Transmission Remap

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Contracting Agency: Corpus Christi Army Depot (CCAD), U.S. Army
Point of Contact: solutions@kbsi.com

Overview

Corpus Christi Army Depot (CCAD) is the primary Army repair facility for Maintenance, Repair and Overhaul (MRO) activities for rotary wing aircraft and their components. The Transmissions Remap effort is focused on improving CCAD production capability for all of Transmission programs and components. CCAD has been struggling during the last several years to meet the increased requirements for rotary-wing transmissions resulting from wartime demand.

CCAD currently supports the MRO of all major transmissions and gearboxes for the “A” and “L” model Sikorsky UH-60 Blackhawk, the Boeing CH-47 Chinook and AH-64 Apache, the Bell UH-1N Huey, AH-1N Cobra, and OH-58 Kiowa.

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Approach

KBSI is providing Industrial Engineering Support to completely restructure the CCAD transmission repair functions. The approach that is being developed is to segment and consolidate the repair processes across each of the transmission commodity lines.

Evaluation tasks are being separated from assembly functions in order to allow for the establishment of a consistent, managed evaluation operation that will feed a kitting and staging function prior to the assembly of subassemblies and, ultimately, the final asset. Removing subassembly functions and viewing them as a separate operation from final assembly allows for better control of work scheduling and pacing, and allows tooling for optimal assembly performance with a manageable work breakout. These shop implementations are being fully coordinated with other developments at CCAD that KBSI has spearheaded, especially the MCA Support and SUMO projects.

The primary benefit of the Transmission Remaps effort will be the reduction of cycletime from an average of over 100 days per asset to less than 60 workdays per asset, as well as significant productivity gains that will result from these cycletime reductions. While this effort is early in the implementation phase, the transmissions shops have experienced an average increase of productivity of nearly 30%, and output is exceeding all levels of production attained during the previous five years.

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