIS

• SPD Established Coral Reach Direction
• Be Proactive
• Pursued FSIP as -135 specific effort
• Report findings through Aircraft Strategic
  Master Plan (ASMP)
• Boeing placed on EA to develop FSIP process
• Use Logic of Other Integrity Programs
• Ensure safety of flight - aircrew and aircraft
• Ensure suitability and effectiveness of aircraft
  functional systems
• Boeing delivered FSIP model for validation and
  verification in Dec 1995
• Focus on aging aspects of Functional Systems
• Reach beyond original intended period of system
  usage
• Supplement existing programs - ASIP, ENSIP, RM
  and RCM

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FSIP GENESIS

• Purpose of FSIP is to PROACTIVELY
• Ensure Operational
• Safety Suitability and
• Effectiveness of Aircraft
• Functional Systems

• Protect the Aircrew and Aircraft
• Ensure the system operates in its environment and
  performs its intended missions

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FSIP - THE PROCESS
MODEL OBJECTIVES

• Identify Reduced Safety Margins
• Identify Durability Issues
• Systematic review of all systems/subsystems/functi
  ons.
• Institute systems approach to safety,
  durability and economic life
• Develop a multi-task process for decision
  milestones
• Reduce the at risk nature of an aging fleet
  priorities
• Enhance aircraft availability
• Support cost containment
• Develop and maintain a Functional Systems Health
  Care Plan

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FSIP - THE PROCESS
FSIP performs a system-by-system review.
A disciplined approach using a multi-task
checklist process
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FSIP - THE PROCESS MULTI-TASK, DISCIPLINED
CHECKLISTS
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FSIP - THE PROCESS MULTI-TASK, DISCIPLINED
CHECKLISTS

• TASK A
• PROJECT INITIATION
• ASSESS/ESTABLISH SYSTEM BASELINE
• ASSESS SYSTEM PERFORMANCE AND USAGE HISTORY
• ASSESS AVAILABLE SAFETY DATA
• ASSESS REQUIREMENTS VS PERFORMANCE
• CONDUCT INITIAL RECORDS AND DATA REVIEW
• DEVELOP AND EXECUTE A USER CONTACT PLAN
• CONSOLIDATE AND WRITE UP FINDINGS

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FSIP - THE PROCESS MULTI-TASK, DISCIPLINED
CHECKLISTS

• TASK B
• CONDUCT CRITICAL SYSTEM SAFETY ANALYSIS
• CONDUCT DETAILED RECORDS/DATA REVIEW
• ASSESS CHANGES SINCE ORIGINAL DESIGN
• GATHER USER/PDM/OH FEEDBACK
• CONDUCT DETAILED SYSTEM/COMPONENT ANALYSIS
• ASSESS SUPPORTABILITY AND AVAILABILITY
• CONSOLIDATE AND WRITE UP FINDINGS

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FSIP - THE PROCESS MULTI-TASK, DISCIPLINED
CHECKLISTS

• TASK C
• EVALUATE CANDIDATE SOLUTION (s)
• DEVELOP SOLUTION
• FINALIZE SOLUTION
• DEVELOP ROM COST AND SCHEDULE

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FSIP - THE PROCESS MULTI-TASK, DISCIPLINED
CHECKLISTS

• TASK D
• FORM IMPLEMENTATION AND PLANNING IPT
• SOLUTION DESIGN
• SOLUTION IMPLEMENTATION

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FSIP - THE PROCESS MULTI-TASK, DISCIPLINED
CHECKLISTS

• TASK E
• SOLUTION PERFORMANCE EVALUATION
• SAFETY AND DURABILITY WATCH
• DATA COLLECTION
• FEEDBACK
• LONG TERM HEALTH MONITORING (LTHMS)

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FSIP - The Process - Task E

• Task E is System Health Monitoring
• Monitor performance of implemented Task D
  solutions (Did it fix the problem)
• Continued safety and durability watch
• Items of concern
• Periodic re-look of Task A/B results
• Data collection and analysis
• Continual feedback
• Sustains vigilant proactive search
• "It is expected that Air Force personnel will
  periodically re-evaluate the SSI's and intervals
  with the benefit of accumulated data From
  D3-11100-5, MSG-II procedures manual
• Long Term Health Monitoring System - LTHMS

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FSIP - The Process - Task E

• LTHMS
• Automated data mining
• A means to monitor all GO/DO maintenance data
  systems
• Provide user with reports, email, cues, etc.
  based on
• Passing a threshold of maintenance activity
• Parts demand/availability
• MTB? (REMIS, GO50, etc) by SN/PN
• Flexible query and conversational interface
  capability

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PROJECT PLANNING GO-50 HOWS (Health of the Weapon
System) REPORT, PLUS .....
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FSIP STATUS - Current Task A/B Priority
TIGER TEAM PRIORITIZATION MEETINGS HELD April
96 May 97 Nov 98 Dec 99 Oct 01 Dec 02

• Sustainment Phase (TASK E) commencement
  initiated

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FSIP STATUS
FSIP Project Planning - Task A B - to date

• Attempting to accelerate initial Task A/B effort
  to COB 05

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97
98
99
00
01
02
03
04
05
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Task Name
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
Landing
Gear
Fuel
Systems
Flight
Controls
Autopilot
Hydraulics/Pneudraulics
Air
Cond,
Pressure,

Ice
Control
Electrical
Components
Instruments,
Radar
Nav,
Interphone
NOTIONAL
Engine(Non-ENSIP),
Turbojet/Turbofan
Power
Plant,
Aux
Power
Plant
NOTIONAL
Cockpit

Fuselage
Compartment,
Airframe(Non-ASIP)
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FSIP FINDINGS

• FINDINGS are the primary Task A B product to
• Document findings
• Track progress
• Record closure
• Mitigation takes many forms

From Tasks A B SF- SAFETY FINDINGS DF -
DURABILITY FINDINGS MF - MISC. FINDINGS

• Three categories documented and tracked
• SFs - items having safety impact
• DFs - items not of an immediate safety impact
• MFs - items not related to safety or durability

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FSIP FINDINGS

• Findings are prioritized by Hazard Risk
  Assessments per MIL-STD-882D

Overall priority
1
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FSIP FINDINGS
HIGHLIGHTS

• Tech Data
• Improper/outdated overhaul manuals
• Update ISO inspections criteria
• No wear and rework limits
• Tech data needs clarification
• Unincorporated Improvements
• Airworthiness Directives
• Service Bulletins

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FSIP FINDINGS
HIGHLIGHTS

• Maintenance
• Specification/requirements changes
• No, or improper lubrication
• Reevaluate time replacement items
• Identify one-time replacement items
• Component Overhaul
• Trends not visible at the systems level
• Major parts now wearing beyond tolerances
• Piece part availability
• Insufficient communication with end user
• Vanishing Vendors

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SUMMARY

• Aging Systems need attention
• FSIP is currently in the Safety Phase
• Aging/Durability Sustainment Phase follows
• Coral Reach/FSIP Program
• Program Manager - Diane Kirts, OC-ALC/LCM
• IPT Co-Chair Lt Eric Reagan, OC-ALC/LCRM
• IPT Co-Chair - Ralph Ward, Boeing
• FSIPs goals are to PROACTIVELY
• Ensure Operational Safety,
• Suitability, and Effectiveness

• QUESTIONS

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BACK UP SLIDES
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SAMPLE TASK CHECKLIST
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SAMPLE TASK CHECKLIST
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SAMPLE TASK CHECKLIST
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SAMPLE TASK CHECKLIST
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SAMPLE TASK CHECKLIST
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SAMPLE TASK CHECKLIST
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