C130 Mission Briefing

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C-130 Mission Briefing Requirements Symposium
2007
Lt Col Francis Geiser Deputy Director, 330th
Aircraft Sustainment Group [phone]
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330th Aircraft Sustainment Group
330 AIRCRAFT SUSTAINMENT WINGCOL TERENCE
SZANTO Commander
330 ACSG/EN GROUP ENGINEERMR RANDY IVEY
330 AIRCRAFT SUSTAINMENT GPMS. MARIAN FRALEY
Director LT COL FRANCIS GEISER Deputy
561 AIRCRAFT SUSTAINMENT SQ561 ACSS/CLMR DUSTY
DODD
560 AIRCRAFT SUSTAINMENT SQ 560 ACSS/CCLT COL
EDGAR VAUGHAN
AIRCRAFT FLT560 ACSS/GFLA MR RICH HORNICK
FMS TECHNICAL COORDINATION FLT561
ACSS//GFIAMR SHERMAN RANKIN
PROGRAM FLT560 ACSS/GFLB MR BROCK THOMAS
FMS PROGRAM FLT561 ACSS/GFIB MS JOYE MARSHALL
C-130J FLT560 ACSS/GFLC MR WAYNE AYER
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What We Do

• Fleet Modernization
• C-130E/H Upgrade Modifications
• Center Wing Box Replacement
• Avionics Modernization Program
• Fleet Management
• C-130E/H PDM, UDLM, Sustaining Engineering
• C-130J Term Sustainment
• Acquisition Support
• Foreign Military Sales
• C-130J Production Block Upgrades

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Tactical Airlift Locations
QUONSET C-130E C-130J
Overseas Bases
DATA SOURCE C-130 PM/CCAT


DATA SOURCE C-130 PM/CCAT




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C-130 Customer Base
Total C-130 Active Aircraft 1418
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C-130 Fleet Demographics
Total USAF Active Aircraft 637
MISSION
MAJCOM
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Aircraft AvailabilityImprovement Plan
AAIP O-6 Level Integration Steering Group
Co-Chairs ACSG and AMC/A4/A5
TNMCS IPT
Depot IPT
TNMCM IPT
Availability Improvement Management Team (AIM)

Depot Possessed
TNMCM
TNMCS
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C-130 Aircraft Availability Improvement
Initiatives
Continue Structural System Improvement Develop
Turboprop Reliability Improvement Lean Field
Level Inspections Shift A/C Acceptance and/or
ISO to Depot Implement Interactive Tech Manual
(IETM) Install Carbon Fiber Brakes Regionalize
ISOs Expand Real-time Field Tech
Support Implement Condition Based Maintenance
(CBM)
TNMCM 18 A/C
eLog21 129 A/C Improve C-130 AA to
Warfighter AAIP 32 A/C
TNMCS 4 A/C
Improve SOS/SOR Accountability - Use Supplier
Scorecard (SOS/SOR/OEM) - Use Customer Support
Tools - Minimize Single-Hit MICAPs Adopt
Proactive Demand Leveling (PDL) Adopt Customer
Oriented Leveling Technique COLT Use Integrity
Programs Like ASIP, FSIP, and MECSIP Minimize
DLA AAC D
AFMC Possessed 10 A/C
Lean PDM Through Critical Chain Project
Management Lean UDLM to Reduce Input Process
Time Lean and Standardize Acceptance
Checklists/Inspection Increase Scheduling
Efficiencies through DMRR-103 Process
Improvements and C-130 Roadmap End to End Value
Stream Mapping Completion of Future Mods (AMP
CWB) Improve Depot Quality
LEGEND Do-Its Events Projects Studies
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Maintenance IPT CarbonFiber Brake

• Description PROJECT
• Purpose Replace current steel brakes and wheel
  with carbon fiber brake assemblies and improved
  wheels on C-130 E/H/J
• Issues
• Lead Ms. Sandra Fitzgerald, 515 CBSS

• Program approved for Improved Item Replacement
  Program (IIRP) Funding
• Draft Request For Proposals Released
• Industry Day Aug 08
• Design/Lab Qualification FY 08 - 09
• Flight Test FY 09 10
• Production/Retrofit Beginning FY 10 11
• Via TCTO Expect 2 - 3 Yrs For Completion

• Stakeholders MAJCOMs, 515 CBSS, Depot, 330
  ACSG
• Goals Reduce Brake and wheel-related TNMCM
  time, system life cycle costs, and spares rqmts.
• Metrics TNMCM, Sustainment costs, inventory
• Additional Benefits Provides 1000 increase
  landings (2,000 vs 233) with six-fold increase in
  wheel fatigue life (25,000 vs 4,000 miles).
  Reduces spares requirements, improves mobility
  footprint and logistics /sustainment costs

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Supply IPT - Kitting

• Description PROJECT
• Purpose Establish Kits for Standard Work.
  Identify kitting opportunities in the C130
  community. Cross cutting issue that may impact
  TNMCS and TNMCM.
• Issues Requires much coordination and lead time
  for kit establishment
• Lead(s) Wanda Fountain, 330 ACSG/GFWA, Matthew
  Morrison MAFLSC/LGWAC, Jim Eubanks, 580 ACSG/GFWA

Status

• Stakeholders AIM team, Supply IPT, Maintenance
  IPT
• Goals Decrease time to perform standard
  maintenance actions. MX will submit one parts
  request that contains all requirements per type
  work to be performed thus decreasing parts
  research time, wait time, and multiple visits to
  bench stock bins. Increase aircraft availability
  by 1 aircraft
• Metrics NMCM by applicable WUC
• Additional Benefits Bundle parts, increase
  supply supportability

• 3 kits in work at DLA
• C130 Reduction Gearbox Assembly
• Kit contains problem parts
• DLA working with customer to resolve
• C130 Engine ISO Kit 5 sub kits
• Material for 2 kits sent to kit build org
• PR created for 2 kits
• 1 kit recently added and approved
• C130 ISO Kit - contains 5 sub kits
• Assets should be available by Aug 07
• - Estimated NSN establishment Sep 07

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Depot IPT - Critical ChainProject Management

• Description PROJECT
• Purpose A change from critical path process to a
  critical chain process within the C-130
  Programmed Depot Maintenance (PDM) Line
• Issues Culture change associated with critical
  change as opposed to critical path
• Lead Mr. Don Chew, 560 MXAB/CD

• Stakeholders Depot, 330 ACSG/Maintenance, WSSCM
  
• Goals Reduction of 30 in average flow days,
  thus reducing Depot Possessed A/C to 16
• Metrics PDM flow days, depot possessed aircraft
• Additional Benefits Schedule efficiencies and
  better induction decisions due to more accurate
  PDM conclusion dates

Status - Instituted on C-130 Nov 15, 2005 - Avg
flow days (all models) decreased from 172 in FY05
to 154 in FY06 while repair hours have increased
by 17 - WIP reduction goals for Q3 FY07 set at
16, reducing 23 from 21 in FY06 - Current focus
is on increasing velocity of maintenance (daily
production process, WSSC forward planning, and
issue resolution)

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PDM UDLM Workload
PDM WR RAFB OO HAFB MA Malaysia ST
Singapore Technology NZ Air New
Zealand UDLM Organic Depots Contract
Facilities Requests for Engineers
FY06 FY07
6,500 7,500
As of 25-Sept 07
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C-130 Overflow Requirement
Note UDLM projection based on historical values
and is subject to change Capacity based upon
space allocated to C-130 workload. Use of
capacity allocated to other weapon systems is not
taken into account in this chart. Projected
workload based on long-range budgeted workload,
however funding is not guaranteed.
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C-130 Overflow Contract

• Provides follow-on effort for overflow work
• Scope UDLM, PDM (Potential), and mod
  installations
• Industry Day Held 31 July2 Aug 07
• Projected Contract award Sep 2008

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Program Flight

• C-130 E/H Mods
• Center Wing Replacement
• AMP
• On the Horizon

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C-130E/H Modifications
ALR-69(V) RWR (2/302) FY16
AAR-47 Sensor Cant (84/397) FY09
ESU (125/162) FY08
CWR (1/369) FY49
I/R UON (2/331) FY10
LAIRCM (71/150) FY10
1553 Data Bus (354/416) FY08
AAR-47 Sensor Upgrade (44/301) FY11
Rainbow Fitting Redesign (N/A) FY09
UON C-130 SATCOM (0/8) FY08
CBM (0) FY12
AAR-47 Smart Cable (345/397) FY11
YMS (0/233) FY10
NVIS Windscreen (0/35) FY10
AMP (2/434) FY20
ANCS (0/14) FY09
Multi-Type 1 Indicator (11/16) FY08
Synchrophaser (46/494) FY08
MAFFS II (0/8) FY09
APN-241 (205/295) FY10
Gen Disconnect (95/14) FY08
MASS (0/6) FY08
Autopilot/GCAS (606/610) FY10
ETCAS (498/535) FY10
a/o 18 October 2007
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Center Wing Challenges

• Aging aircraft structural problems
• Fatigue cracking
• Center Wing
• Spar Caps
• Routine inspections in the field
• Bonded Repair Optimization
• Center Wing Options
• Inspect / Repair
• Replace
• Retire

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CWR Schedule
Phase 2
Phase 3
Sole Source 122 CWB Kits
MC-130H, HC-130P/N, C-130H1/2/3, AC-130U, and
EC-130H
Mar 07
FY16
Competition 234 CWB Kits
HC-130P, HC130-N, and C-130H2/3
FY10
FY49
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C-130 AMP

• Description
• AMP consolidates and installs mandated DoD
  Nav/Safety, CNS/ATM Broad Area Review
  requirements
• Standardized cockpit and avionics
• USAF AMC (Combat Delivery)
• Current certified quantity 222 (3 RDTE 219
• production) 3 Mission Design Series (MDS)
  H2, H2.5 H3

• Executive Schedule

• Nunn-McCurdy Certification Jun 07
• SAF SAE Acq Strategy Panel completed Sep 07
• OSD OIPT completed Oct 07
• Program re-plan ongoing
• Contract award Dec 07
• Operational Assessment early 08
• Milestone C decision in Jun 08
• LRIP award in Jul 08
• Installs divide Contractor, WR-ALC, OO-ALC

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On the Horizon

• C-130 LAIRCM Integration
• AAR-47 MWS Sensors
• C-130 Paratroop Door Threat Scanning Seat
• SAFIRE Look-Out Capability
• C-130 Jump Platform
• Electronic Flight Indicator
• C-130 Loadmaster Crash-worthy Seat
• JPADS-MP (Mission Planning System)
• C-130 Wheel and Brake System Improvement
• Auxiliary Hydraulic Pump

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Aircraft Flight

• Customer and Supplier Relationships
• C-130 Depot Level Maintenance
• Programmed Depot Level Maintenance (PDM)
• Unscheduled Depot Level Maintenance (UDLM)
• Contract Field Teams (CFT)
• Depot Field Teams (DFT)
• Organic and Contractor Support
• Technical Orders

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Conditioned Based Maintenance Plus (CBM)

• DESCRIPTION
• DOD 5000.2, Paragraph 5.2.1.2, AFI 63-107
• Condition-Based Maintenance (CBM) can be defined
  as a set of maintenance processes and
  capabilities derived from real-time assessment of
  weapon system condition obtained from embedded
  sensors and/or external test and measurements
  using portable equipment. The goal of CBM is to
  perform maintenance only upon evidence of need.

CBM

• Contract awarded 8 Nov 2006 MERC
• Business Case Analysis (BCA) delivered
• Three-pronged Approach
• RCM
• PDM Algorithm Development
• Instrumentation Sensor Research
• 2012 POM consideration

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JCA
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C-130J Sustainment Flight
The C-130J Integrated Sustainment Office
Providing the Long Term Sustainment for the USAF
C-130J

• 61 Aircraft Delivered thru 25 Sept 2007
• 26 Additional Aircraft to be Delivered by FY10
• 3 Additional GWOT Aircraft Added

Partnership with Industry
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Partnering Opportunities

• Expand to Include Multi-National Users
• All C-130J Users are Potential Partners Under LTS
  Contract
• Depot Source of Repair
• Propulsion Initiatives
• Potential Transition of Engine Management to OC
  ALC FY11
• AE 2100 Engine Depot Activation
• R-391 Propeller Management to Remain at WR-ALC
• Reliability and Maintainability Solution
  Improvements
• Focus on 20 That Cause 80 of the Problems
• AFSO21 Continuous Improvement Program
• Effective Usage of Manpower and Funding
• Develop and Field Interactive Electronic
  Technical Manuals (IETMs)

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Progressive Maintenance Program

• Transition from ISO Based to Progressive Concept
• Commercial-Like Letter-Check
• Field Units Retain A and B Checks
• Minor Lubrications, Visual and Zonal Inspections
• Interval Same As Current HSC 30 Weeks
• HVIP Regional Facility Performs C Checks
• Major In-Depth Lubes / Inspections / Ops Checks
• Interval Doubles From ISO 120 Vice 60 weeks

Two Years, 4 Months Between C Checks
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Who We Support

• Foreign Military Sales
• 641 aircraft
• 8 MDS
• 41 countries
• Technical Coordination Group
• 270 aircraft
• 5 MDS
• 24 countries
• What We Do
• Acquisition
• Sustainment
• Modernization

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Opportunities

• Wings Engines
• Avionics

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FMS - Wings, Engines, Props

• USAF C-130E Retirements (planned)
• FY07 51 C-130Es
• 23 of 51 reserved for USAF Outer Wings
• 28 of 51 A/C potential for FMS use Engines
• Engines - approximately 50 require overhaul
• Propeller Assemblies - approximately 25 require
  overhaul

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FMS - Avionics

• Potential Avionics Upgrade/Modifications
• Primary driver is aging Self Contained Navigation
  System (SCNS)
• Becoming unsustainable
• Not CNS/ATM compliant
• No growth potential
• USAF AMP replaces SCNS
• Operational Requirements
• 8.33 Khz VHF Channel Spacing (requires new VHF
  radios)
• FM Immunity for Instrument Landing System (ILS)
• Basic Area Navigation (BRNAV) with RNP-5 (Req Nav
  Performance)
• Terrain Collision Avoidance System (TCAS)
• Precision Area Navigation (PRNAV) with RNP-1,
  2010
• TCAS Mode S Mode 5, 2008
• Automatic Dependant Surveillance (ADS-B), 2008
• Avionics Upgrade Cost Dependant on
  Requirements
• NRE 5M - 20M, Recurring Cost per A/C 3M - 8M

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Summary

• Never a dull day in Combat Delivery
• Its going to get harder before it gets easier!

People First Mission Always!
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C-130 Center Wing Issues

• USAF - Three-Pronged Risk Management Approach
• Impose Flight Restrictions and Grounding
• Flight Restrictions begin at 38K EBH
• Aircraft Grounded at 45K EBH
• Inspection and Repair TCTO to Allow Unrestricted
  Operation
• USAF TCTO 1908 Inspects Entire CW Lower Surface
• Successful Repair May Lift Restrictions Until 45K
  EBH
• Center Wing Replacement of Selected Aircraft
• NOTE C-130E models not included in USAF Center
  Wing Replacement (CWR) Program
• Drives Development (NRE) Costs for FMS

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USAF Planned C-130E Retirements

• 51 FY07 C-130E Retirements (Inviolate Storage)
• 23 of 51 A/C reserved for USAF Outer Wings
• 28 of 51 A/C potential for FMS use
• FY07 USAF C-130E Retirements Primary Cause
  Center
• Wing Structural Health
• 34 Aircraft gt 45K EBH (Grounded)
• 10 Aircraft gt 40K EBH (Restricted)
• 7 Aircraft gt 38K EBH (Restricted)
• Tail Numbers for FY08 beyond - not yet
  identified