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U.S. Army Aviation & Missile Life Cycle Management Command, G-3 G3-0852 – AMC CBM Summit (Smith) – 07/18/2008
Condition Based Maintenance
Condition Based Maintenance
CBM TeamAMCOM G-3 Office
CBM TeamAMCOM G-3 Office
2U.S. Army Aviation & Missile Life Cycle Management Command, G-3 G3-0852 – AMC CBM Summit (Smith) – 07/18/2008
PREVENTIVEPREVENTIVE INDICATORSINDICATORS DIAGNOSTICSDIAGNOSTICS PROGNOSTICSPROGNOSTICS ONON--CONDITIONCONDITION
Condition Based Maintenance (CBM)
Reactive Maintenance
Time Based Inspection/Overhaul
Digital Source Collector InstallationKnowledge DevelopmentFault DiagnosisRemaining Useful Life CalculationInspection Targeting
Digital Source Collector InstallationKnowledge DevelopmentFault DiagnosisRemaining Useful Life CalculationInspection Targeting
Proactive Maintenance
‘On Condition’Inspection/Overhaul
CBM Program Objectives:
Decrease Maintenance Burden on the Soldier
Increase Platform Availability and Readiness
Enhance Safety
Reduce Operations & Support (O&S) Costs
Key CBM Enablers• Digital Source Collectors• Flight Line Diagnostics• Data Fusion/Analysis Currently Monitored by Vibration
Structural Part, Possible Addition for Monitoring
Main Rotor HubMain Rotor ShaftBifilarsSwashplate ASSYSwashplate GuideSwashplate Bearing**PC Links
M/R SpindleSpherical BearingM/R Spindle Tie RodControl HornM/R Shaft ExtenderM/R Damper
T/R BladeT/R Pitch Change HornPC Links
Main Transmission ModuleAccessory ModuleGenerators (2)Hydraulic Pumps (2)Planetary Carrier
Engine (No. 1 & 2)Driveshafts (2)**Input Modules (2)
Tail Rotor GB**Retention Plates (2)Gearshaft
Viscous Bearings (4)**
M/R BladeM/R Blade Tip CapM/R Blade Expandable PinM/R Blade Cuff
Oil Cooler Axial FanOil Cooler Fan Bearing**APU
T/R Pitch Change ShaftT/R Pitch Change Bearing
Intermediate GB**
T/R Driveshafts (7)**
VibrationAbsorbers (2)
Monitored Master Parts List –
UH-60A/L (56 Parts)
3U.S. Army Aviation & Missile Life Cycle Management Command, G-3 G3-0852 – AMC CBM Summit (Smith) – 07/18/2008
Transmission PipelineSatelliteFed ExMailNIPR
Five CBM Domains
Collection1
Transmission2
ExtractTransfor
m
Load
ExtractTransfor
m
Load
User NeedsUser NeedsUser Needs
Analysis4
SupplyEngineering
Other
SupplyEngineering
Other
Action/Decision5
Maintenance TTPInspection RemediationPart Re-engineeringAirworthiness Release (AWR)Supply Optimization
Overarching Architecture Compliance
Overarching Architecture Compliance
Warehousing3OEM
CBM DWH T&E
PM Flt Mgt Sys
IMMC
LOGSA Academi
a
Improved diagnosticsMaintenance actions based on component health Reduced MMHPlanned maintenance
– Unscheduled vs. Scheduled
Flight Line Decisions
OIF/OEFCONUS
OCONUSOEM
LCMC
OIF/OEFCONUS
OCONUSOEM
LCMC
DSC Data– UH-60– AH-64– CH-47
ULLS A (E)Component Historical data (2410)
Dire
ct F
undi
ng a
nd S
&T
Leve
rage
Dire
ct F
undi
ng a
nd S
&T
Leve
rage
4U.S. Army Aviation & Missile Life Cycle Management Command, G-3 G3-0852 – AMC CBM Summit (Smith) – 07/18/2008
Aviation CBM Process OverviewAviation CBM Process Overview
PrognosticsPrognosticsFlight RegimesFlight Regimes
CI DevelopmentCI Development
Failure AnalysisFailure Analysis
Data WarehouseData Warehouse
At Platform Work StationsAt Platform Work Stations1.1. Process DSC DataProcess DSC Data2.2. Immediate Action InformationImmediate Action Information3.3. Transfer DSC Data and Transfer DSC Data and
Processed Information Processed Information to ULLSto ULLS
Data Loaded Into CBM Data Loaded Into CBM Data WarehouseData WarehouseActionable Actionable
Maintenance Maintenance & Supply & Supply
InformationInformation
Engineering Analysis Engineering Analysis Component Health Component Health and Remaining Life and Remaining Life
Soldiers Perform Immediate Soldiers Perform Immediate Maintenance ActionsMaintenance Actions
55
22
44
BN Production Control Office BN Production Control Office 1.1. Plans Maintenance ActivitiesPlans Maintenance Activities2.2. Collates Unit DataCollates Unit Data3.3. Portal Into STAMISPortal Into STAMIS 33
Key Enablers:Key Enablers:Digital Source CollectorsDigital Source CollectorsFlight Line DiagnosticsFlight Line DiagnosticsPlanned MaintenancePlanned MaintenanceData FusionData FusionEngineering AnalysisEngineering AnalysisActionable InformationActionable Information
11
3322
5544
66
66
Digital Source Collector (DSC)Digital Source Collector (DSC)1. Monitor Component Health 1. Monitor Component Health 2. Downloaded Regularly2. Downloaded Regularly
11
5U.S. Army Aviation & Missile Life Cycle Management Command, G-3 G3-0852 – AMC CBM Summit (Smith) – 07/18/200810/27/2008 2008-08-12 PEO AVN Platforms & CBM+ 5
Six DSC Functions:
Rotor Smoothing
Main and Tail Rotor Vibs and Track
Weight, Pitch Link and Trim Tabs
Exceedance MonitoringOvertemp, Overtorque, etc.
Structural HealthRegime Recognition and Fatigue Life Management
1
2
3
Logbook InterfaceTalk to ULLS-A(E)
5
Drive Train HealthSwashplates, Drive Shafts and Hanger Bearings
Nose, Intermediate and Tail GearboxesMain Transmission and Clutches
APU, APU Clutch and Engines
6
Engine HealthPower Assurance
4
20.5 lbs
UH DSC SolutionAH DSC Solution
MSPU3.4 lbs
MDR10.2 lbs+
6U.S. Army Aviation & Missile Life Cycle Management Command, G-3 G3-0852 – AMC CBM Summit (Smith) – 07/18/2008
Data Transmission Paths
HUMS Server
VSAT
Internet
Manual Transmission
DSC Data
Wired or WirelessMigration
PrognosticsFlight Regimes
CI DevelopmentFailure Analysis
Data Warehouse
MFOQA Server
Top Tier Server
Dashboard
DSC Vendor and PMWebsites
VSAT
Flight VisualizationGCSS-A
Aircraft Notebook
7U.S. Army Aviation & Missile Life Cycle Management Command, G-3 G3-0852 – AMC CBM Summit (Smith) – 07/18/2008
CBM Data Storage
• Vibration Data
• Maintenance Data
• Component History
• Aircraft State Data
Data Analysis Views
Normalize / MergeData Sets
Fusing Data to Assemble the Component life Cycle Puzzle
IVHMS/VM
EP Data
Form 2410
Apache MDR
Serialized Component History
Time
3 Sigma
Vibr
atio
n (IP
S)Pr
obab
ility
of f
ailu
re
GM
Known “good”signature
Failure Initiation
“monitoredanomaly”
We are managing these unscheduledevents into scheduled maintenance
We have a lot of data in this region
8U.S. Army Aviation & Missile Life Cycle Management Command, G-3 G3-0852 – AMC CBM Summit (Smith) – 07/18/2008
Data Management Solution
Time Based Component
Replacement
Time Based Component
Replacement
On Condition Component
Replacement
On Condition Component
Replacement
• Only Changed Data Transmitted to CBM-DW
• Normalize Disparate Data Sources
• Determine CI Thresholds for Data Decisions
• Score Flight Regimes
• Develop Data Management Plan
• Transmit Subset Required for Daily Analysis
• Prioritize Data Movement
• Common Data Source Interface
• Refine CI Thresholds
Continuous CBM+ Process
CBM-DW Correlates
and Fuses Disparate
Data SourcesCBM-DW Correlates
and Fuses Disparate
Data Sources
All Uncorrelated, Disparate Source Data Transmitted to CBM-DW
All Uncorrelated, All Uncorrelated, Disparate Source Data
Disparate Source Data Transmitted to CBMTransmitted to CBM--DWDW
SD4
SD5 SD6 SD7
DRR
Today
SD8
30 Sep 08
201030 Sep 0930 Jun 0931 Mar 0931 Dec 08
9U.S. Army Aviation & Missile Life Cycle Management Command, G-3 G3-0852 – AMC CBM Summit (Smith) – 07/18/2008
Analysis: Turning Data Into Knowledge
Failure Mode 1(ex. Spalling)
Failure Mode 2(ex. Corrosion)
Failure Mode 3(ex. Crack)
Failure Mode 4
Failure Mode 5...
Failure Mode N
Sensors Algorithms Actions
Vibration
Do Nothing
Temp Inspect
Oil Debris Repair
Pressure
Replace
CBM Data AnalysisReliability Centered Maintenance Analysis
1 per Million Flight Hours
Depot Teardown Data
Depot Teardown Data
Analysis Develops A National Level Knowledge Foundation That Analysis Develops A National Level Knowledge Foundation That Gives Actionable Information to Maintainers in the FieldGives Actionable Information to Maintainers in the Field
FMECAFailure Modes,
Effects and Criticality Analysis
FMECAFailure Modes,
Effects and Criticality Analysis
Failure Mode = Spalling
Field TeardownInspection
Vibr
atio
nTime
ReplaceRelevant
NotRelevant
Condition
Indicators
&
Health
Indicators
10U.S. Army Aviation & Missile Life Cycle Management Command, G-3 G3-0852 – AMC CBM Summit (Smith) – 07/18/2008
CCHM
Hellfire II (AGM-114K) Guidance Section
Methodology – Transition Technology That Automatically Measures And Records Captive Carry Time for Each Missile
Participants – AMRDEC (ED, AED, AATD), RTTC, NSWC-Crane, JAMS PMO and OEM Contractor
Payoff – Demonstrate the Capability in Iraq in FY09; Enable the Capability for New Production HELLFIRE (P++)
Captive Carry Exposure Data Will Optimize Reset Maintenance –
Ongoing RCM Study Will Estimate Reliability Improvement and
Reduction in Reset Costs
082808-Marotta-HF CCHM Init-Cap Carry HM
Hellfire Captive Carry Health Monitor (CCHM)
11U.S. Army Aviation & Missile Life Cycle Management Command, G-3 G3-0852 – AMC CBM Summit (Smith) – 07/18/2008
Enhances SafetyAH-64A Tail # 90-00314 Involved in Class-A on 5 Apr 07
– Static Mast Bearings Suspected; DSC Installed– Reviewed Data for Fleet; 90-00314 ‘Warm’, However, Tail #90-00118 ‘Hot’
Tail Rotor SP Tail Rotor SP AccelerometerAccelerometer
314 Is “Warm”
118 Is ”Hot”Data
Inspection Confirms CBM Data
Saved 1 AHSaved 1 AH--64A Potential Class A Accident64A Potential Class A Accident=$16M Aircraft and 2 Pilots=$16M Aircraft and 2 Pilots
118 Tail Rotor Swashplate Tear Down:
Ball & Race Corrosion Damage = Impending Failure
12U.S. Army Aviation & Missile Life Cycle Management Command, G-3 G3-0852 – AMC CBM Summit (Smith) – 07/18/2008
New Apache CBM Benefits
Part Benefit Metric
COSSI APU Clutch
250 Hr TBO Extension (Additional 250 Hr Extension May Be Granted After Teardown of 5 Clutches That Reach New TBO of 1750 Hr Resulting in a 33% Increase)
16% Increase
Tail Gearbox Field Replacement of Leaking Output Seal; Over 50% of Tail Gearboxes
Removed for This Reason
Move an Unscheduled 28 MMH Task to a Scheduled 10 MMH Task and Save $50k Part
Fwd and Aft Hanger Bearings
Defer Replacement of Leaking Bearing Until 250 Hr Inspection Cycle
Move an Unscheduled 5.5 MMH Task to a Scheduled Task
AH-64D CBM Manual and MIM to Be Released Oct 08
USCUSC
RAPTRRAPTR
• 46 Gearboxes Replaced in 10 Months
• $2.8M Annual Savings
13U.S. Army Aviation & Missile Life Cycle Management Command, G-3 G3-0852 – AMC CBM Summit (Smith) – 07/18/2008
Benefits: NMCM% DecreaseImprovement:
5.3%
Pre-Hums Average: 16.2% Post-Hums Average: 10.9%
14U.S. Army Aviation & Missile Life Cycle Management Command, G-3 G3-0852 – AMC CBM Summit (Smith) – 07/18/2008
$15.5M:
33 T700 Engines not Replaced on
UH‐60/AH‐64 for Overspeed/Overtorque
~$30M:
Additional AH‐64/UH‐60 Flight Hours
Available Due to Increased
Readiness/Availability + MTF Hours Saved
~$49M:
Three Class A Accidents Avoided
~$6.6M:
Components not Replaced, Returned to
Service, and Overhaul Savings Due to Early
Failure Detection
~$101.1M
CBM BenefitsCBM Benefits Increased Readiness/Reduced O&S CostsIncreased Readiness/Reduced O&S Costs
2007 AH-64 UH-60 CH-47
# of Aircraft 184 145 30
MMH Avoided 6,652 3,820 923
Hrs Reduction in MTF hours 736 514 42
Impact of Equipping UH-60 A/L Aircraft With DSCs
FY 2007 Impact of Equipping Aircraft With DSCs
Benefits: May 06 – Mar 08
Cost Savings/Avoidance
of ~$101M
(Accidents Avoided, Components
Not Replaced Unnecessarily,
MTF Hours Saved,…
)
*Filtered to remove invalid data. Flight hours not directly comparable.
105 Aircraft Before DSC After DSC ∆
FMC* 75.2% 85.1% 9.9%
MC* 80.1% 86.9% 6.8%
NMCM* 16.2% 10.9% 5.3%
Total Flt Hours* 44,528 67,994
Monthly OPTEMPO* (Hrs/Month/Aircraft) 31.3 53.8 22.5
U.S. Army Aviation & Missile Life Cycle Management Command, G-3 G3-0852 – AMC CBM Summit (Smith) – 07/18/2008
BackupBackup
16U.S. Army Aviation & Missile Life Cycle Management Command, G-3 G3-0852 – AMC CBM Summit (Smith) – 07/18/2008
Data Collection
* Includes Active, Reserve, and National Guard Units
DSC Fielding Through Sep 08Aircraft
TypeTotal # of Aircraft DSC Equipped OIF OEF Percent
Complete
AH-64A690
0293
0 042%42%
AH-64D 293 120 24
CH-47D
513
59
71
12 8
13%13%CH-47F 0 0 0
MH-47E/G 12
UH-60A
1702
67
286
0 14
17%17%UH-60L 162 32 38
UH-60M 57 0 0
MH-60K/L 0
MH-6 51 16 31%31%
OH-58D 345 2
TOTALTOTAL 33013301 668668 164164 8484 20%20%
17U.S. Army Aviation & Missile Life Cycle Management Command, G-3 G3-0852 – AMC CBM Summit (Smith) – 07/18/2008
Data Collection Backup
TYPE SYSTEM VMEP MSPU IMD-
HUMS IVHMS MAST VXP L3 Com MDR VADR
TOTAL A/C with
some form of
DSC
CBM CAPABLE AIRCRAFT
AH-64A 40 40 0
AH-64D 6 293 520* 520 293
CH-47D 5 19 1 37 2 64 59
CH-47F 46** 46 0
MH-47E/G 10 2 55** 67 12
UH-60A 44 4 62 1 111 67
UH-60L 40 122 162 162
UH-60M 57 57 57
MH-60 3 3 0
MH-6 16 16 16
OH-58D 2 2 2
TOTAL 98 340 45 278 3 2 46 520 55 1088 668
TOTAL AH-64 CH-47 UH-60 OH-58D MH-6 *Maintenance Data Recorder, not included in HUMS total
668 293 71 286 2 16 ** Total a/c delivered. Not included in CBM Capable Aircraft total
a/o 29 Sep 08—epi 1208
18U.S. Army Aviation & Missile Life Cycle Management Command, G-3 G3-0852 – AMC CBM Summit (Smith) – 07/18/2008
Aircraft Notebook Configuration
DSC Data
IETM
DSC Ground Station
• Common interface between DSC and ULLS-A(E)– Automate exceedance write ups in ULLS– Analysis User Interface– Data transmission in open standards.– ICD development by STAMIS developers
• Interface between ULLS-A(E) and IETM
– Automate the process to access IETM information.
Interoperability Requirements to Share Data Across Systems:•Size the notebook to ensure all applicable software can be integrated on one machine.•All software must have current DIACAP to ensure data integrity.•Common data standards, systems must speak the same language.
• Receive automated IETM updates• Provide PM specific
information through the PM websites
19U.S. Army Aviation & Missile Life Cycle Management Command, G-3 G3-0852 – AMC CBM Summit (Smith) – 07/18/2008
MFOQA Server Configuration
MFOQA Server
HUMS DATA
UnitULLS-A(E)
JTDI Top Tier Server
Sends data to
the Top Tier
Receives C
BM and ULLS
updates
ELUMS
Dashboard
MFOQA Workstation
•Electronic Life Usage Management System (ELUMS)
software capabilities including:– Receive and distribute
• CI threshold changes• IETM updates• ULLS LCF changes
– Configuration Management of all unit documents– Parse CBM data and distribute to multiple applications
Data migration from the Individual Aircraft notebooks
•HUMS data•Maintenance Actions
JTDI
MFOQA Server:•Store and manage CBM data at the unit.•Interoperability across multiple systems•Interface to CBM/MFOQA data and applications across the unit.•Serve as conduit to Enterprise CBM Servers
JTDI
GCSS-Army Portal
Interoperability Requirements for the MFOQA Server:•Size the server to ensure all CBM data can be stored and managed at the unit.•All software must have current DIACAP to ensure data integrity.•Common data standards, systems must speak the same language.
20U.S. Army Aviation & Missile Life Cycle Management Command, G-3 G3-0852 – AMC CBM Summit (Smith) – 07/18/2008
Data Storage Data Warehouse Structure
MCDS
ULLS-A
Disparate Data Sources Imported Into CBM-DW
Use
r Int
erfa
ce a
nd
Bus
ines
s In
telli
genc
e (B
I)
Direct Use Customers
Data Mart
Indirect Customers
OSD Business System Certified 4th Qtr FY06DIACAP Certified 4th QTR FY10
ETL/
3rdPa
rty
Tool
s
Dat
a Se
rvic
es
2410MDR
IVHMS
MSPU
CBM-DW
Sour
ce D
ata
Ret
entio
n La
yer
Rel
atio
nal L
ayer
Dim
ensi
onal
Laye
rETL = Extract, Transform, Load
ETL
Receive, Normalize, and Integrate Data = 70% of Effort
Correlate Data Sets Into Usable Information = 30% of Effort
CBM-DW Receives, Normalizes And Correlates Data Sets
21U.S. Army Aviation & Missile Life Cycle Management Command, G-3 G3-0852 – AMC CBM Summit (Smith) – 07/18/2008
CBM IMMEDIATE ADVANTAGES
•Improves The Airworthiness of Our Fleet
•Increases Our Aircrew Confidence in Their Aircraft
•Decreases MTBMA and MTBF, Reduces Overall Cost Drivers
•Invaluable for Troubleshooting, Getting Aircraft Back in the Fight Faster!
•Greatly Improves Track and Balance, Faster Better = Longer Component Llife
•Re-Focuses Precious Maintainer Man-Hours
•Detects Impending Component Failure Eliminates Guess Work and Improves Predictability
•Improves and Encourages Proactive Maintenance vs. Reactive Maintenance
•Improves Overall Maintenance Decision Making Process (MDMP)
“Install On Every Aircraft” – CW5 Gribensk – 3ID BAMO
A “SIXTH SENSE” FOR THE MAINTAINER TO MAKE DECISIONS!