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Distribution Statement A: Approved for public release; distribution is unlimited
12/3/2012
Birthplace, Home & Future of Aerospace
F-22 System Program Office
F-22 ASIP Roadshow:
Benefits on overall
ASIP Execution
DEC 2012
1
George Crosthwaite & John McClure
AFLCMC/WWUE
Distribution Statement A: Approved for public release; distribution is unlimited
12/3/2012
Birthplace, Home & Future of Aerospace
Background
• Started in 2008 due to field communication
issues, and to track down reasons for missing
data
• Currently there are 7 AFBs operating the F-22
– Scattered among several MAJCOMs: ACC,
PACAF, AETC, AFFTC and ANG
– Visit 1 per quarter
2
Distribution Statement A: Approved for public release; distribution is unlimited
12/3/2012
Birthplace, Home & Future of Aerospace
Format
• Brief OG and MXG commanders on usage and
overarching topics
• Meet with AMUs and FSs to discuss issues on
the unit level
• Meet with the LO shop to go over any coatings
issues and stripping techniques
• Meet with the NDI shop to discover any
complications with tools or procedures
• Meet with ACC representatives to cover not
only base issues but the fleet as a whole* *Only occurs at ACC HQ base
3
Distribution Statement A: Approved for public release; distribution is unlimited
12/3/2012
Birthplace, Home & Future of Aerospace
Purpose
• Present current usage and discuss ways to
alleviate severity
• Make sure commanders are knowledgeable
about who we are and what we do
– Rotate ~ every 2 years
• Provide communication channels for any
future problems
• Alert field of any upcoming/ongoing issues,
find out any issues the field is experiencing
unbeknownst to the SPO
4
Distribution Statement A: Approved for public release; distribution is unlimited
12/3/2012
Birthplace, Home & Future of Aerospace
Data
• Achieving 90+%
fleet average on
data download rates
– Back in 2008 the
worst jet download
rate was 65%
– In just 4 years that
jet is still the worst
but now over 80%
5
50.00
55.00
60.00
65.00
70.00
75.00
80.00
85.00
90.00
95.00
100.00
Perc
en
t
Ho
urs
Aircraft
Sortie Time
Sortie Time Received
Distribution Statement A: Approved for public release; distribution is unlimited
12/3/2012
Birthplace, Home & Future of Aerospace
Integrity Data Collection Trend
6
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
Inte
gri
ty D
ata
Ca
pu
tre
Ra
te
IAT Report Number
Data Capture Rate
Required Capture Rate
Ju
ly 2
00
4
Ju
ly 2
008
De
c 2
00
6
De
c 2
00
9
Se
p 2
01
2
ASIP Road
Shows Begin
Distribution Statement A: Approved for public release; distribution is unlimited
12/3/2012
Birthplace, Home & Future of Aerospace
Usage
7
Control Point CPH-0014A
FS610 Bulkhead
LHS Lower Wing Attach Lug
• Represents fatigue critical structure
• Correlates well to wing loads and
NzW (primary fatigue driver)
Distribution Statement A: Approved for public release; distribution is unlimited
12/3/2012
Birthplace, Home & Future of Aerospace
Usage
8
0
200
400
600
800
1000
1200
1400
0 200 400 600 800 1000 1200 1400
Eq
uiv
ale
nt
Fli
gh
t H
ou
rs
Actual Flight Hours
TrainingNon-…
More
Less
Severe
Distribution Statement A: Approved for public release; distribution is unlimited
12/3/2012
Birthplace, Home & Future of Aerospace
Usage Trends
• Compare quarterly and current year trends
9
Distribution Statement A: Approved for public release; distribution is unlimited
12/3/2012
Birthplace, Home & Future of Aerospace
Engine Usage
• Not affiliated with ASIP
• Organized visits already in place
• Engine SPO can
relay the timeline
for major engine
maintenance
based on current
usage
10
Increased
Usage
Distribution Statement A: Approved for public release; distribution is unlimited
12/3/2012
Birthplace, Home & Future of Aerospace
Rotation
• Aircraft Fatigue
Severity Ranking
– Semi-annual
– Base Specific
• Allows Rotation of
Severe Missions
11
EFH AFHSeverity
RatioAFH
Severity
RatioAFH
Severity
Ratio
933 735 1.27 62 1.56 50 3.50 5366
1011 829 1.22 52 0.87 10 0.90 5546
746 627 1.19 48 1.50 56 0.74 5977
880 765 1.15 55 1.64 45 0.72 6077
1258 1233 1.02 37 1.22 46 0.70 6585
1023 974 1.05 45 1.12 71 1.25 6596
856 823 1.04 47 1.12 46 0.76 6836
1142 1142 1.00 32 1.02 64 0.71 6858
1028 1018 1.01 56 0.82 33 0.54 6893
1172 1203 0.97 89 0.97 34 0.74 7036
935 935 1.00 47 0.69 22 0.84 7065
785 785 1.00 41 1.04 56 1.03 7215
729 729 1.00 42 0.93 55 0.88 7271
488 488 1.00 25 0.64 33 1.21 7512
958 1038 0.92 41 1.21 48 0.37 7709
724 772 0.94 56 0.76 40 0.37 7810
646 691 0.93 52 0.89 39 1.17 7917
486 523 0.93 48 0.66 49 0.56 8122
652 732 0.89 38 0.63 45 0.51 8325
628 740 0.85 54 0.80 39 1.00 8803
713 937 0.76 63 1.18 53 0.79 9795
435 573 0.76 18 0.68 94 0.77 10093
606 847 0.72 48 0.55 56 0.45 10583
431 604 0.71 53 1.33 47 0.60 10776
510 784 0.65 42 0.89 79 0.43 11779
All Usage through June
20122nd Quarter 2012 1st Quarter 2012
Time
Remaining
to Reach
8000 EFH
at Current
Avg. Rate
Data is for illustration – not actual values
Distribution Statement A: Approved for public release; distribution is unlimited
12/3/2012
Birthplace, Home & Future of Aerospace
Weight Reduction
• Reducing weight by removing stores to
minimum requirements
– 4% life savings, which works out to ~2 more
years of service
• Saving high G maneuvers until later in flight
– Lower fuel weight
12
Distribution Statement A: Approved for public release; distribution is unlimited
12/3/2012
Birthplace, Home & Future of Aerospace
Flight Procedures
• Distance to range restrictions
– Range is close to base, less chance to burn fuel
weight before maneuvering
• G warm-up maneuvers
– Accounts for 10% of all high Nz events
– Recommended performing at higher altitude to
lower wing loads
13
Distribution Statement A: Approved for public release; distribution is unlimited
12/3/2012
Birthplace, Home & Future of Aerospace
Flight Procedures
• Syllabus
– Mission types that are more severe are generally
higher priority
• 11 mission profiles
• Air-to-air training the most severe and highest priority
• Jet availability
– Less Ao the more focus on BFM
– Scheduling with depot inductions and overfly
requests around PMPs
14
Distribution Statement A: Approved for public release; distribution is unlimited
12/3/2012
Birthplace, Home & Future of Aerospace
Tank Carriage
• External fuel tank usage was exceeding the anticipated 10%
– Bases stated their lack of flying with tanks
– Restructured calculation of base usage to exclude Ferry Flights
0%
5%
10%
15%
20%
25%
30%
Fleet Base A Base B Base C Base D Base E Base F
External Tank Usage
Total Tank Usage
TO Base = Landing Base
15
Distribution Statement A: Approved for public release; distribution is unlimited
12/3/2012
Birthplace, Home & Future of Aerospace
Software
• Software update added an ICAW from Over-G
monitoring that was not in previous OFPs
– Field started seeing ICAWs, mostly during demo
flights, and was unaware of the cause
• Further update resulted in a “nuisance” Over-
G Hard Landing ICAW that asserted on startup
– Happened randomly and only on some jets
• Meeting with the field/pilots allowed us to
address the changes in the flight software so
they were aware and could alter their planning
accordingly
16
Distribution Statement A: Approved for public release; distribution is unlimited
12/3/2012
Birthplace, Home & Future of Aerospace
Corrosion
• Ongoing problem with F-22
– Corrosion on the cockpit floor being the most
recent find
– Make sure they are pro-actively looking for and
preventing corrosion
17
Distribution Statement A: Approved for public release; distribution is unlimited
12/3/2012
Birthplace, Home & Future of Aerospace
Coating Issues
• Keeping them on the lookout
18
Distribution Statement A: Approved for public release; distribution is unlimited
12/3/2012
Birthplace, Home & Future of Aerospace
Tooling
• Provide MX community with new tools to demo
shortly after they make the approved list
– EVC Quick Skive Pneumatic Removal Tool
– Pneumatic Pencil Grinder
19
Distribution Statement A: Approved for public release; distribution is unlimited
12/3/2012
Birthplace, Home & Future of Aerospace
NDI
• Ultrasonic inspections were shut off to protect
aircraft safety
– TOD was generically created and for old UT
systems
– Ensure that bases were submitting an AR to get
proper procedures
– AR database can be accessed to match
inspections without submitting new request
• Tasks currently being reworked
– Provide the NDI personnel at the base the
burndown schedule of the rework
20
Distribution Statement A: Approved for public release; distribution is unlimited
12/3/2012
Birthplace, Home & Future of Aerospace
SPO Benefit
• Better physical understanding of the jet
21
Distribution Statement A: Approved for public release; distribution is unlimited
12/3/2012
Birthplace, Home & Future of Aerospace
Summary
• Link Operations with Usage Tracking Data
• Identification of Maintainer Issues
– TO Clarification
– NDI Readiness
– Aircraft Downtime Drivers
– Emerging Repair Issues
– Data Collection Challenges/Procedures
22
Distribution Statement A: Approved for public release; distribution is unlimited
12/3/2012
Birthplace, Home & Future of Aerospace
Conclusions
• Necessary to have direct contact with the field
to keep communication lines open
• Warfighter Understands Impact of Flying
Profiles and Usage Variation Has on Service
Life
• Identify and Mitigate Emerging Maintenance
Issues to Optimize Aircraft Availability
23
Communication is the key to successfully
sustaining any product for the warfighter
Distribution Statement A: Approved for public release; distribution is unlimited
12/3/2012
Birthplace, Home & Future of Aerospace
Acknowledgements
• Lockheed Martin
– Suresh Patel
– Pete Caruso
• Engine SPO
– Gary Burns
– Mike Duffy
• SSO
– Dave Nielson
24
Distribution Statement A: Approved for public release; distribution is unlimited
12/3/2012
Birthplace, Home & Future of Aerospace
Questions?
25