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

Overview

The Army’s Engine Process Analysis Services (EPAS) project funded by the Rotary Wing Aircraft Sustainment Program (RWASP) is now paying dividends in three key areas: (1) Overhaul Cycle Time Reduction: 342 to 146 days and going down; (2) Improved Engine Life: 240 to 1080 hours on the wing; and (3) Increased Deliveries: 8 to 75 engine equivalents per month. The estimated payback to the Army from the EPAS project is $140M over the next ten years.

The EPAS Team (AMCOM/CCAD/AT&T/KBSI), using the Air Force Lean Value Chain and KCHR technologies, has affected major improvements without major equipment or facilities investments and moderate increases in CCAD manpower. A summary of how this was accomplished is provided in the following list.

Created 100% visibility into inventory and assembly requirements.

Structured, simplified, and streamlined process flows. Improved inter-and intra-shop communication to achieve common goals and schedules.

Re-engineered every prime T700 engine shop to a common standard and direction.

Implemented shop floor knowledge tools and process know-how.

Mapped process flow to identify non-value added activities and created information “Enablers.”

Established Bill of Materials for Remanufacture.

Established modular work cells.

Kitted $187M in T700 parts “LOST” in the system.

Created production systems based on Pull Strategy and Production Control Visibility.