NCMS Events

2014 CTMA Annual Partners Meeting Register


The 15th CTMA Annual Partners Meeting is a combination virtual and networking event.

This year’s Partners Meeting theme is “Focused Technology Transition” and participants will discuss methods for successfully implementing technology at maintenance facilities and to identify other technology initiatives that impact weapon system readiness.

Live panel discussions will be via video-conference with rebroadcast over the internet to anyone registering for the event.  Participants can tune-in to the meeting based on their interests in the agenda.

DoD and industry personnel are encouraged to participate at the NCMS Headquarters in Ann Arbor, Michigan.  This year’s program includes twelve panel sessions that address improving efficiencies, transitioning new technologies as well as focusing on specific technology capabilities.  Previous OSD Maintenance Challenge Award winners will also provide updates on both the Fastener Removal Improvement Technology  Adoption and Industrial Human Augmentation System Prototype Redesign for Affordability Programs.

A networking reception including table top displays for attendees that are participating at NCMS will be held the evenings of 20 and 21 May.

Tuesday, 20 May 2014
Kick-off 0820 Welcome and Opening Remarks – Greg Kilchenstein, Tony Haynes, Debbie Lilu
0830 – 1000

Joint Technology Exchange Group (JTEG) Panel

Read Abstract

Department of Defense Depot Maintenance Activities are constantly under pressure to become more efficient. One of the most effective ways to improve efficiency is to identify and insert new technologies, which all of the Services do through various Service and DoD technology programs such as CTMA. The JTEG was created to better leverage technology improvements in depot maintenance through the collaboration of the Services, Joint Staff, OSD, and industry.  The JTEG serves as a forum for the exchange of information on new technology, processes, and equipment developments and is a strong advocate for new technology with cross-service potential. The panel will highlight the JTEG objectives and recent activities, while the Service representatives will present key technology insertion actions they are conducting as well as review their overall technology needs with respect to maintaining and upgrading depot maintenance capabilities.

Potential Panel Members:

Office of Secretary of Defense – Greg Kilchenstein (confirmed) – Moderator
Air Force JTEG Principal – Thomas Naguy, HQ Air Force Materiel Command (confirmed)
Navy JTEG Principal – Kurt Doehnert, NAVSEA (confirmed)
NAVAIR JTEG Principal – Robert Kestler, FRC East (confirmed)
Army JTEG Principal – Jerry Bates, Army Materiel Command (proposed)
Marine Corps JTEG Principal – Greg Russell, Marine Depot Maintenance Command (confirmed)
Joint Staff – Steve Morani, Logistics Directorate (confirmed)

1000 – 1030

Fastener Removal Improvement Technology Adoption Program - Mervyn Rudgley, Perfect Point EDM (confirmed) 

Read Abstract

The Fastener Removal Improvement Technology Adoption (FRITA) project is a collaborative effort between Perfect Point EDM, NCMS, and several aircraft maintenance Depots across the DoD. The project introduces a new technology for the optimization of aircraft fastener removal procedures, and presents a plan to streamline the adoption of this technology into DoD.

The current approach to aircraft fastener removal is extremely labor intensive and has traditionally resulted in high damage rates, requiring the use of standard twist drills to separate the fastener head and body. The commonly accepted side effects of the existing method include low productivity, structure damage, noise, repetitive motion and eye injuries, and the FOD hazard to equipment and personnel resulting from thousands of drill shards.

A new technology known as the e•drill has been developed by Perfect Point EDM to address and mitigate the disadvantages associated with fastener removal using conventional methods. A handheld implementation of EDM (Electro-Discharge Machining) technology, the e•drill uses spark erosion to cut a circular groove into the head of a fastener to a depth corresponding to the head thickness. After cutting, a thin fillet of material is left which is easily fractured when struck with a hammer and punch. The cutting process produces fine particulate debris that is flushed away and captured by a closed-loop fluid handling system, resulting in a fast clean cut whose only remnants are the fastener head and body. The effectiveness and cost savings attributable to e•drill implementation have been conservatively estimated at better than a 50% reduction in labor, a 75% reduction in damage rate and associated costs as well as tremendous ergonomics and safety benefits.

While a limited number of military locations have put the e•drill into service, the DoD has yet to realize the benefits of the system on an extensive scale. Currently, the engineering analysis and training development required for narrow local approvals have been largely inconsistent and have required redundant efforts. The objective of the FRITA project is to address these issues by coordinating the efforts of multiple locations to develop a common set of Engineering, Process and Training specifications pertaining to e•drill deployment that will be applicable across multiple facilities and Services within the DoD.

1030 – 1045 BREAK
1045 – 1115

Industrial Human Augmentation System Prototype Redesign for Affordability - Keith Maxwell, Lockheed Martin Missiles and Fire Control (confirmed)

Read Abstract

In November 2012, OSD and NCMS sponsored a two week evaluation of the second generation (2G) iHAS prototypes at PSNS&IMF. In addition, the zeroG arm alone, without an exoskeleton lower extremity, was evaluated for two more weeks. To create the mobile, mechanical load transfer system prototypes, the battery and hydraulics were removed from three HULC units and with some other relatively minor design changes.

Lockheed Martin produced three Multi-Attachment Non-Tethered Industrial System (MANTIS) lower extremity exoskeletons. The data substantiates the improved productivity and quality, and the reduced strain and fatigue experienced when using the iHAS.The collaboration with Lockheed Martin Missiles & Fire Control (LMMFC), National Center for Manufacturing Sciences (NCMS) and the U.S. Navy, Naval Sea Systems Command, Carderock has accelerated the advancement of both the science of human augmentation and the engineering of an advanced exoskeleton.  The collaboration between NCMS, LMMFC and the U.S. Navy has already demonstrated benefits in the Puget Sound Naval Shipyard where the technology proved to increase productivity and reduce musculoskeletal injuries across a range of heavy industrial occupations.  The testing in the shipyard and elsewhere has provided beneficial design efforts, which has enabled LMMFC to design a more optimal human augmentation solution, the MANTIS 2G.

The MANTIS 2G design concept leverages the innovative design of the original MANTIS exoskeleton which leveraged the development of the HULC exoskeleton.  Our focus for the second generation development was threefold: 

  1. Preserve and enhance the system’s ability to augment the human to dramatically increase productivity across a broad range of tasks.
  2. Protect the human from musculoskeletal injuries caused by muscle over exertion.
  3. Reduce the cost to manufacture the system to enable wide technology adoption; thereby maximizing the savings to customer organizations.  

With those three goals, leveraging ten years of exoskeleton development knowledge and two years of intensive engagement with the U.S. Navy and other industrial customers, LMMFC commenced the MANTIS 2G Design Concept.

1115 – 1230 LUNCH
1230 – 1400

Additive Manufacturing Partnerships and Depot Maintenance & Sustainment

Read Abstract

The benefits of an Additive Manufacturing (AM) user-based program to DoD and other Federal agencies have been clearly demonstrated by the RARE Parts team through the CTMA program.  This partnership reduces learning curves required to design and to manufacture using AM.  Members come from industry & Government users of AM – membership is open to all branches of DoD, DOE, NASA, and other entities of the federal government having a need to use AM in their mission, manufacturing, maintenance or repair operations.

Now, the DoD Metals Additive Manufacturing Qualification and Certification Working Group, Chartered under the JDMTP Metals Subpanel, and the CTMA RARE Parts Team are working together to further the adoption and use of Additive Manufacturing within DoD and other Government agencies.  At an initial meeting on 4 March 2014, this joint initiative was proposed and ultimately undertaken under the auspices of the JDMTP Metals Subpanel AM Charter.  This public- private working group aims to proliferate AM skills and knowledge base throughout the DoD, other Federal agencies, and our supply chain communities and to realize the benefits of leveraging resources and expertise through collaboration and cooperation.

Potential Panel Members:
MET-L-FLO – Carl Dekker, (confirmed) – Moderator
NAVAIR – Dr. William Frazier (confirmed)
Baxter Healthcare – Terry Kreplin (confirmed)
Pratt & Whitney Aerospace – Matthew Donovan (proposed)
Army ARDEC – Stephen Luckowski (confirmed)
Navy N4 lead – TBD

1400 – 1415 BREAK
1415 – 1545

Environment/Energy/Health/Safety Panel

Read Abstract

This panel will present key issues facing the Services regarding compliance with national mandates to preserve the precious resources of our planet including its most important asset, the health and safety of its workforce.   Each Service will have the opportunity to articulate its progress towards meeting its HSE objectives.  Additionally, several NCMS/CTMA initiatives will be highlighted that directly impact meeting those objectives.  They include: Trichrome (Replacement for Hexavalent Chromium), Conforming Anodes for Electroplating, eDrill (FRITA), and SAVES, an exciting new technology (Aerovoltiac) that converts wind energy to electrical generation without large, complex wind turbine systems.

Potential Panel Members:
NCMS – Bill Chenevert (proposed) – Moderator
Advanced Tooling – George Cushnie (proposed)
Accio Energy – Dawn White (confirmed)
NAVSEA, Port Huemene – Thomas Torres (proposed)
Air Force, Hill AFB, Rick Crowther (proposed)
Air Force, Warner Robins – TBD
Army, Environmental (EQT) – Mark Feathers (proposed)

1545 – 1600 Wrap-up and Adjourn – Greg Kilchenstein, Tony Haynes
1630 – 1900 Evening Table Top Displays and Reception (NCMS Headquarters)
Wednesday, 21 May 2014
0820 – 0830 Opening Remarks – Greg, Tony, Debbie
0830 – 0945

Education and Training Panel

Read Abstract

The aging workforce (at least 50% of Federal workers will be eligible for retirement within five years) coupled with the impact of inconsistent, unstructured OJT, translates into all DoD Maintenance Activities having to face a severe shortage of skilled workers being able to maintain military assets passing  through the depots.  In addition, as new technologies emerge, the introduction of those new technologies becomes increasingly difficult when the workforce has only superficial process knowledge.  Finally, process improvement training such as Lean Manufacturing and Six Sigma from industry is needed at the depots to improve workflow and throughput to increase warfighter readiness.

A key fact to consider when planning effective workforce training is to consider how it is developed, who the target audience is and how it is deployed.  A large group viewing a poorly prepared Power Point without any hands-on exercises just to get a check mark in a workers file is not very useful technical training.  There are new, innovative educational technologies available that addresses that issue and will be considered in this panel discussion.  They include on-site, hands-on training (Virtual Workplace Simulator), Computer Based Training (CBT) for Metal Finishers (NCMS developed via CTMA) as well as several other unique training programs developed locally by the military depots.  Industry experts offering innovative technical training technologies and depot representatives will make up the panel.

Potential Panel Members:
NCMS – Matt Sakey (confirmed) – Moderator
Pendaran– Hossien Nivi (confirmed)
Lockheed Martin – Richard Biedenbach (proposed)
US Army, CCAD – Jeremy Smith (confirmed)
NAVSEA – Kurt Doehnert (proposed)
Siemens – Matt Brennan (confirmed)

0945 – 1100

Composite Material Repair Panel

Read Abstract

Composite material part replacement is both difficult to remove and expensive to replace. Solutions are needed to repair rather than replace composite components in DoD aircraft. OEM engineers are now considering the repairability of structural and secondary composite components during the initial design phase of a project.  This panel will address new technologies designed to improve composite repair techniques that satisfy OEM requirements.

Issues facing composite repair include:

  • Damage to composite components is not always visible to the naked eye.  The extent of damage is best determined for structural components by suitable non-destructive test (NDT) methods.
  • The quality of the repair, compaction of the repair patch and integrity of the bond line in adhesively bonded repairs becomes critical requiring a range of new technologies.
  • Standardized training and certification for the repair technician is needed.
  • Manual repairs are time-consuming, and therefore, expensive. Development of automated repair technologies and techniques are needed to not only to reduce time and cost but also the risk of human error.
  • Repaired components are expected to meet the original specification and mechanical performance requirements.  This requires extensive and costly testing and validation.

Potential Panel Members:
Wayne State University – Dr. Golam Newaz (confirmed) – Moderator
NAVAIR, FRC Southwest – Chris Root (confirmed)
Air Force Headquarter Materiel Command – Tom Naguy (proposed)
Navy, FRC East – Robert Kestler (confirmed)
Air Force, Dr. Dave Hansen (proposed)
NAVAIR – Ed Harris (proposed)
Navy, FRC Southwest – Justin Massey (proposed)
American GFM – Frank Elliott (proposed)
Manufacturing Resources, Inc. – Jeff Calkins (proposed)

1100 – 1215

Advanced Electronics/Wiring Diagnostics Panel

Read Abstract

Modern weapon systems can have thousands of wiring circuit paths as well as multiple complex electronic LRUs/WRAs. Frequent handling, maintenance actions, aging, and extreme operational environments can all cause progressive deterioration of the performance of wiring systems and LRU/WRA circuit paths. These oftentimes result in solid state opens or shorts, premature failures of a system, degradation of system function, or intermittent faults with the potential for a safety concern. It is therefore very important that all wiring and circuit path faults present be detected, isolated and repaired.

Industries such as aircraft, aerospace, telecommunications, and transportation have long recognized automated testing of electrical systems as the optimal way to ensure the integrity of complex, critical systems. Automated test programming and execution quickly and consistently identify opens, shorts, and other wiring problems in cables, harnesses, subassemblies, and final products.  It is imperative that the military continue “up its game” in Advanced Electronics and Wiring Diagnostics.

This panel will examine the military Services’ needs for wiring and LRU/WRA circuit path testing and the variety of approaches and technologies they are pursuing to meet their requirements. The panel will focus on technologies that have been deployed and others that are currently under investigation through CTMA.

Potential Panel Members:
LMI – Ray Langlais (confirmed) – Moderator
Eclypse International– Chris Teal (confirmed)
Solavitek – Alain Lussier (confirmed)
NAVAIR Pax River or Lakehurst – Olidiu (Ollie) Muja (confirmed)
Air Force, Warner Robins – Patrick Cobb or Frank Zahiri (proposed)
Army, 160th SOAR Special Operations – Steve Blaser (proposed)

1215 – 1330 LUNCH
1330 – 1445

Cold Spray Panel

Read Abstract

Cold spray is a low-temperature, solid state consolidation process, whereby metal or combinations of metallic and non-metallic particles are injected into a high-velocity gas stream and are directed upon a suitable substrate where they impact and consolidate to form a coating or freestanding structure, without melting. Cold spray is used to form corrosion and wear resistant coatings, and can also be used to provide dimensional restoration and a means to repair worn and/or corroded parts fabricated from a variety of materials including aluminum, titanium, magnesium and steel.

A similar “cold” process, Kinetic Metallization spray technology, is different from the typical cold spray technology.  The deposition process operates at sonic speeds at lower pressures than other cold spray equipment. Kinetic sprays can successfully spray heavy metals such as Tungsten Carbide or Niobium. This panel will explore both cold and kinetic spray repair.

Potential Panel Members:
Army Research Laboratory – Victor Champagne (confirmed) – Moderator
Marine Depot Maintenance Command – Greg Russell (confirmed)
Centerline – Wally Birtch (confirmed)
NAVAIR – Fred Lancaster (proposed)
HF Webster Engineering Services, Inc. – Robert Hrabe (proposed)

1445 – 1500 BREAK
1500 – 1615

Automatic Test Equipment (ATE)

Read Abstract

Automatic Test Equipment is crucial to the maintenance and sustainment of DoD’s inventory of electrical/electronic/computational systems. Virtually all defense systems other than small arms contain electronic command, control, and communications systems. ATE is used to test individual circuit cards for debug and repair purposes and also to test reassembled systems before they are returned to service. Historically, OEMs specified and often produced proprietary test equipment necessary for M&S of the systems they designed and delivered, which led to a lack of commonality in ATE components and software, which in turn drives a large logistics footprint and increased issues with DMSMS.

In recent years, DoD has begun to experiment with adapting commercial ATE to military use, Performance Based Logistics (PBL) agreements to minimize the logistics footprint, and synthetic instrumentation to emulate complex test modules and reduce the number of different test modules required to support a given system. ATE is a pervasive, cross service issue. This panel will address issues in the current ATE domain, current and emerging best practices, and trends for the future.

Potential Panel Members:
Navy, Keyport – Brian Blair (proposed)
Lockheed Martin – Rick Freeman (proposed)
AIDI – Hugh Winquist (proposed)
Army, Tobyhanna – Rick Foley (proposed)
Representatives of the AF and NAVAIR, TBD

1615 – 1630 Wrap-up and Adjourn – Greg Kilchenstein, Tony Haynes
1700 – 1900 Evening Table Top Displays and Reception
Thursday, 22 May 2014
0820 – 0830 Opening Remarks Greg, Tony, Debbie
0830 – 1000

Non-Destructive Inspection Panel

Read Abstract

Finding and identifying hidden flaws in a structure or damage to it often requires the ability to see through an object or under coating layers. Numerous technologies are used to good advantage but strengths and weakness are most often application dependent. Technologies currently in widespread use include eddy current, x-ray, phased array ultrasonics, radiography, thermography and so forth. Applications include weld inspection, fatigue crack detection, corrosion detection, bond quality, hidden damage, delamination, voids, and so forth.

NDI needs are pervasive and cross service, more specifically a cross section of ships, airplanes and ground systems. This panel will discuss NDI technologies, novel applications, and emerging trends.

Potential panel members:
NAVSEA – Kurt Doehnert (proposed)
Air Force Materiel Command – David Campbell (proposed)
Depth Measurement Systems – John Chadwick (confirmed)

1000 – 1130

Point of Maintenance Aid Tools Panel

Read Abstract

MRO (Maintenance, Repair, and Overhaul) maintenance within DoD (Department of Defense) has many challenges not seen within other industries.  Because of the age of the assets and their many different operating environments, there is no such thing as a standard repair.  Each asset requires a technical inspection (TI) to determine the level of maintenance required.  Because the assets are often deployed, the TI must be something that is easily portable and requires minimal training since a wide variety of personnel need to be able to accurately perform the TI.  Ideally all data collected about the asset would be transferred to the Program Office enabling fleet wide trend and root cause analysis.  Because these assets are often used in direct support of the troops, delays in deployment or long inspection/repair cycles are not possible.

This panel will focus on the unique requirements of MRO maintenance, the challenges that exist within the existing infrastructure, and brainstorm opportunities for solving these challenges in the 21th century.

Potential Panel Members:
B1 SPO – Stephanie (proposed)
Air Force ACC – Chief McCarthy (proposed)
Army, Red River – Mike Oestmann (confirmed)
Aspire Solutions, Inc. – Randy Kirk (confirmed)
Adapx – Phil Cohen (proposed)

1130 – 1300 LUNCH
1300 – 1430

Joint Intermittent Testing (JIT) Panel

Read Abstract

The Department of Defense (DOD) experiences a $2 – $10 billion annual impact due to removal and replacement of Line Replaceable Units (LRUs)/Weapon Replaceable Assemblies (WRAs) which subsequently test No Fault Found (NFF) during depot testing, and are turned right back around to the field.  Visual inspection is ineffective in detecting the intermittent faults (IFs), the root cause of this high NFF rate.  Military weapon system verification and validation results indicate three out of four aircraft in a mission-ready status contain electrical interconnect issues.

A modern avionics system has thousands of internal and external circuit paths.  These systems are subject to hostile operating environments and will likely fail intermittently long before they fail permanently.  IFs occurs randomly in time, place, amplitude and duration.  Electromechanical devices go into a long and frustrating period of low-level intermittency as their mechanical tolerances change.  Even a single undetected and hence unrepaired circuit in an electronic box may cause random malfunction. It is vital that all intermittent circuits present in these boxes be detected, isolated and repaired.  With the proper test equipment it is now possible to detect and repair these intermittent circuits.

Potential Panel Members:
NAVAIR Lakehurst – Dr. Russ Shannon (confirmed) – Moderator
Naval Air Station Patuxent River – Oliviu (Ollie) Muja (proposed)
Air Force, Hill – Don McClenny (proposed)
NAVAIR Lakehurst – Shane Campana (proposed)
Universal Synaptics – Ken Anderson (confirmed)

1430 – 1445 BREAK
1445 – 1615

Model Based Enterprise Panel

Read Abstract

Model-Based Enterprise (MBE) is an integrated and collaborative environment, founded on 3D product definition shared across the enterprise, enabling rapid, seamless, and affordable deployment of products from concept to disposal.  It represents a fundamental shift to 3D from 2D which is a major perturbation from the normal behavior.  Several case studies have documented significant savings generated when implementing MBE.  Toyota has shown a 50% reduction in costs.  Boeing and BAE Systems have documented similar savings.  NAWCAD Lakehurst has shown that it can eliminate a full 30% of the labor required for part fabrication.  The purpose of the forum is to identify challenges, research, implementation issues, and lessons learned in manufacturing and quality assurance where a digital three-dimensional (3D) model of the product serves as the authoritative information source for all activities in the product’s lifecycle.

Potential Panel Members:
Naval Air Warfare Center Lakehurst – John Scmelzle (confirmed)
Navy, FRC East – Angela Padgett (confirmed)
NAVAIR, FRC Southwest – Chris Root (proposed)
Siemens – Matt Brennan (confirmed)
Anark Corporation – Chris Garcia (proposed)
ITI TranscenData – Mark Haines (proposed)

1615 – 1630 Wrap-up and Adjourn – Greg Kilchenstein, Tony Haynes



Detroit Metro (DTW)


Holiday Inn Hotel & Suites Ann Arbor Univ. Michigan Area
Government Rate – $99
NCMS Rate (mention NCMS when calling directly) – $99 Standard King or Double, $119 Leisure Suites

Four Points Sheraton
Government Rate – $99
Industry Rate ( Please reference Set Number 380319) – $119

Location Virtual

Hosted By NCMS
3025 Boardwalk
Ann Arbor MI 48108

Visit Website
May 20, 2014 - May 22, 2014
Virtual Attendee$0.00
On Location (Government)$0.00
On Location (Industry)$100.00