This forum will focus on improving the business processes of maintenance with the principal objective being improved operational performance as a result of increased maintenance effectiveness in terms of greater productivity, shorter maintenance cycles, increased quality of the process, and better use of resources. The discussion will include the implementation of CBM+ strategy in DoD maintenance organizations as well as new planning and scheduling tools.
1300-1309: Welcome and Overview – Greg Kilchenstein (OSD-MPP)
1309-1310: Administrative Notes – Debbie Lilu (NCMS)
1310-1340: AI-Based Predictive Maintenance Solution – Don Cotriss (C3IoT)
1340-1405: Utilizing Alt FUnding MEchanisms to Mitigate Production & Infrastructure Maintenance Issues – Brad Niles (RIA)
1405-1430 C-17 HSC Initiative – TSgt Brian Moody (860th AMXS)
1430-1455: Cloud Based System Health Record (SHR) – Carlos Hernandez (Global Strategic Solutions, LLC)
Event: On 19 December 2017, the Joint Technology Exchange Group (JTEG), in coordination with the National Center for Manufacturing Sciences (NCMS), hosted a virtual forum on “Improved Business processes”.
Purpose: The purpose of this forum was to exchange information on improving the business processes of maintenance with the principal objective being improved operational performance as a result of increased maintenance effectiveness in terms of greater productivity, shorter maintenance cycles, increased quality of the process, and better use of resources. The discussion included the implementation of CBM+ strategy in DoD maintenance organizations as well as new planning and scheduling tools.
Welcome: Greg Kilchenstein (OSD) welcomed everyone to the forum, thanked the presenters and all the listeners for their attendance, and briefly previewed the agenda.
Administrative: This was an open forum. The presentations, along with questions and answers, were conducted through Adobe Connect. A separate audio line was used. Approximately 60 participants from across DOD and industry joined in the forum.
AI-Based Predictive Maintenance Solution – Don Cotriss (C3IoT) explained that the C3 Predictive Maintenance uses machine learning algorithms integrated with business processes to prioritize equipment maintenance and maximize uptime. C3 Predictive Maintenance goes beyond traditional rule-based systems by using AI / machine learning to identify failures proactively. Its algorithms analyze all relevant information including sensor data, asset management systems, plus structured and unstructured data such as technician notes, and external data sources such as weather. C3 Predictive Maintenance is capable of predicting failure significantly in advance of legacy rule-based systems, with higher precision and recall. The application’s AI / machine learning algorithms are dynamic and learn over time, adapting to emerging failure modes. It also can use unsupervised AI / machine learning algorithms to detect anomalies across all datasets – allowing operators to intercept unusual operating modes.
Utilizing Alt FUnding MEchanisms to Mitigate Production & Infrastructure Maintenance Issues – Brad Niles (RIA) described several ESPC projects at TACOM to include Plating Modernization, HVAC, and Painting Modernization. He explained a combined analysis which included a BCA to compare the status quo against CIP funded, and ESPC funded methods. ESPC provided the best overall value.
C-17 HSC Initiative – TSgt Brian Moody (860th AMXS) briefed the Modified Home Station Check (HSC) initiated at the 860th AMXS. HSC uses a modified schedule with 24 hour coverage over two 12 hour shifts work schedule. The initiative covered a 720 Day Cycle (Six – 120 Day Inspection Intervals). The impacts from the C-17 HSC were:
· Improved Fleet Health Through Mx Consolidation
· Reduced Home Station Check down-time by 31% going from 19.3 days of scheduled mx per aircraft to 13.2 days over a two year inspection cycle
· Increased Squadrons Aircraft Availability (AA) by 78 days over a two year inspection cycle
Cloud Based System Health Record (SHR) – Carlos Hernandez (Global Strategic Solutions, LLC) described how the System Health Record (SHR) Platform is designed to consume structured or unstructured data from multiple data sources enabling:
· Asset connectivity and a common, open information model
· Interoperability, communication, capture and sharing of common fundamental health record data and system functionality
· Collection of the “right data” as part of the overall workflow and aggregated through the “persistent” system health record
· Use of the data for predictive analytics
SHR enables visibility of current fault symptoms, current health state, ATE tests needed, and bad actors and estimated system performance life remaining (PLR) or time-to-failure derived from predictive analytics Apps.
Closing Comments: Greg Kilchenstein thanked the presenters for their contributions and the audience for their participation. He suggested continuing the information exchange beyond the forum and the importance of teaming/partnership to the DoD maintenance community.
1) Obtain “public release” versions of the presentations and post to the JTEG website. These meeting minutes, the Q&A, and those briefing slides approved for public release, will be posted on the JTEG website at http://jteg.ncms.org/ . (All presenters, LMI, NCMS)
Next JTEG Meeting: The next JTEG virtual forum is 30 January, 1:00 – 3:00 pm EST. The topic is “Innovation Venues”.
POC this action is Ray Langlais, email@example.com , (571) 633-8019
AI-Based Predictive Maintenance Solution – Don Cotriss (C3IoT)
Q1. With a reduction of 206 unscheduled maintenance actions as a result of this capability, what is the direct impact on AWACS readiness rates?
A1. It extends to another 5 systems. We experienced a 14-18% increase in readiness.
Q2. Who is the USAF POC / Project Officer for this?
A2. Col Randy Ackerman at Tinker AFB
Q3. How important is component serialization or unique identity in support of this process?
A3. Important, but not as much as one might think due to little change on the quality of components over time. It would be important if there were a mod change.
Q4. Which authoritative data systems are necessary to support this analysis?
A4. AWACS / F-15 consolidated existing data sources. Also, new aircraft.
Q5. Can we aggregate the component failure risks to manage AWACS sortie completion risk overall?
A5. Yes, in fact as part of the IB doing precisely that. Rolling up component level and determining risk for aircraft and the downtime associated to that failure.
Q6. Is the AI engine limited in terms of the amount of data that can be analyzed?
A6. It is not limited by data at all. It uses an elastic infrastructure and is highly scalable.
Utilizing Alt FUnding MEchanisms to Mitigate Production & Infrastructure Maintenance Issues – Brad Niles (RIA)
Q1. Can you discuss the basics of an ESPC? What is Honeywell’s role? How does RIA pay and from what account?
A1. The contractor is responsible for paying the 3rd part In this case it was through the Corps of Engineers. Honeywell would pay the amount if short of the savings.
Q2. What happens if you save more than what Honeywell projected? Do you have a shared energy savings account?
A2. It goes into our pocket and lowers our rates.
Q3. Does the ESPC guarantee energy reliability as part of the contract?
A3. No, that is not part of the contract.
Q4. How does RIA leverage the savings to “stand up a new operation”? Can RIA reinvest the savings in the plant?
A4. Not really. The savings go into reducing costs of operation.
Q5. Does Honeywell pay for the discussed capital improvements as part of the contract?
A5. Yes, they paid for everything. Paint booths, plating, etc.
Q6. How difficult was it to baseline legacy costs?
A6. It wasn’t too bad. It was done while in the design phase.
Q7. Do you know if the Corps of Engineers is available to assist other DOD activities? Do they have ready contracts?
A7. The COE has contracts. Not sure if they go outside DoD. DoE has similar vehicles.
C-17 HSC Initiative – TSgt Brian Moody (860th AMXS)
Q1. What has been the result of HSC improvements on C-17 unscheduled maintenance? Are we tracking that metric?
A1. We are now changing all the tires during scheduled maintenance to avoid doing during unscheduled maintenance.
Q2. When did the 860th begin this process?
A2. Four years ago.
Q3. Are you using any automated tools?
A3. No. We do use paperless forms. We also create our own jobs and order our own parts.
Cloud Based System Health Record (SHR) – Carlos Hernandez (Global Strategic Solutions, LLC)
Q1. If the capability can collect and assimilate unstructured data, why are the data standards cited as important in the analysis?
A1. It is more about the inputs once you get the data; we are not typically mining data. The standards are important to exchange the data.