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Contracting Agency: U.S. Army
Point of Contact: solutions@kbsi.com

Overview

Faced with the need for maintaining the combat readiness of helicopters that are seeing more frequent, more widespread, and more wearing use, U.S. Army Aviation is investigating ways to streamline maintenance practices and logistics support. The Army’s Utility Helicopter (UH) Program Management Office (PMO), in the helicopter RESET program, is mandating a much deeper inspection, cleaning, and repair of returning combat aircraft, in addition to the standard Phase inspections. In short, the Army is looking for ways to do more, to do it better, and to do it more quickly.

Approach

In achieving these objectives, the PM-UH realized the need for reducing the cycle-time of RESET processes and for leveraging emerging maintenance management information systems, data mining, simulation, and traditional industrial engineering analysis to reduce the Turn Around Time (TAT) of RESET execution and reduce soldier workload

KBSI, as part of the Rotary Wing Aircraft Sustainment Program (RWASP) initiative, helped develop designs and technology for streamlining UH-60 Black Hawk disassembly, inspection, and reassembly at the Corpus Christi Army Depot (CCAD). KBSI’s expertise in process modeling and analysis was applied to the complete overhaul of the UH-60 aircraft and the development of a more streamlined process using the IDEF3 modeling method. Through a partnership with F Co. 1/160th SOAR (A), KBSI transitioned these depot findings to the RESET activities, developing a streamlined set of standard processes and a standard methodology for Phase/RESET (STIR) maintenance.

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SFL: CH-47 Soldier Focused Logistics
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BDSS: Battalion Decision Support System
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ODSS: On Demand Simulation Support
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To augment the application of these standardized streamlined RESET processes, KBSI leveraged technology from the Air Force Logistics Center (OC-ALC) sponsored On-Demand Simulation Scheduling (ODSS) program. ODSS established advanced decision support technologies that aid in the daily management of workflow and personnel. WorkSim, a resource-constrained daily work dispatching tool developed for ODSS, generates optimized daily dispatching schedules from process descriptions, helping users maintain status information about repair items, resources, maintenance events, and scheduled workloads. WorkSim also provides sophisticated experiment management and analysis support, allowing users to simulate schedules for user-defined conditions and metrics such as flow days for each aircraft, average flow days across all aircraft and for each aircraft type, total aircraft repaired in a given duration, etc. WorkSim schedules can be generated in either Microsoft Excel or Project, and schedules account for task precedence, resource requirements, and user-defined priority and due dates.

In collaboration with the D Company, 4/101st Aviation Battalion, the Army Research Laboratories (ARL), the Cargo PMO, CCAD, Edwards AFB, the Air Force Research Laboratories, and the Office of Naval Research (ONR), KBSI is transitioning opportunities for dynamic planning, asset tracking and visibility, kit management, supply chain responsiveness, requisition processing, optimal resource dispatching, work status tracking, reliability centered maintenance, and mission driven sustainment and logistics. The focus of this work is on discovering how to apply data available in the Army’s Health Utilization Management System (HUMS) and Maintenance Management Information Systems (Sapphire, ULS-A Sc6, CPME, etc.) to drive advanced decision support tools that enable data driven decision making within Unit of Action business operations and the Fleet Management Level and help optimize Go-To-War capabilities. These investigations are currently driving a number of ongoing Unit of Action Automation and Architecture projects within the UH-PMO and in conjunction with the Army’s Common Logistics Operating Environment (CLOE) initiative.

Results

KBSI’s RESET work with UH-60 Black Hawk maintenance activities have generated some astounding results. The comprehensive and streamlined processes have dramatically accelerated training among crew members and created the basis for common metrics across teams, delivering predictable, repeatable, and visible results. Optimized scheduling allows planners to accurately utilize available manpower, and TAT has been reduced by 20 to 30%, radically increasing the turn around time for aircraft and reducing overall maintenance costs. Combat readiness? Each seven days of reduced TAT results in approximately ten additional aircraft available for the field.

 

 

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