I n t e g r i t y - S e r v i c e - E x c e l l e n c e

Legacy Systems SustainmentConsolidated System Obsolescence

Mitigation

Mr. Sam CallowayF-15 System Program Office

Avionics Hardware Engineering

296 Cochran Street Bldg 300

Robins AFB, GA 31098-1622

Prepared for National Defense Industrial Association Conference

21 –22 October 2003

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Outline

• The Environment• Guidance and Enabling Activities• Define Platform Configurations• Data Collection• F-15 Sustainment Approach• SUSTAIN

– Force Structure Reduction (FSR) Prediction– Mission Degradation– Sustain FSR Analysis– Reliability Analysis– Sustainment Cost– Technology Insertion

• LFEA Partnerships• Summary

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• It’s a Readiness Issue:– AF transformation CONOPS require effects-based

capabilities– Acquisition programs buy tomorrow’s capability– What about today’s?

• DMS & Parts Obsolescence:– Threaten availability of today’s capabilities– Drive bills for premature acquisition of new

systems and mods• Brings a Solution to the Table for an

Enterprise Problem

The Environment

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• F-15 is an aging aircraft system – Obsolescence is a major threat to Mission Readiness

• Budgeting and solution processes have long lead times • The scope of the problem is too large for manual analysis= Need for automated, proactive management approach

The Environment

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“The loss or impending loss of manufacturers of items or suppliers of items or raw materials may cause material shortages that endanger a weapon systems’ or equipment’s development, production, or post-production support capability. The DoD Components shall proactively take timely and effective actions to identity and minimize the DMSMS impact on DoD acquisition and logistics support efforts.”

DoD 4140.1-R, May 23, 2003

The Environment

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AFI 63-1201Assurance of Operational Safety,

Suitability, and Effectiveness “... ensure that activities such as operational

use, configuration changes, maintenance repairs, and parts substitutions do not degrade system or end-item baselined characteristics over their operational

life…”

The Environment

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Guidance and Enabling Activities

• Functional Obsolescence– Upgrade system capability to counter an evolving

threat– User driven system upgrade

• Hardware Obsolescence– Maintain existing capability– Sustainer driven, component or board solutions– DMSMS resolution– Replace low reliability or high cost-of-ownership

components or assemblies

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Guidance and Enabling Activities

• Maximize support to the Warfighter• No degradation to operational performance or

reliability (OSS&E)• DMSMS• Maximize reliability and maintainability• Minimize cost of ownership• Evaluation of ALL relevant information• Evaluation of component vs. higher assembly

technology refreshment alternatives

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• 4 steps to success:

– Define platform configuration

– Establish data collection capability with priority

– Develop analysis tools and business case process

– Create industry partnerships for long-term supportability

Guidance and Enabling Activities

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Define Platform Configurations• It is imperative to define Weapon System configuration

indentured from the platform to consumable bit/piece part.• The USAF uses the Work Unit Code, WUC, to manage the

platform configuration, which allows direct comparison of information across disparate systems.– Defines configuration from Platform to Lowest Level of

Repair– All maintenance data is archived and retrieved via the WUC

• All cost and inventory data is managed via NSN– Therefore, a WUC to NSN cross reference is vital to correlate

data for technology refreshment candidates.

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Data Collection

• There is a plethora of existing, official databases from which to gather data, and choosing the right subset to use is critical for making optimum sustainment decisions. LFEA uses information from eight sources.

D043D043

G337G337 G009G009 G037GG037G G072DG072D G097G097 H075CH075C H117H117 E046AE046A E046BE046B

D043AD043A

D046D046

J090BJ090B

J041J041

PEMSPEMS

G072EG072E

G072AG072A

G037EG037E

G035AG035A

G019CG019C

D034AD034A

D035AD035A

D130D130

D143CD143C

D200D200

D087ED087E D087KD087KD041D041ACPSACPS

G017G017 G029G029

G030G030

DODDOD

J090AJ090A

G004CG004CDOCDOC

H033H033 H036CH036C H084H084 H159H159

Q072Q072 Q111AQ111A RANDRAND

J023J023

D003BD003B

E300VE300V H069H069 H103H103

D035TD035T D062D062 D071D071

D075D075

DCPSDCPS

G005MG005M G004LG004LD035KD035K

D035LD035L

ASMASM

J071J071

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Data Collection

• Where data is lacking, establish new capabilities

– AVCOM – DMS management

– LDMS – Depot repair activity

• Data programs must provide benefits to all those involved in the collection and use of the information.

WR-ALC/LFEA INITIATIVES

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F-15 Sustainment Approach

SUSTAINMission Readiness

Inventory AssessmentReliability EvaluationSustainment Cost Sustainment ActionTechnology Insertion

AVCOMComponent

obsolescenceLDMS (G-300)

Depot repair management

USAF and DoD Data bases

Air Force sustainment action

implementation

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• Automates most of the analysis and business case development for technology refreshment at the component and assembly levels

• Generates a prioritized list of component and board level projects

SUSTAIN

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Force Structure Reduction (FSR) Prediction

• Platform FSR drivers

• A clear illustration of what is going to cause a problem, and when it must be dealt with

Platform

Systems

SYS 1SYS 2SYS 3SYS 4SYS 5SYS 6SYS 7SYS 8SYS 9SYS 10SYS 11SYS 12SYS 13

F-99

All Platforms Contributing to F-99 Depletion

SYS 1SYS 2SYS 3

SYS 4SYS 5SYS 6

SYS 7SYS 8

SYS 9SYS 10

SYS 11SYS 12

F-99 Depletion

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FSR Prediction

• Drilldown from system to board depletion drivers

System

Box

SYS 6 PNs Contributing to SYS 6 Depletion

SYS 6 Depletion

LRU 1LRU 2

LRU 3LRU 4

LRU 5LRU 6

SYS 6

SYS 1SYS 2SYS 3SYS 4SYS 5SYS 6

LRU 1LRU 2LRU 3LRU 4LRU 5LRU 6

F-99

SYS 7SYS 8SYS 9SYS 10SYS 11SYS 12

SYS 6

SYS 6

Box

Board

LRU 2 Depletion

LRU 2 PNs Contributing to LRU 2 DepletionLRU 2

SRU 1SRU 2SRU 3

SRU 4SRU 5

SRU 6SRU 7

SYS 1SYS 2SYS 3SYS 4SYS 5SYS 6

LRU 1LRU 2

F-99

SYS 7SYS 8SYS 9SYS 10SYS 11SYS 12

LRU 3LRU 4LRU 5LRU 6

LRU 2

LRU 2

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Mission Degradation

Components driving board depletion Resulting board depletion curve

• Identifies individual contributing components

FSR Alert: Part Slot(s) for Assembly SRU 1

U1U2U3

U4U5

SYS 1 LRU 1 SRU 1 SYS 1 LRU 1 SRU 1

SRU 1SRU 1 Scaled POSSYS 1

FSR Alert: Assembly SRU 1 (Serviceables plus Repairables)

SRU 1 Scaled WRMLRU 1 Depletion StartForce Structure Depletion Start

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FSR Alert: Part Slot(s) for Assembly SRU 1

U1

U2

U3

U4

U5SYS 1

Mission Degradation

Resulting board depletion curve, “Modified board”, indicates resolution

Resolve single component driver, U3

• Sensitivity Analysis allows “what if” scenarios

FSR Alert: Assembly SRU 1 (Serviceables plus Repairables)

Modified SRU 1SRU 1 Scaled WRMLRU 1 Depletion StartForce Structure Depletion Start

SRU 1SRU 1 Scaled POSSYS 1 Depletion Start

SYS 1 LRU 1 SRU 1

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• Platform FSR Avoidance Prioritization by component

SUSTAIN FSR Analysis

• Automating the component technology refreshment business case process

U3

U45U1

U51

U4

U16

SYS 1SYS 2

SYS 3SYS 3SYS 3SYS 3

SYS 7

LRU 1LRU 1

LRU 3LRU 2LRU 5LRU 6LRU 7

SRU 1SRU 8

SRU 3

SRU 2SRU 5SRU 1SRU 11

U3U45

U1

U4U51U16

U8 2016Q3 200

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Reliability Analysis

Historical failures, by type, and associated flying hours

Trend analysis and prediction, based on past

performance

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SY

S 1

SY

S 2

SY

S 3

SY

S 4

SY

S 5

SY

S 6

SY

S 7

SY

S 8

SY

S 9

SY

S 1

0

SY

S 1

1

SY

S 1

2

SY

S 1

3

SY

S 1

4

SY

S 1

5

SY

S 1

6

SY

S 1

7

SY

S 1

8

SY

S 1

9

SY

S 2

0

SY

S 2

1

SY

S 2

2

SY

S 2

3

SY

S 2

4

Sustainment Cost

System sales cost comparison at the Platform

SRU sales cost per LRUSales Cost Breakdown

Year: 2001 Repair Level: SRU HLA (LRU 2)

WU

CA

A

WU

CA

B

WU

CA

C

WU

CA

D

WU

CA

E

WU

CA

F

WU

CA

G

WU

CA

H

WU

CA

I

WU

CA

J

Work Unit Code

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Technology Insertion

Prioritized ranking of technology refreshment assembly candidates

SRU 1SRU 2SRU 3SRU 4SRU 5SRU 6SRU 7

SRU 8SRU 9SRU 10SRU 11SRU 12SRU 13SRU 14SRU 15SRU 16SRU 17

SRU 18SRU 19SRU 20SRU 21SRU 22

Individual assembly ratings

SRU 5 SYS 5LRU 1LRU 2LRU 3

F-99

SRU 1SRU 2SRU 3SRU 4SRU 5SRU 6SRU 7SRU 8SRU 9SRU 10SRU 11

SYS 6SYS 7SYS 8SYS 9SYS 10SYS 11SYS 12SYS 13SYS 14SYS 15

LRU 4LRU 5LRU 6LRU 7

SRU 5SRU 5

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LFEA Partnerships

DepotsMTIGTRI

GTRI

BoeingRaytheon

MTI

Sarnoff DLA

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• > 15 Government / Industry partnership –DLA/DSCC/Sarnoff

• Provides a continuing source of Form, Fit and Function replacement microcircuits, manufactured in Sarnoff’s Class Q wafer foundry

• Eliminated/avoided 100 SRU redesigns using 229 unique GEMed components through 2002

• F-15 cost avoidance utilizing GEM devices > $50.1M

Generalized Emulation of Microcircuits (GEM)

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• Develops and Demonstrates Advanced Emulation capability (beyond GEM)

• Partnering with PM’s, OEM’s, and organic activities for long term support– Provide obsolescence supportability

analysis– Implement customer supplied VHDL– Provide reverse engineering services– Design AME devices for new systems– Replace multiple microcircuits on a

board• F-15 Example

– Team of MTI and WRAFB redesigned PACS, CPU SRU using AME devices – permanently designing out obsolescence

Advanced Microcircuit Emulation (AME)

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Summary

• WR-ALC/LFEA has established a standardized approach for identifying, prioritizing, and building the business case for both component and assembly technology refreshment.

• Reliance on automated software tools has made the process extremely efficient, repeatable and robust.

• Teamwork between LFEA, other government organizations, and their industrial and university partners is the enabling factor in this successful program.