CTMA Projects

Active Projects

Problem: Well over half of all maintenance actions performed on aircraft are the result of electrical systems anomalies.  Based on the ever increasing complexity of these integrated systems, troubleshooting the root cause of these prevalent anomalies is extremely manpower intensive. The issues with checking aircraft electronics and wiring systems quickly, effectively and within reasonable cost targets are universal.  Generally the worst case scenario is military aircraft due to their age and deteriorating systems coupled with multiple wiring/systems upgrades over time.

Benefit: Improvements derived through this initiative will be fully transferrable to the commercial aircraft and air carrier industry.  Common worldwide standards can be created.

Solution/Approach: To address the common issues facing both commercial and military aircraft fleets of being able to quickly find and repair electrical faults as well as track wiring performance (by tail number) over time, a new unique electrical system testing technology has been identified.  Two aircraft will be chosen for the evaluation of AMUET, the C-130 (used commercially) and B-1.  Comparisons will be made to data using conventional automated test equipment and handheld test data.

Impact on Warfighter:

  • Reduced maintenance turnaround time to hours as opposed to days, weeks or months
  • Validation of integrity of wiring systems
  • Decreased lifecycle cost of aircraft
  • Safer air travel

DoD Participation:

  • U.S. Air Force (Warner Robins ALC)
  • U.S. Air Force (Oklahoma City ALC)
  • NAVAIR Electrical Test Equipment (Lakehurst)

Industry Participation:

  • Solavitek
  • Georgia Tech University

 

NCMS Project Manager: Bill Chenevert, (734) 995-7989, billc@ncms.org

 

Problem: U.S. Military ground, air and sea operations worldwide adversely impact environmental security by consuming extraordinary amounts of fossil fuels, emitting large amounts of carbon emissions and requiring high manufacturing and maintenance rates and a large infrastructure to support operations.

Benefit:

  • Decreased fuel costs
  • Decreased engine and spare part requirements
  • Decreased emission of CO2 and NOx

Solution/Approach: The Environmental Security Technology Certification Program (ESTCP) funded work project WP-201009 in 2010 to evaluate Compressor Airfoil Protective Coating for Turbine Engine Fuel Efficiency. The project was managed by the Office of the Secretary of Defense (OSD), Maintenance and concluded with an engine sand ingestion test comparing an uncoated and MDS Coating Technologies (MCT) BlackGold® coated AGT1500 engine in September 2012. The test results from the comparative sand ingestion test demonstrated significant benefits in coated compressor parts protecting against erosion.

The specific project work scope would include the development of a business case analysis utilizing the current CTMA-developed business case analysis model. Using inputs provided by all project participants, NCMS will exercise the model and project benefits for increased part savings, engine performance retention and fuel savings.

Impact on Warfighter: The efforts from the continued development and transition of this coating technology will enable the logistics community to reduce the logistics footprint, reduce demand for expensive long lead time of compressor components, and will ultimately improve maintenance capacity, increase aircraft readiness and throughput.

DoD Participation:

  • U.S. Army (Anniston AD)
  • U.S. Army (TACOM)
  • U.S. Marine Corps
  • Kansas Army National Guard

Industry Participation:

  • Honeywell
  • MCT

 

NCMS Project Manager: Debbie Lilu, (734) 995-7038, debral@ncms.org

Problem: Parts availability is being severely impacted by several factors:  1) by a shrinking industrial base (diminishing sources of supply), 2) by aging DoD weapon systems needs for components that are no longer in production, 3) low volume requirements, 4) and by the lack of capable artisans and tradesmen resulting from workforce aging.  Driven by these realities and our weapons systems sustainment objectives, a transformative rapid production arena is being exploited by the DoD MPP, Additive Manufacturing (AM)

Benefit: AM has the potential to produce a part “recipe” for a difficult-to-get/make parts that could quickly be transmitted to a depot or FOB for build in the field or ship for build at sea.  The RARE team provides a broad depth of knowledge and real-world experience, as well as updates on the latest research and development in AM.

Solution/Approach: The RARE Parts initiative, as an industry-government user driven body working to mature the AM system builders and their design and construction of machinery systems as a whole to benefit U.S. industrial production base use, looks to address those challenges that currently limit adoption and widespread use of AM technology by industry and by the public at large by:

  • Engaging the RARE Parts collaboration to actively participate on ASTM-ISO standardization development bodies and on the NIST AM testing and measurements authorative group.
  • Investigating manufacturability of prototype and spare parts using AM for armament and other team defined applications.
  • Collaborating on DARPA’s Open Manufacturing AM process parameter “schema” collection, storing and sharing data throughout industry and government.
  • Working with MSAT Database (Army Research Lab-NASA) usage throughout industry and government to place AM materials properties-AM process data into a centralized public repository.
  • Broadening the application horizon with investigation of AM printed electronics

Impact on Warfighter:

  • Accessible, trustworthy characterization and qualification data on AM materials and processing systems for design and application needs.
  • Increase in parts availability and weapon systems readiness.
  • Reduce foreign outsourcing and improve national economy.

DoD Participation:

  • U.S. Navy (FRC East)
  • U.S. Navy (FRC Southwest)
  • U.S. Army (Picatinny)
  • U.S. Army (Corpus Christi)
  • U.S. Army (Tobyhanna)
  • U.S. Army (Anniston)
  • U.S. Navy (NUWC Keyport)
  • U.S. Navy (TRF Kings Bay)
  • U.S. Navy (NFPC Philadelphia)
  • U.S. Navy (China Lake)
  • U.S. Navy (Portsmouth)
  • U.S. Navy (Pearl Harbor)
  • U.S. Air Force (Oklahoma City)
  • U.S. DoE NNSA (Honeywell FM&T)
  • NASA, Marshall Space Flight Center

 

Industry Participation:

  • UTC Pratt & Whitney
  • General Pattern
  • H.A. Burrow Pattern Works
  • Lockheed Martin Missile & Fire Control
  • Baxter Healthcare
  • UTC Aerospace
  • Met-L-Flo
  • Applied Technology Integration

 

NCMS Project Manager: Connie Philips, (313) 618-8760, conniep@ncms.org

 

Problem: The Department of Defense (DoD) owns, operates and maintains thousands of industrial fleet vehicles, performing a wide range of critical support tasks. Despite myriad of major service sponsored maintenance initiatives focused on improving maintenance automation and readiness for tactical vehicle fleets, aircraft vessels and combat vehicles, very little has changed regarding the business process associated with maintaining, managing and improving operational readiness of the industrial vehicle fleet.

Benefit: Total projected savings for the entire fleet are estimated to be from $4,920 – 46,760 per vehicle per year or $738,000 – $1,014,000 per year (based on the fleet size of 150 vehicles).

Solution\Approach: This project will develop a variation from a commercial off-the-shelf (COTS) wireless fleet management hardware and software solution, termed the Centralized Fleet Automated Management System (CFAMS). The version proposed will be evaluated and tested at the RRAD and will feature FIPS 140-2 compliant Wi-Fi based Vehicle Asset Communicators that allow the system to operate on the Army’s separately installed wireless network backbone.

Impact on Warfighter:

  • Reduce vehicle maintenance costs
  • Increase operator productivity
  • Decrease damage to vehicles
  • Increase in fleet operation readiness/availability

DoD Participation:

  • U.S. Army (Red River AD)
  • U.S. Army (Anniston AD)
  • U.S. Army (Rock Island Arsenal)
  • U.S. Marines (Albany)

Industry Participation:

  • I.D. Systems, Inc.

 

NCMS Project Manager: Debbie Lilu, (734) 995-7038, debral@ncms.org

Problem: Industry and DoD are both migrating away from stove-piped legacy logistics information systems in order to adequately perform their supply maintenance functions.  As industry and DoD modernize the logistics information architecture, there is a clear gap that has arisen between user knowledge specific to their functional business processes and initial training during post deployment of these systems.

Benefit: This partnership will result in a cost effective solution that has a shorter transition period and well trained GCSS MC Cadre and a more efficient process from which software enhancements can be developed and implemented improving the overall capability.

Solution/Approach: In an effort to address these implementation gaps, industry has developed and is currently maturing various organizational change management procedures to derive best practice solutions.  Through this collaborative initiative, industry and DoD partners will assess global ERP implementation deployment strategies, current implementation gaps, and develop optimal draft operation procedures for supply and maintenance activities as well as identify training gaps.

Impact on Warfighter:

  • Economize software development
  • Improved logistics operations, processes and procedures for implementing GCSS-MC
  • Expand deployment knowledge-base
  • Increase efficiency and effectiveness

DoD Participation:

  • U.S. Marine Corps, Installations & Logistics
  • U.S. Marine Corps Logistics Command
  • U.S. Marine Corps Systems Command

Industry Participation:

  • Anglicotech, LLC

 

NCMS Project Manager: Steve Hale, (734) 995-2195, steveh@ncms.org

 

Problem: Currently the nation has limited economically feasible options for alternative fuel vehicles and equipment directly from domestic original equipment manufacturers.  There are, however, options available as aftermarket conversions that have proven to be very viable options.  One such readily available alternative fuel is propane.  The Department of Defense has volunteered to conduct demonstrations at various military installations throughout the nation.

Benefit: Further development of viable alternative fuel solutions is critical to meeting the nation’s energy demands while reducing carbon emissions and dependence on foreign oil.

Solution/Approach: For a fleet to determine which solution is best for its needs, fleet management must understand its vehicle needs and duty cycle to ensure the solution provides beneficial results.  This initiative will focus on evaluating the utility, feasibility, and maintainability of utilizing propane as a power source in wheeled vehicles and related equipment.  This will be accomplished by converting current vehicles and equipment at the target bases to propane, tracking their performance during an evaluation period, and converting the vehicles back to their initial state at the end of the evaluation period.  It will also include the additional collection of seasonal data from the initial pilot program to develop a business case analysis on the viability of utilizing liquid propane engine technology in medium-duty truck fleets.

Impact on Warfighter:

  • Cost savings ($1.50 vs. $3.50+ for unleaded gas or diesel)
  • Cleaner reducing greenhouse gases/emissions
  • Sustainable and readily available
  • Less abuse to engines
  • Extended service cycles

DoD Participation:

  • U.S. Marine Corps (Camp Pendleton)
  • U.S. Marine Corps (Camp Lejeune)
  • U.S. Marine Corps (MCB Quantico)
  • U.S. Marine Corps Fleet Vehicle Management
  • U.S. Air Force Fleet Vehicle Management
  • U.S. Army (Tobyhanna)
  • Defense Logistics Agency – New Cumberland

Industry Participation:

  • CHS, Inc.
  • American Diesel Systems, LLC
  • Power Solutions International, Inc.
  • Bi-Phase Technologies, LLC
  • Troika Solutions, LLC

 

NCMS Project Manager: Debbie Lilu, (734) 995-7038, debral@ncms.org

 

Problem: Several U.S. Military aircraft operate in both sand and salt environments resulting in both erosion and corrosion of gas turbine engine compressor airfoils.

Shipboard gas turbine engines can experience both erosion and corrosion due to water wash maintenance procedures used to remove salt deposits with the engine.

Benefits:

  • Increase flight-readiness of such aircraft as the C-130, P-3, E-2 and V-22.
  • Estimated cost savings of $100M annually in increasing mean-time-between-overhaul (MTBO) by 1.5X.
  • Increase system reliability, maintain engine shaft horsepower, decrease fuel consumption and enhance safety-of-flight.
  • Increase MTBO of compressor system by 1.5 to 2X in desert and maritime operations.

Implementation: The application of MDS-PRAD’s ER-7 erosion resistant coating has resulted in an average Time-On-Wing (TOW) of coated T64 engines of 1,000+ hours. The result was a significant TOW that equated to a savings of $8M per H-53 aircraft. Through a collaborative partnership with NCMS and the CTMA program, MDS-PRAD will continue the research and development of erosion corrosion coatings and applying erosion/corrosion coatings on compressor airfoils representing the T56/501K engines. In addition, MDS-PRAD would apply erosion resistance coatings both ER-7 and NGCV4 (next generation coating) and conduct erosion/corrosion tests as a basis of comparison.

Impact on Warfighter: Additional TOW for the T56 engine equates to additional C-130 aircraft being available and ready to complete another mission. A reduction in spare engines and a decrease in maintenance support crew would be required. Additionally, an engine operating with a healthy compressor will consume less fuel that will decrease the amount of logistical fuel support required.

DoD Participation:

  • S. Navy (Patuxent River)
  • U.S. Navy (FRC East)
  • U.S. Marine Corps (ALS)
  • U.S. Air Force (OC-ALC)
  • U.S. Army (TARDEC)
  • U.S. Army (ANAD)

Industry Participation:

  • MDS Coating Technologies
  • Rolls-Royce
  • StandardAero
  • Honeywell

 

NCMS Project Manager: Debbie Lilu, (734) 995-7038, debral@ncms.org

Problem: In the military vehicle fluids are changed on tight schedules and as part of preparation for operations. The Joint Oil Analysis Program (JOAP) has determined that in excess of 80% of all oil changed in military vehicles meets manufacturer specifications. However, most wheeled vehicles in DoD are not participating in oil analysis programs and oil changes are routinely performed based on elapsed calendar days versus oil conditions. Ultimately, it would be advantageous to both the public and the military to move toward condition-based maintenance (CBM) for vehicle fluids. As part of a CBM program, performing oil changes based on oil quality would keep equipment in optimal condition and eliminate wastes.

Benefit: The ability to have a device that provides units in the field a rapid means to screen and assess lubricants and hydraulic fluids across all weapon systems including ground systems and eventually for sea and air systems.

Solution/Approach: The purpose of this collaborative initiative is to advance the state of acceptance of Expeditionary Fluid Analysis Devices that can accurately determine the condition of a vehicle’s oil so that the most cost effective and environmentally conscious maintenance decision can be made. This CTMA initiative complements and leverages the efforts of the Expeditionary Fluid Assessment Support Team to develop and identify the specifications and requirements for expeditionary fluid analysis. Capabilities can then be acquired and validated for use in the DoD maintenance and repair operations.

Impact on Warfighter:

  • Reduces maintenance down time
  • Increases operational availability
  • Reduces the logistics footprint (materiel, waste, disposal)
  • Reduces overall sustainment costs

DoD Participation:

  • Expeditionary Fluid Assessment Support Team – Army, Navy, Air Force, Marine Corps and Coast Guard

Industry Participation:

  • Portable Fluid Analysis technology providers

 

NCMS Project Manager: Debbie Lilu, (734) 995-7038, debral@ncms.org

 

Problem: Fastener removal is a task required for all aspects of aircraft maintenance, from simple repairs to major modification and SLEP (Service Life Extension Program) efforts. The current approach to fastener removal requires the use of standard twist drills to separate the fastener head and body for removal. This method is extremely labor intensive, has traditionally resulted in high damage rates, and presents a number of serious ergonomic dangers. 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.

Benefit: The FRITA project will accelerate DoD realization of these savings by creating a blueprint for adoption of this technology. The benefits of such a blueprint include simplification of deployment and elimination of redundancies and ambiguities in approval and certification processes.

The vision is that this project may serve as a model for coordinating communication between locations and Services for more rapid technology insertion.

Solution\Approach: The proposed technology solution is a handheld implementation of EDM (Electro-Discharge Machining) technology that cuts 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 between the fastener head and shank; this fillet is easily fractured when the cut fastener is struck with a hammer and punch. The cutting process produces a 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.

Impact on Warfighter:

  • Reduction in fastener removal cycle time
  • Achieve accuracies that significantly reduce the rate of damage incurred
  • Reduced operator fatigue
  • Elimination of noise pollution and hazards to personnel and equipment from drill shard
  • Cost savings to logistics operations
  • Established training and usage standards

DoD Participation:

  • U.S. Navy (FRC Southwest)
  • U.S. Navy (FRC East)
  • U.S. Army (CCAD)
  • U.S. Army (AMRDEC)
  • U.S. Air Force (OO-ALC)

Industry Participation:

  • Perfect Point EDM

 

NCMS Project Manager: Bill Chenevert, (734) 995-7989, billc@ncms.org

 

Problem: Many industrial tools such as heat induction units, grinders, blasters, and water lances employed for corrosion control, remediation, and other uses, are often heavy and awkward to use. These factors limit productivity and impact quality as workers need frequent rest and stretch breaks as a result of the efforts in using these heavy tools, and from applications that require uncomfortable contortions of the worker’s body. These factors also limit the worker’s allowable tool weight.

Benefit: This technology has direct applicability to all DoD industrial, maintenance and repair organizations as well as the commercial industry. It is applicable to the majority of heavy industrial equipment that requires construction, maintenance or repair in DoD industrial facilities. This includes grinding, welding, sanding, water and abrasive blasting operations and many other processes used in vehicle, aircraft, and ship maintenance and repair.

Solution/Approach: Augmenting the worker with an exoskeleton and attached tool holding arm (these together constitute iHAS unit) would provide the means to remove the weight of the tool from the worker while providing maximum mobility. The focus of this CTMA initiative is to enable the heavy maintenance community to adopt iHAS-like capabilities to the benefit of their maintainers and business enterprise. The shipyards will execute industrial test and evaluation assessments of iHAS units doing actual production work in the shipyards over a five month period addressing a variety of corrosion control applications. In addition, the Naval Surface Warfare Center, Carderock Division will record physiological data at Norfolk using a BioHarness.

Impact on Warfighter:

  • Reduces injuries
  • Reduces rework
  • Boosts productivity and improves quality
  • Impacts financial and human bottom line

DoD Participation:

  • NAVSEA 04X
  • U.S. Navy (Puget Sound NSY & IMF)
  • U.S. Navy (Norfolk NSY)
  • Naval Safety Center
  • NSRDEC
  • U.S. Navy (NSWC Carderock)

Industry Participation:

  • Lockheed Martin
  • BAE
  • Equipois

 

NCMS Project Manager: Dana Ellis, (360) 782-1370, danae@ncms.org

Problem: Current capability requirements documents are dated and do not reflect future operational demands anticipated by operating forces in the “new normal” as defined for the post OEF Marine Corps. GCSS-MC capabilities were originally defined In the GCSS-MC Operational Requirements Document (ORD) dating from 2003. The Block I Capability Development Document (CDD) and Capability Production Document (CPD), and the Future increments CDD all build from the requirements established in the original ORD. Additional application and system capabilities and linkages are added and defined in the Sense and Respond Logistics Initial Capability Document (ICD) and DRAFT Logistics IT Portfolio Information System, Initial Capabilities Document (IS ICD). Additional transactional capabilities were defined in multiple Universal Needs Statements (UNS) for the Marine Logistics Support System (MLS2) and other logistics information technology (IT) capabilities. The requirements documents require significant review, updating, and integration; the UNS capabilities must all be evaluated for relevancy and either integration into current programs or development as separate program of record.

Capabilities must be assessed for critical linkages and reliance. Current prioritization of capability development does not reflect a reliance on a later developmental priority. As a result the ability to successfully achieve the top priority may be delayed while waiting to achieve a lower priority capability. In a non-fiscally constrained environment the program office can work multiple priorities in parallel. In the current fiscally constrained environment it is essential to link reliant capabilities and develop cost optimization to ensure capabilities are fully functional and delivered in a timely manner.

Benefit: The repeatable, testable, and defendable analysis benefits the war fighter, DoD and industry at a time when DoD budgets are shrinking, but the need for essential tools is not. DoD will derive additional benefits from this effort through the facilitation of practical investment decisions, cost documentation, and efficiencies, and will improve force readiness and ground equipment performance in line with DoD imperatives. This initiative will also reduce Service-level risk associated with the mix of forces, logistics information system enablers, and ensure the ultimate solutions are attainable within fiscal constraints.

Solution/Approach: This initiative will provide a refined identification and prioritization of logistics capabilities, applications, and systems in order to effectively and efficiently develop decision recommendations for future GCSS-MC capability integration against budget adjustments and resourcing alignment. This will be done in four (4) primary phases:

  • Capabilities vetting & modification with GCSS-MC enterprise stakeholders
  • Grouping of systems into packages of dependencies and precursors
  • Prioritization of applications/systems to develop utility values
  • Alignment of cost against prioritization in order to develop an optimization curve to influence future resourcing

Impact on Warfighter: Improve delivery of a solution that ultimately enhances supply chain visibility, accountability, and accuracy within DoD through improvements in data collection, development, and utilization of the shared data environment, and increased accuracy in logistics accounting records.

DoD Participation:

  • U.S. Marine Corps (CIO)
  • U.S. Marine Corps (GCSS-MC PMO)
  • U.S. Marine Corps I&L

Industry Participation:

  • Whitney, Bradley and Brown, Inc.

 

NCMS Project Manager: Bill Chenevert, (734) 995-7989, billc@ncms.org

Problem: The health of electrical systems is vital to the reliable operation for both commercial and military aircraft, naval vessels, ground vehicles, trains, and alternative energy generators. FADEC systems are vital to engine control and performance. Failure of a FADEC system could result in a complete loss of engine control, a reduction in power or an inadvertent uncommanded-by-pilot action shutdown. Such failures have results I failed missions, loss of aircraft and worst case, the loss of air crew and passengers.

Benefit: Provides opportunities to perform in-situ testing on a wide array of installed complex electronic components in a broad array of weapon systems across all the military services. Increased readiness and reliability of the MH-6M and the MH-47G will be the direct benefit of this initiative. Successful demonstration of the AWTS technology on the FADEC systems will be applicable and transferrable to the entire C/MH-47 fleet, the entire MH-6M fleet, and the OH-58D fleet which uses the same FADEC as the MH-6M.

Solution/Approach: The Phase II initiative will operationalize the use of the Eclypse technology by the 160th SOAR(A) personnel. They will be trained in the design of test adapter cables, and for the basic programming and operations of test program sets enabling them to quickly respond to issues being faced in weapon systems electrical systems that are jeopardizing readiness and reliability. Additional hardware will enable more complete testing of the MH-6M with extension to the MH-47G and applicability to the OH-58D.

Impact on Warfighter:

  • Increased operational and weapon systems readiness and reliability
  • Reduced costs
  • Speed test development for Abrams fleet

DoD Participation:

  • U.S. Army – 160th SOAR(A)
  • MELB PMO
  • U.S. Army (Anniston)

Industry Participation:

  • Eclypse International

 

NCMS Project Manager: Steve Hale, (734) 995-2195, steveh@ncms.org

 

Problem: Building Navy ships is a very rigorous and exhausting task performed each day by workers at shipyards. Non-augmented workers endure injuries from muscle fatigue, ergonomic stress, and exhaustion on a daily basis from manipulating heavy tools for extended periods of time. Because of this, shipyards lose millions of dollars each year through workers’ compensation and training new worker.

Benefit:

  • Reduce worker fatigue and strain
  • Reduce total ownership costs
  • Reductions in rework

Solution/Approach: The work that will be accomplished under this project includes two prototype iHAS units for test and evaluation (T&E) of many different maintenance and repair applications doing actual production work at Puget Sound Naval Shipyard. To facilitate project execution, two MANTIS units will be leased to the Navy to begin T&E until the next generation units are ready for delivery. The T&E will include measuring worker productivity, work quality and ergonomic considerations. In addition, a Safety Assessment of the iHAS will be performed by a cross organizational, multi-service team to assess the risks of using an iHAS in comparison to the benefits the iHAS provides.

Impact on Warfighter:

  • Boost productivity
  • Reduce injuries
  • Improve quality

DoD Participation:

  • U.S. Navy (Puget Sound NSY)
  • U.S. Navy (NSWC Carderock)

Industry Participation:

  • Lockheed Martin

 

NCMS Project Manager: Dana Ellis, (360) 782-1370, danae@ncms.org

 

Problem: The USAF T56 engine Program Office implemented the Workscope Cost Optimizing Tool (WCOT) in 2006. This tool recommends optimal repair workscopes based on the underlying reliability and cost of repair options. The success of the program in improving T56 reliability has been directly tied to the quantity and quality of data collected at the depot and in the field through the use of the Maintenance In-Depth Maintenance Data Collection System (MIDCS) database within the USAF’s Data Repository Center (DRC).

The development and sustainment of the Workscope Cost Optimization Tool  is data-intensive. The removal times and observed failure modes of numerous engine parts must be manually collected, not only at the depot, but also at Intermediate Repair sites. Manual data collection creates two significant problems. First, it introduces error through the incorrect recordings that are transcribed and entered into government systems. Secondly, it is expensive. Not only are serial numbers written down, but they are subsequently key-punched into databases. The burden this places on field units is substantial and consequently, requests to track additional engine parts are often rejected by the field simply because the data recording process is so labor-intensive.

Benefit: The use of UID tagging and data collections methods will benefit the DoD in three ways:

  • Reduced labor burden on the field level personnel, with subsequent cost savings.
  • Improved accuracy in the data collection efforts.
  • Provide an understanding as to how data accuracy impacts the accuracy of existing and future prediction tools.

Implementation: Under this project, the collection of engine component reliability data through UID means will be piloted. Specifically, this project will:

  • Pilot, and if necessary, simulate the use of UID on engine parts to support the Workscope Cost Optimization Tool development process.
  • Measure the time savings associated with the use of UID vs. manual collection of engine data.
  • Measure and compare the error rates of manually and UID collected data sets. In this regard, the project will refer to previous work that baselined the errors in the reliability data sets.
  • If appropriate, build a business case for the widespread adoption of UID as a way to improve data quality and reduce the cost of data collection.
  • The work will be accomplished on engines that are using the workscoping tools currently within the AMC and AFSOC Commands.
  • UID data will be downloaded directly into the USAF’s reliability MIDCS data base at each event. This will prevent the need for USAF personnel to document the component details at each removal event.

This process will set the path for tracking components relevant to engine reliability and cost without burdening maintainers, resulting in further cost savings from current implementation efforts.

Impact on Warfighter: The use of UID can greatly enhance the level of data collection, while maintaining integrity and reducing the burden on the war fighter.

Reductions in the time required to collect component data in the field will improve throughput in the shops by reducing delays. The reduction in time required to collect the data will free personnel for other duties, possible resulting in an increase in maintenance capacity.

DoD Participation:

  • U.S. Air Force (Lackland)

Industry Participation:

  • StandardAero

 

NCMS Project Manager: Debbie Lilu, (734) 995-7038, debral@ncms.org

Problem: The Military Services are currently challenged by detecting and isolating faults in aircraft wiring cables and avionics line replaceable units (LRU). These faults include opens and shorts, degraded and intermittent signals, and insulation degradation. The magnitude of the challenge is daunting with the DoD spending approximately $2B annually just removing and replacing LRUs that when tested, reveal no fault found (NFF). Additionally, legacy electronic components are experiencing increasingly reduced reliability as a result of component age and usage, current visual inspection processes lack effectiveness and can identify only approximately 25% of total weapon system wiring problems. DoD estimates that 75% of aircraft in a mission ready status contain intermittent electrical interconnect issues with potentially catastrophic implications.

Several newer technologies address the identification and isolation of electrical faults in weapon systems, including intermittent faults. However, there is no defined requirement for detecting and isolating intermittent faults and no test validation process for assessing the capabilities of intermittent detection and isolation devices offered by industry.

Benefit: The ability to test, identify, isolate, and repair intermittent fault problems for all weapon systems will result in substantial cost savings as well as weapon system availability for all the services. Complex electronic intermittent faults are not a problem that is isolated to DoD equipment.

Solution/Approach: This initiative complements and leverages NAVAIR and Air Force fault detection and isolation projects to develop test, fault detection, isolation and root cause determination for field level and depot level use. By properly identifying the parameters defining intermittent faults, joint intermittence test requirements can be developed and published, and intermittence test equipment can then be acquired and validated for use in the DoD maintenance and repair operations.

  • Define and validate joint requirement for intermittent fault detection
  • Identify, define, and establish joint test methods and capabilities to assess and validate industry proposed intermittence detection and isolation capabilities
  • Publish joint performance requirements – Mil-PRF, report and recommendations

Impact on Warfighter:

  • Reducing maintenance downtime
  • Increasing operational availability
  • Reducing the logistics footprint (materiel, waste, disposal)
  • Reducing overall sustainment costs

DoD Participation:

  • U.S. Navy (NAVAIR)
  • U.S. Air Force (Ogden ALC)

Industry Participation:

  • Lectromech
  • Eagle Solutions

 

NCMS Project Manager: Dana Ellis, (360) 782-1370, danae@ncms.org

 

Problem: Currently, commercial industries are lacking in software and hardware capabilities that communicate information not only from system-to-system but also to multiple facilities globally and across service providers. Any sharing of information, resources or services is usually ad hoc, disjointed and informal with no traceability, a lack of accounting for lifecycle management or cost consideration. Another result of this shortfall of capability is a significant redundancy of parts stocks, consumable inventory, maintenance capability, and services.

Both industry and military services have been pursuing efforts (IT, process procedural and contractual) in an attempt to rectify this issue. Industry has been actively engaged in rectifying this shortfall through the development of overarching information system-agnostic standards for the exchange of hardware pedigree data required for maintenance and sustainment. DoD has also been an active participant and has taken specific actions to evaluate these data interoperability standards. Although much has been accomplished to date, further work needs to be accomplished in order for the maintenance community to leverage standards data exchange processes.

Benefit: By developing data exchange flows and integrating back-end systems, the DoD can begin to leverage the inherent benefits of mutual sustainment activities and achieve sustainment cost reduction across the Joint Force.

Solution/Approach: Developing tools, technologies, and processes that can leverage the benefits associated with operating across organizational boundaries will enable the maintenance and sustainment community to share logistics capacity and materials. This collaborative effort will focus on easily exchanging and sharing relevant information, underlying logistical data, without negating the positive attributes of the individual data characteristics (AIS, process and procedures) as an enabler to Logistics Interoperability and Integration. Work will address Joint Logistics Interoperability CONOPS and an expansion of capabilities that not only will be available to commercial industry but will further offer Joint Forces the ability to pool and share resources as well as associated maintenance and repair data.

Impact on Warfighter:

  • Improved weapon system reliability and readiness
  • Reduced costs

DoD Participation:

  • Headquarters Marine Corps I&L
  • Marine Corps LOGCOM
  • ODASD (MPP)
  • Joint Staff J4

Industry Participation:

  • NEXUS Life Cycle Management, LLC
  • Portac
  • Black & Rossi

 

NCMS Project Manager: Debbie Lilu, (734) 995-7038, debral@ncms.org

 

Problem: The National Defense Authorization Act (NDAA) for Fiscal Year 2010 directed that “The Chief Management Officer of the Department of Defense (DoD) shall, in consultation with the Under Secretary of Defense (Comptroller) (USD (C)), develop and maintain a plan to be known as the Financial Improvement and Audit Readiness (FIAR) Plan”.

The Under Secretary of Defense for Acquisition Technology and Logistics (USD (AT&L)) echoed USD (C) priorities for the FIAR Plan “to validate the existence and completeness (E&C) of mission-critical assets on the path to complete financial statement audit readiness” defined as the following:

  • Existence – all accountable property in DoD systems of record exists and their records match actual physical assets.
  • Completeness – all accountable property is identified and accurately recorded in a DoD system of record.

 

The current version of the FIAR Guidance, published in December 2011, is a four-part approach for Service components to achieve audit readiness. Mission critical assets are a key consideration under the FIAR plan including the subsets of Military Equipment (ME) and Operating Materials and Supplies (OM&S) that are the primary focus of the Deputy Commandant for Installations and Logistics (DC I&L). USD (AT&L) defines ME as weapons systems used directly by the Armed Forces to carry out battlefield missions, has an expected useful life of two or more years, and does not lose its identity or become a component part of another article. The target ME assets for audit readiness are those with an acquisition cost of $100,000 or greater and include assets such as light armored vehicles, howitzers, tanks, and certain communications equipment.

Benefit: This project will enable our industry partners to better anticipate equipment requirements in support of reconstitution and the critical transition to a Middle Weight force. The military learns from industry using best practices to better account for its equipment based on operational user observations and suggestions with an emphasis on understanding total ownership costs. Industry is better able to satisfy Marine Corps requirements when they are well defined based on careful analysis, sound data, and best commercial practices. Industry partners may later leverage those lessons learned to products they produce for commercial consumers.

Solution\Approach: Deputy Commandant for Installations and Logistics (DC I&L) established an E&C Integrated Product Team (IPT) to improve business processes and steer actions for the Marine Corps FIAR audit readiness efforts to comply with the Department of the Navy (DoN) schedule for asserting to audit readiness for the E&C of ME by FY14. The IPT will review and improve the sustainable process to maintain an effective and efficient inventory management strategy into the future to improve equipment accountability and visibility.

On 2 March 2011, the Assistant Commandant of the Marine Corps (ACMC) tasked the DC I&L with establishing a Marine Corps Enterprise Ground Equipment Manager (EGEM) to execute Principle End Item (PEI) inventory management. Key aspects include ownership of inventory distribution, delivery, coordination, reporting, and visibility to manage and communicate PEI inventory posture to meet Marine Corps-wide equipping needs and accountability requirements. Per CMC White Letter 03-08 of 16 May 2008 and DODI 5000.64, property accountability is a multi-step, multi-player process. This process requires logistic chain management corrective action between stakeholders to include HQMC-level financial management (Programs and Resources (PR)), acquisition (MARCORSYSCOM and Program Executive Offices (PEOs)), and Logistics (I&L and MARCORLOGCOM) to improve processes to achieve equipment accountability and visibility (EAV) for audit readiness.

The objective of this project is to analyze and document the accountability processes pertaining to the existence and completeness of military equipment as required by the FIAR Plan and to inform DC I&L chain management corrective actions as the EGEM.

Impact on Warfighter:

This project will assist in improving equipment accountability throughout the Marine Corps by assisting in the establishment of the EGEM, in:

  • Validating the Master Data Repository.
  • Improving military equipment accountability processes to produce cost efficiencies.
  • While supporting the warfighter with the equipment needed to complete their mission.

DoD Participation:

  • S. Marine Corps Requirements Oversight Council (MROC)
  • Deputy Commandant, Installations and Logistics (DC I&L)
  • S. Marine Corps Combat Development Council (MCCDC)
  • S. Marine Corps Systems Command (MCSC)
  • S. Marine Corps Logistics Command (MCLC)
  • S. Marine Forces Commands (MARFORs)

Industry Participation:

  • The Columbia Group

 

NCMS Project Manager: Tony Haynes, (734) 995-4930, tonyh@ncms.org

 

Problem: The Deputy Commandant for Installations & Logistics (DC I&L) is tasked to coordinate and improve the logistics chain continuum from requirements determination; to acquisition, manufacturing, and fielding; to sustainment within the operating forces and maintenance in the depots, and ultimately through disposal. Integral to accomplishing these tasks is improving equipment accountability across the Marine Corps. The DC I&L is also charged with leveraging commercial best practices and tools whenever appropriate and in the best interest of the Marine Corps. In order to comply with these directives, DC I&L requires a comprehensive assessment of Financial Improvement and Audit Readiness (FIAR) enablers currently in use and an thorough understanding of the potential to improve FIAR process outcomes via the adoption of best commercial practices and technologies.

Benefit: The efforts by this project will identify the enterprise requirements, acquisition, maintenance, and sustainment initiatives that directly support and complement the OSD-mandated supply chain and total ownership costs efficiencies. The DoD benefits from this effort will facilitate prudent investment decisions, cost documentation and efficiencies, and improve force readiness and ground equipment performance in line with DoD and Department of Navy imperatives.

Solution/Approach: The objective of this effort is to perform in-depth analysis of mission critical asset audit readiness and supplemental support processes and technologies and to identify potential corrective action plans that would improve financial management processes and technologies that leverage commercial best practices and tools.

Impact on Warfighter: This effort helps reduce the Service-level risk associated with the mix of forces, equipment, and support attainable within fiscal constraints.

  • Improve equipment accountability
  • Validation of unit inventories

DoD Participation:

  • U.S. Marine Corps (LPC-2)

Industry Participation:

  • The Columbia Group

 

NCMS Project Manager: Jeff Walker, (360) 782-1370, jeffw@ncms.org

 

Problem: The Deputy Commandant for Installations & Logistics (DC I&L) is tasked to coordinate and improve the logistics chain continuum from requirements determination; to acquisition, manufacturing, and fielding; to sustainment within the operating forces and maintenance in the depots, and ultimately through disposal. An integral step in that process is to reduce equipment maintenance and sustainment costs to maintain the high levels of readiness expected for our nation’s “Force-in-Readiness.”

Benefit: The efforts by this initiative will identify the enterprise requirements, acquisition, maintenance and sustainment initiatives that directly support and complement the OSD-mandated supply chain and total ownership costs efficiencies. The DoD benefits from this effort to facilitate prudent investment decisions, cost documentation and efficiencies, and improves force readiness and ground equipment performance; in line with DoD and Department of Navy imperatives. This effort helps reduce the Service level risk associated with the mix of forces, equipment, and support attainable within fiscal constraints.

Solution/Approach: The objective of this effort is to build and expand upon existing work products; develop and implement policies, processes, and procedures; facilitate requirements development and technology integration to improve maintenance, sustainment and processes across the logistics chain in support of our Marine Corps Operating Forces.

Impact on Warfighter: The processes, procedures, and products addressed in this initiative will better prepare the Marine Corps to return to its expeditionary role, providing for an improved operational readiness for the expeditionary warfighter.

DoD Participation:

  • U.S. Marine Corps (LPC)

Industry Participation:

  • The Columbia Group

 

NCMS Project Manager: Tony Haynes, (734) 995-4930, tonyh@ncms.org

 

Problem: The Marine Corps will be required to do more with diminishing resources, reduced personnel, changes in organizational structure with significant manning and equipping changes. There will be increased dependence on maintenance and cost efficiencies to extend the service life of the limited equipment in the inventory. Critical to success is accurate data and an effective means to determine Total Ownership Cost (TOC) of weapon systems and ground equipment. Multiple commands and supporting information technology systems involved in the acquisition, fielding, sustainment, and disposition of material, coupled with inaccurate or missing data has precluded accurate TOC determination and analysis.

The primary objective is to develop a validated maintenance and sustainment life cycle cost model for USMC weapon systems. Achievement of this objective requires data gathering and analysis of the two key components:  the Operating Forces (OPFOR) and the Supporting Establishment (SE). These analyses must feed the Capabilities Based Assessment (CBA) in support of the Marine Corps Force Development System (MCFDS) as input into the Planning, Programming, Budgeting, and Execution (PPBE) system.

The Deputy Commandant, Installations and Logistics (DC I&L) is tasked to coordinate and improve the logistics chain continuum from requirements determination; to acquisition, manufacturing, and fielding; to sustainment within the operating forces and maintenance in the depots, and ultimately through disposal. The Marine Corps in conjunction with the Navy must eliminate redundancies and reduce equipment developmental and maintenance costs while maintaining the high levels of readiness expected for our nation’s “Force-in-Readiness.”

Benefit: The efforts by this project will identify the enterprise requirements, acquisition, and sustainment initiatives that directly support and complement the OSD-mandated supply chain and total ownership costs efficiencies. The DoD benefits from this effort to facilitate prudent investment decisions, cost documentation and efficiencies, and improves force readiness and ground equipment performance; in line with DoD and Department of Navy imperatives. This effort helps reduce the Service level risk associated with the mix of forces, equipment, and support attainable within fiscal constraints.

Solution\Approach: In the performance of this effort, the project participant shall provide technical analysis and subject matter expertise to the DC I&L within the following areas:

  • Sustainment Planning and Equipment Accountability
  • Analyses and Cost Framework for Ground Combat Systems Analyses
  • Implementation Support.

Impact on Warfighter:

  • Process improvements
  • Cost savings
  • Improved support.

DoD Participation:

  • U.S. Marine Corps Requirements Oversight Council
  • Deputy Commandant, Installations & Logistics
  • U.S. Marine Corps Combat Development Command
  • U.S. Marine Corps Systems Command
  • U.S. Marine Corps Logistics Command
  • U.S. Marine Forces Commands

Industry Participation:

  • The Columbia Group

 

NCMS Project Manager: Tony Haynes, (734) 995-4930, tonyh@ncms.org

 

Problem: The tremendous amount of logistics data created as a result of recent operations currently resides in the Master Data Repository (MDR). The MDR has data quality issues, is inefficiently organized and risks losing data due to a lack of a data utilization strategy and storage plan.

Benefit:

  • Reduce the risk of critical data loss
  • Decrease sustainment costs
  • Improve depot performance through greater data fidelity and retrieval
  • Improve acquisition decision making
  • Reduction of total lifecycle management equipment costs
  • Support the Joint Logistics Enterprise

Solution/Approach: This initiative will assess and develop Master Data Management (MDM) solution alternatives that will provide standardization and support quality control for core reference data. The anticipated results from this CTMA initiative will capitalize on cutting edge commercial industry capabilities to conduct a proof of concept to demonstrate an alternative to the current server based capability. Based on the results of the proof of concept an overarching strategy will be developed outlining a cohesive and comprehensive data utilization strategy.

Impact on Warfighter:

  • Increased efficiencies of current and future resources
  • Reduced costs from the improvement in resource allocation
  • Enhanced readiness due to a more rapid response to the warfighter
  • Reduced institutional risk

DoD Participation:

  • U.S. Marine Corps I&L (LPV)
  • U.S. Marine Corps Logistics Command
  • U.S. Marine Corps Maintenance Command
  • U.S. Marine Corps System Command
  • U.S. Marine Corps Combat Development & Integration (LID)

Industry Participation:

  • Untied Global Group, LLC
  • Troika Solutions, LLC

 

NCMS Project Manager: Dana Ellis, (360) 782-1370, danae@ncms.org

 

Problem: Currently, no program exists to track the condition of the several hundred Navy aircraft on display at various geographical locations. To ensure that these artifacts are not neglected and are maintained in a condition that ensures public safety and respect for the Navy’s heritage, a program is needed to track the inventory’s condition. The condition of the artifacts is currently unknown and responsibilities are stove piped without accountability and/or traceability. Despite the common need of the displays, today there is no coordinated maintenance program for the static displays, no standardized sustainment processes exists, and no data on impact to the environment of static displays are on record. Without an established program to preserve and display these artifacts, the ability to inform, educate, and inspire the general public will diminish along with their appreciation that “freedom is not free.”

Benefit: Public support for bearing the cost of freedom is crucial. The books, artifacts, static displays, and events all play an important role in promoting public awareness of the need and support for continued military funding at levels appropriate for the necessary high level of preparedness and our National Defense.

Solution/Approach: This collaborative CTMA initiative will provide a venue in which the public and private communities can efficiently and effectively work together to identify necessary and cost-effective approaches to improve maintenance and sustainment and ultimately ensure public safety and protection of the environment where these artifacts and aircraft are located.

Impact on Warfighter:

  • Identify, analyze, assess, track and inspect publicly displayed Fleet artifact and aircraft inventory
  • Ensure effective maintenance and sustainment of artifacts and aircraft
  • Protect public safety
  • Evaluate environmental impacts
  • Maintain respect for Navy’s heritage

DoD Participation:

  • Naval History and Historical Command (NHHC)
  • Naval Reserve Units
  • OSD

Industry Participation:

  • Possessors of Naval Artifacts and Aircraft
  • The Columbia Group
  • Wounded Warrior Detachments
  • OEMs of Naval Artifacts and Aircrafts and SME retires (as required)

 

NCMS Project Manager: Bill Chenevert, (734) 995-7989, billc@ncms.org

 

Problem: It is very costly for commercial industry (including the DoD) to maintain IT capabilities in order to manage their day-to-day business. Industry continues to look for ways to operate more efficiently in order to maintain their IT cost competitiveness. Many companies today are investigating the feasibility of outsourcing IT and utilizing improving internet capabilities. One area continues to gain interest is Cloud Computing, specifically Platform as a Service (PaaS).

Benefit: The results of this initiative can be leveraged across DoD to drastically impact readiness planning and management through improved interoperability/access to more legacy systems and accurate data. Additionally, the DoD will enhance the ability to provide logistics support and reduce risk and sustainment costs.

Solution/Approach: The Marine Corps have similar problems with their IT systems and have shown a particular interest in using Cloud Computing as a solution. This CTMA initiative is a follow-on to a previous CTMA Master Data Management (MDM) Solutions initiative in which a multi-purpose shared data environment ELDW that provided global data aggregation and management, centralized reporting, and analytical processing for tactical and depot logistics systems was developed. This new initiative will take the previous efforts one step further by evaluating the integration of ELDW and PaaS to further reduce GCSS-MC interfaces, improve data accessibility, increase and improve legacy LOG IT system interoperability and reduce future capability development costs.

Impact on Warfighter:

  • Support the Joint Logistics Enterprise
  • Decrease sustainment costs
  • Improve depot performance through increased interoperability of legacy systems
  • Improve acquisition decision making
  • Enhanced readiness due to more effective and efficient data analysis
  • Reduced institutional TLCM risk

DoD Participation:

  • Headquarters Marine Corps I&L (LPV)
  • Marine Corps LOGCOM
  • Marine Corps SYSCOM (PM, GCSS-MC and PM, Ammo)

Industry Participation:

  • One Network Enterpises, Inc.
  • Troika Solutions, LLC

 

NCMS Project Manager: Debbie Lilu, (734) 995-7038, debral@ncms.org

 

Problem: Over the last 10 years, manufacturers in instrumentation, industrial machinery, consumer electronics, medical industry, nuclear industry, aviation industry, packaged goods and other complex engineered products have discovered the benefits of PLM solutions and are adopting PLM software and best practices in increasing numbers. However, the DoD has lagged behind industry by continually maintaining a huge catalog of legacy systems that contain technical data spanning best practices of several decades. The continuation of the PLM initiative for Aircraft Sustainment will significantly improve the maintenance and service lifecycle process and expand beyond the success of the initial F/A-18 initiative.

Benefit: Industry is challenged with PLM technology in developing assets for the DoD while supporting a larger supplier base to manufacturing parts for DoD. Working together with DoD to incorporate best practices with their own suppliers (even if they are internal) to ensure that they are producing the right parts, especially the flight critical components will increase the operational readiness of the warfighter and reduce costs.

Solution/Approach: The project approach will be built on the substantial work accomplished through the earlier NCMS projects. Because the work performed at each of the FRCs varies and each location is at a different level of maturity, the approach has been divided into three sections, one for each FRC location. Upon completion of the project, the three FRC locations will share a common PLM backbone with similar functionality, tailored to their unique organizational configuration. The common backbone will enable the FRCs to share data, resources and manufacturing capabilities in an efficient configuration managed environment through the lifecycle of their products.

Impact on Warfighter:

  • Single source bill of materials
  • Trackable service activity history
  • Cohesive collaboration between FRCs
  • Savings in time, money and energy

DoD Participation:

  • U.S. Navy (FRC Southwest)
  • U.S. Navy (FRC Southeast)
  • U.S. Navy (FRC East)

Industry Participation:

  • Siemens PLM

 

NCMS Project Manager: Dana Ellis, (360) 782-1370, danae@ncms.org

 

Problem: Puget Sound Naval Shipyard and Intermediate Maintenance Facility (PSNS & IMF) is the U.S. Navy’s designated site for breaking and recycling nuclear-powered ships and submarines. In 2008, PSNS & IMF received a Notice of Violation (NOV) for exceeding the Puget Sound Clean Air Act (PSCAA) 20% Opacity Limit while using the no longer available methyl acetylene propadiene (MAPP) gas for metal cutting. The main generator of visible particulate matter (PM) emissions was identified as oxy-fuel torching, the site’s primary metal cutting technology. PSNS & IMF has since been searching for alternative or modification technologies to bring its shipbreaking and recycling operations under compliance. PSNS & IMF was the first organization to actively address the need for opacity reduction during metal-cutting operations.

The ships are much larger than the submarines and cannot be contained by the currently installed enclosures, the short-term emergency remedy invested by the site. It is expected that all cutting on ships must be performed outside. Therefore, the advantage of zero emission is needed immediately in order to ensure no violation of opacity limit during the first stages of dismantling the ships.

Benefit: DoD will have a faster and more economical method for the environmentally responsible dismantling of their decommissioned ship fleet.

The environmentally improved technology being developed for DoD is applicable to private industry as well as the U.S. infrastructure is being rebuilt, which entails the use of the cutting technologies being developed in this initiative.

Implementation: This initiative will evaluate MagneGas technologies to help minimize opacity at the source without compromising worker convenience, safety, or cutting efficiency. This technology has the potential to be the alternative cutting solution that would keep PSNS & IMF in compliance of State and Federal Air regulations. The purpose of this field demonstration is to validate MagneGas as an alternative metal cutting technology for reducing opacity emissions.

This project evaluates a cold cutting technology during shipbreaking and repair operations intended to reduce particulate opacity to less than 20% while maintaining worker safety and production schedules.

Impact on Warfighter: The goal is to maintain the Navy’s mission readiness without further violation of environmental initiatives and compliance goals.  As environmental compliance is part of the site’s mission goals, it can be argued that the funds are being used to ensure sustainability of its performance in shipbreaking and recycling.

DoD Participation:

  • U.S. Navy (NAVFAC ESC)
  • U.S. Navy (PSNS & IMF)
  • U.S. Navy (NAVSEA 04X)
  • PMS 312
  • PMS 392

Industry Participation:

  • MagneGas

 

NCMS Project Manager: Dana Ellis, (360) 782-1370, danae@ncms.org

 

Problem: The Shareable Operational Resources Tool (SORT) was developed initially to demonstrate the benefits of merging “Product” level data through its NATO (or National) Stock Number (NSN) or Reportable Item Code (RIC), and “Item” level data using Item Unique Identification (IUID) as a means to provide visibility of common or shareable resources between forces within a contingency operation.

SORT exists in 2 forms:  As a web-based portal hosted at the NATO Support Agency (NSPA), and as dSORT (deployable SORT), a commercial off-the-shelf (COTS) product which is capable of being hosted on the internet as well as closed networks.

Due to funding limitations, SORT functionality has fallen behind commercial upgrades incorporated into dSORT which add functionality or address shortfalls which identified during employment in exercises and user evaluations. Resource constraints in DoD and in Allied nations precipitate the need to provide means to reduce redundancy in a manner that is low-risk to success of exercises and contingency operations.

Benefit: This will result in both improved capability and awareness of SORT as a means to implement Multinational Logistics capabilities in exercises and Contingency Operations – reducing deployed footprint requirements, strategic lift, and demand for high-priority shipment of items into theater when they exist outside of the traditional supply chain.

Solution/Approach: Although SORT has high-level backing, it has yet to be embraced during operational planning and execution. This project is designed to address this issue by integrating SORT coincident with various standard logistics information systems and processes and to demonstrate its capability via live exercises with both multinational participation, as well as the command planning level (CPX) as well as live forces (LIVEX).

This CTMA initiative will develop capabilities necessary to upgrade SORT (NSPA) that enable logistics services within SORT (NSPA) in addition to addressing other identified shortfalls, and will demonstrate this to multinational forces in a 2014 exercise using the Maintenance and Repair DEX.

Impact on Warfighter:

  • Improved weapons system readiness, availability, global visibility and tracking
  • Class IX inventory reductions by enabling mutual multinational logistics support during coalition operations
  • Reduction of deployed footprint
  • Reduction of supply and maintenance response times
  • Automation of existing Acquisition and Cross Servicing Agreement processes
  • Reduction of costly expedited materials shipments from outside of theater
  • Efficient redistribution of assets during turnover, drawdown and re-deployment

DoD Participation:

  • OSD
  • NATO Support Agency

Industry Participation:

  • Topline Technologies
  • Nexus LCM
  • Black & Rossi, LLC

 

NCMS Project Manager: Debbie Lilu, (734) 995-7038, debral@ncms.org


 

Problem: The T700-GE-401C engine are jointly operated in all military services, powering H-60, AH-64 and AH1 aircraft. These types of aircraft are operated in both erosive and maritime environments. These austere operating environments degrade compressor airfoil condition and performance.

Benefit: The overall benefits of the application of an EC/RC on compressor blades are significant such as:  increase time-on-wing, retain engine power, increase engine compressor life, decrease amount of infield compressor washes, decrease maintenance actions, and reduce environmental impact per each engine repair & overhaul. This coating will also decrease overall maintenance costs and reduce compressor replacement, and spares reduction. Due to overall compressor efficiencies fuel savings would also be achieved. Lastly, the coating on the compressor blades would reduce manufacturing of critical materials such as titanium and ultimately decrease spare parts procurements

Solution/Approach: The purpose of this project is to jointly develop the engineering change required for coating implementation of compressor blades. This project will leverage ongoing joint initiatives currently evaluating engine compressor Erosion/Corrosion Resistance Coating (EC/RC) for increased durability, with extensions to field testing and evaluations. This effort complements NAVAIR’s activity as joint service lead to explore the benefits of ER/CR on the H-60 helicopter and to qualify this coating on T700 engine components used by the services.

Impact on Warfighter:

  • Reduce logistics footprint
  • Reduce demand for expensive long lead time of compressor components
  • Improve maintenance capacity
  • Increase aircraft readiness and throughput

DoD Participation:

  • U.S. Navy (NAVAIR Patuxent River)
  • Special Operations Command (SOCOM)
  • U.S. Army Aviation & Missile Command (AMCOM)
  • U.S. Army Missile Research, Development and Engineering Center (AMRDEC)
  • Technology Application Program Office (TAPO)
  • U.S. National Guard

Industry Participation:

  • MDS Coating Technologies

 

NCMS Project Manager: Debbie Lilu, (734) 995-7038, debral@ncms.org

 

Problem: Maintenance and sustainment support efforts in commercial industries are heavily reliant on Test Measurement and Diagnostic Equipment (TMDE).  This maintenance and sustainment support is performed by specialized technicians and mechanics across the public sector and within DoD.  A combination of tools and test equipment are used and collectively these tool and test equipment are classified into six categories:  General Purpose Electronic Test Equipment, General Purpose Mechanical Test Equipment, Tool Sets & Kits, Automated Test Systems, Application Program Sets, and Calibration Systems.  Given the breadth of TMDE within industry and military alike, there are many opportunities for improvements as well as identifications of gaps and overlaps.

Benefit: When widely adopted, DoD stands to benefit from clear TMDE requirements development through a reduced maintenance burden that improves equipment availability.  This will ultimately translate into supply, maintenance management and maintenance touch labor reductions.  This will not only ease the burden of impending reductions in USMC/DoD end strength, but also reduce the required number of spares and consumable parts needed especially for deployed units.

Solution/Approach: TMDE is used through the Services to assist in the setup, monitoring, testing, troubleshooting, alignment, repair and rebuild of weapons systems.  As the quantity and complexity of DoD weapon systems increase so too do the requirements for the TMDE used to support it.  The initiative will define an effective TDME for industry and the military through a Marine Corps demonstration project to identify gaps, vulnerabilities, assess alternatives for improvement, and to validate requirements for an effective enterprise-wide TMDE.

Impact on Warfighter:

  • Defined requirements
  • Improved lifecycle operations and management
  • Reduced maintenance burden
  • Cost reductions

DoD Participation:

  • U.S. Marine Corps, Capabilities Development and Integration
  • U.S. Marine Corps Systems Command (TMDE)
  • U.S. Marine Corps, Installations & Logistics

Industry Participation:

  • Whitney, Bradley and Brown, Inc.
  • PORTAC Consulting, LLC

 

NCMS Project Manager: Bill Chenevert, (734) 995-7989, billc@ncms.org

 

Problem: Maintenance and sustainment support efforts in commercial industries are heavily reliant on Test Measurement and Diagnostic Equipment (TMDE). A combination of tools and test equipment is used. Double and triple redundant TMDE systems are often in place generating more costly manufacturing processes and inefficiencies. The key enabler for improving TMDE systems within the Marine Corps is their Electronic Maintenance Support System (EMSS).

Benefit: The results of this analysis will be extrapolated to support broader industry, public, and DoD applications. By using qualitative and quantitative tools the analysis will be repeatable and testable. The public will benefit when industry’s lifecycle cost reduction translates into reduced prices for goods and services.

Phase II benefits will provide DoD with cost-informed alternatives to support TMDE and EMSS implementation across a broader user community, and expose DoD to additional industry vendors thereby expanding the defense market.  When widely adopted, DoD stands to benefit from clear requirements development through a reduced maintenance burden that improves equipment availability.  This will ultimately translate into supply, maintenance management and maintenance touch labor reductions.  This will not only ease the burden of impending reductions in end strength, but also reduce the required number of spares and consumable parts needed – and all of the deployment and distribution required to supply these items to deployed units which operate the equipment more heavily than in garrison training.

Solution/Approach: The Phase II objective is to assess EMSS’s capabilities and limitations, to identify emerging commercial technologies to address/improve EMSS, to understand the potential benefits/risks to EMSS capability requirements, to identify cost impacts over time, and to collaboratively develop an implementation plan for the marines and commercial industry to consider.

Within Phase II of this project, the CMTA team will perform systems requirements analysis and development of cost informed implementation strategies. Secondly, the team will work in close concert with the core stakeholders and subject matter experts to evaluate the impact of formal Requirements (JCIDS and Marine Corps Force Development processes and systems), as well as enterprise and systems architectures describing the systems, processes and standards required to implement any recommended solutions within the Marine networks.

Impact on Warfighter:

  • Reduced time assets spent in maintenance
  • Improved equipment readiness
  • Reduced operating, overhead and lifecycle costs
  • Flexible hardware platforms improving TMDE support

DoD Participation:

  • U.S. Marine Corps, Installations & Logistics (LPC)
  • U.S. Marine Corps Systems Command (TMDE team lead)
  • U.S. Marine Corps, Capabilities Development and Integration (LID)

Industry Participation:

  • Whitney, Bradley and Brown, Inc.
  • PORTAC Consulting, LLC

 

NCMS Project Manager: Bill Chenevert, (734) 995-7989, billc@ncms.org

 

Problem: As with all transformational initiatives, policy and guidance are not enough to affect the needed sweeping changes to achieve critical mass for CBM+ implementation. Budget constraints will impact not only the ability to operate and maintain equipment across the DoD, but also to invest in process and system improvements designed to mitigate the impact of the resource constraints. This “catch-22” situation results in individual weapon systems programs taking the initiative to develop CBM+ solutions, which ultimately result in multiple, non-integrated solutions which use multiple proprietary technologies. This dissuades program resources to fill enterprise gaps, disallows most programs access to CBM+ solutions, and delivers sub-optimal solutions in “stove-pipes” and creates barriers which impede most legacy platforms from access to best-in-class commercial practices and technologies.

Benefit: This initiative will afford subject matter experts the opportunity to assess the recently issued CBM+ AG BCA template and process for developing business case analyses in support of enterprise-level CBM+ implementation.

  • Reduced maintenance burden to produce the required levels of equipment availability
  • Improvement in data exchanges for information between operational, logistics, sustainment and acquisition communities
  • Greater life cycle management

Solution/Approach: Partner with the Marine Corps and industry to formally define and document the current gaps, vulnerabilities, assess alternatives, and validate requirements of enterprise-wide CBM+ implementation. By leveraging the Joint Capabilities Integration and Development System (JCIDS) process, the CTMA team will not only validate the requirements for CBM+ using novel industry-best capabilities based assessment tools, but will also provide a detailed documentation of the scope, plans, and capabilities that CBM+ entails within most ground equipment maintenance and life cycle management processes.

Impact on Warfighter:

  • Standardized approach to maintenance
  • Reduce cost of business operations
  • Reduce the number of spare and consumable parts needed
  • Improved logistics
  • Improved resource management

DoD Participation:

  • U.S. Marine Corps, I&L (LPC-1)
  • U.S. Marine Corps Capabilities Development and Integration (LID)
  • OSD-led Joint Service CBM+ Action Group

Industry Participation:

  • Nexus Life Cycle Management
  • Whitney, Bradley and Brown

 

NCMS Project Manager: Debbie Lilu, (734) 995-7038, debral@ncms.org

 

Problem: Despite a myriad of major service-sponsored maintenance initiatives focused on improving maintenance automation and readiness for tactical vehicle fleets, aircraft, vessels and combat vehicles, very little has changed regarding the business process associated with maintaining, managing and improving operational readiness of the industrial vehicle fleet. For example, there is typically significant, ongoing over-maintenance of these vehicles because maintenance schedules are based on straight calendar time or on hour meters that imprecisely reflect key time and seat time, rather than on actual motion time where most wear and tear occurs. Industrial fleet vehicles tend to be a non-controlled asset with no key control or operator accountability. These vehicles are potentially available to unlicensed and/or untrained operators who are most often responsible for lost work time accidents and/or costly damage to both the vehicle and cargo/inventory within a given facility.

Benefit: The efforts in this project will identify the enterprise requirements, acquisition, maintenance, and sustainment initiatives that directly support and complement the OSD-mandated supply chain and total ownership cost efficiencies. The benefits derived by the DoD from this effort will facilitate prudent investment decisions, cost documentation and efficiencies, and improve force readiness and ground equipment performance in line with DoD imperatives. This effort will help reduce the Service-level risk associated with the mix of forces, equipment, and support attainable within fiscal constraints.

Efforts will improve equipment accountability specifically across the DoD through validation of unit inventories via data mining and data cleansing in the Accountable Property System of Record (APSR) and accounting records. This project will identify and test process improvements evaluated through corrective action plans to maintain accurate records, both physical and electronic, to ensure data used for decisions is correct.

Solution/Approach: A variation of commercial off-the-shelf (COTS) wireless fleet management hardware and software will be installed on 50 industrial trucks to be identified by Defense Logistics at a selected site. The purpose of this 60-day phase is to establish evaluation metrics relative to equipment maintenance costs, timelines and related procedures, in addition to studies for vehicle operator preventative maintenance, fleet availability, and fleet and operator productivity

Impact on Warfighter:

  • Increased fleet operation readiness/availability
  • Maintenance/repair cost reductions
  • Labor cost reductions
  • Operator productivity increases
  • Decline in damage to vehicles, cargo and facility
  • Improved vehicle locating and fleet optimization

DoD Participation:

  • Defense Logistics Agency
  • U.S. Army (Anniston AD)
  • U.S. Army (Rock Island Arsenal)
  • U.S. Air Force

Industry Participation:

  • I.D. Systems, Inc.
  • IBM

 

NCMS Project Manager: Debbie Lilu, (734) 995-7038, debral@ncms.org

Problem: Despite a myriad of major Service sponsored maintenance initiatives focused on improving maintenance automation and readiness for tactical vehicle fleets, aircraft, vessels and combat vehicles, very little has changed regarding the business process associated with maintaining, managing and improving operational readiness of the industrial vehicle fleet. For example, there is typically significant, ongoing over-maintenance of these vehicles because maintenance schedules are based on straight calendar time or on hour meters that imprecisely reflect key time and seat time, rather than on actual motion time where most wear and tear occurs. In fact, on average, industrial fleet vehicles are actually in motion only 30% of their key/seat time[1]. Furthermore, because there is no positive control over the vehicle or its whereabouts at any given time, vehicle fleet size at any given site tends to average 15-25% higher than required for day-to-day tasks[2], and require multiple man hours per week[3] spent unproductively trying to locate vehicles. Finally, because industrial fleet vehicles tend to be a non-controlled asset with no key control or operator accountability, these vehicles are potentially available to unlicensed and/or untrained operators who are most often responsible for lost work time accidents and/or costly damage to both the vehicle and cargo/inventory within a given facility.

Benefit: The efforts in this project will identify the enterprise requirements, acquisition, maintenance, and sustainment initiatives that directly support and complement the OSD-mandated supply chain and total ownership cost efficiencies. The benefits derived by the DoD from this effort will facilitate prudent investment decisions, cost documentation and efficiencies, and improve force readiness and ground equipment performance in line with DoD imperatives. This effort will help reduce the Service-level risk associated with the mix of forces, equipment, and support attainable within fiscal constraints.

Efforts will improve equipment accountability specifically across the DoD through validation of unit inventories via data mining and data cleansing in the Accountable Property System of Record (APSR) and accounting records. This project will identify and test process improvements evaluated through corrective action plans to maintain accurate records, both physical and electronic, to ensure data used for decisions is correct. Careful record keeping ensures that limited DoD resources are applied judiciously in the austere fiscal environment in which it now operates

Solution/Approach: Commercial off-the-shelf (COTS) wireless fleet management hardware and software solution, termed the Centralized Fleet Automated Management System (CFAMS) will be installed on fifty (50) vehicles to be identified by the Marine Corps Albany Logistics Base (preferably 20 each 9,000 lbs. forklifts and 30 each 4,000/5,000 lbs. forklifts.

Impact on Warfighter:

  • Increased fleet operation readiness/availability
  • Maintenance/repair cost reductions
  • Labor cost reductions
  • Operator productivity increases
  • Decline in damage to vehicles, cargo and facility
  • Improved vehicle locating and fleet optimization

DoD Participation:

  • U.S. Marine Corps (Albany)
  • U.S. Army (Anniston AD) observer
  • U.S. Army (Rock Island Arsenal) observer
  • U.S. Air Force observer

Industry Participation:

  • I.D. Systems, Inc.

 

NCMS Project Manager: Debbie Lilu, (734) 995-7038, debral@ncms.org

[1]  Based on client business cases and ROI studies from clients including Ford Motor Company and the U.S. Postal Service (USPS).

[2]  Based on client business cases and ROI studies from Price Chopper and Ford Motor Company.

[3]  Based on client business cases and ROI studies from the U.S. Postal Service (USPS).

Completed Projects

Completed Projects

155MM Spindle Corrosion Improvement Program (SCIP)
The Spindle Corrosion Improvement Program – Phase I designed, fabricated and tested a prototype hard chromium plating (HCP) conforming anode system for depositing chromium onto 155mm Howitzer spindles. Plated spindles were subjected to an equivalent of approximately five months of unprotected exposure to the elements. The spindle plated using the CTMA prototype tooling performed approximately five times better than the existing HCP process.

Price per copy: NCMS Members $100.00 available April 2016; Non-members $150.00 available
April 2017

2D-3D Data Model Between Fleet Readiness Center Southwest, Fleet Readiness Center East and Fleet Readiness Center Southeast
The project focused on allowing resources from other FRC locations to participate in any portion of the Manufacturing Model Management System process via remote access to FRC Southwest’s PLM environment to prove the “One FRC” concept promoted by COMFRC. Capabilities to search and share data enhanced maintenance and logistics processes.

Price per copy: NCMS Members $100.00 available June 2016; Non-members $150.00 available
June 2017

Advanced Digital Fabrication & Repair (ADF&R), A Rapid Manufacturing and Repair Program (RM&R) – Phase I
Advanced digital fabrication rapid prototyping (ADF-RP) rapid tooling technologies offer an economical and time-saving solution to the legacy and obsolescent part supply and repair issues being faced today throughout the maintenance and supply systems. Comprehensive investigations of ADF-RP technologies and their applications included: Benchmarking State-of-the-Art, Standards, Software/Data Capture, System Developments and Integration, Material Developments and Application, Advanced Digital Fabrication, and Technology Transfer.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Advanced Distributed Learning Using the Maintenance Mentoring System (MMS) – Phase I Deployment
Both DoD and the commercial industrial sector had an immediate need for diagnostics and repair tools, based on logical thought processes and utilizing fully interactive information retrieval technologies, that allows skilled technicians with diverse experience, training, and expertise levels, to effectively troubleshoot and repair systems efficiently and at significantly lower costs. The Maintenance Mentoring System (MMS) was designed to increase the accuracy, cost effectiveness, and efficiency of the maintainer. The existing technical information was reengineered for during-the-job delivery. For deployment technology, commercial-off-the-shelf (COTS) hardware and software was utilized to implement the information solution directly at the worksite.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Advanced Mobile Electrical Fault Detection and Isolation Tester (AMEFDIT) for All Aircraft Subsystems
The purpose of the initiative was to evaluate the new electrical wiring tester, AMUET, developed by a Canadian company, Solavitek, on two selected electrical subsystems on the C-130 at Warner Robins ALC. While the project budget imposed some limitations on the scope of work, the overall results demonstrated that AMUET was a very agile platform to configure and operate. AMUET capabilities were demonstrated on two subsystems on the C-130 (engine instrument and anti-skid braking). Objectives for set-up and operational performance in the D-Level and potentially for the O-Level testing were met.

Price per copy: NCMS Members $100.00 available September 2016; Non-members $150.00 available September 2017

America’s VOICe™ Focus on Depots
Imaginestics, created a web-based system called America’s Virtual Opportunity Interchange Center (VOICe)™ . Buyers could post their opportunities within that marketplace which either filtered to suppliers who were subscribed or use a state-of-the-art matching engine to automatically find supplier matches. As a secure, hosted networking platform, the America’s VOICe™ platform allowed both buyers and suppliers to make their data and opportunities as public or private as desired and associate themselves with vetted trust networks of companies as appropriate for their needs.

Price per copy: NCMS Members $50.00 now available; Non-members $75.00 now available

Assembly Design and Documentation (AD&D) – Phase I
Assembly/disassembly planning and documentation remains a manual process that is often dependent on the skill and experience of the individual defining the process. This project utilized commercial software solutions integrated with technology developed. Initial trial of the system achieved reductions in assembly process planning cycle times from about 30 days without the automation developed in this project to 15 days with it.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Automated Intensifier Measurement System (AIMS II)
This project developed and deployed automated test equipment for night vision tubes which as the ability to replace the outdated manual test equipment presently used by government and industry. This capability will reduce cycle time for returned night vision devices and significantly reduce costs by increasing the reuse of image intensifier tubes.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Automated Intensifier Measurement System (AIMS) Correlation Upgrade Support
AIMS uses automated machine vision techniques to reliably characterize image intensifier tubes and low light digital sensors. Although reasonable correlation was established between the NVESD manual test sets and AIMS, there were some tests that required refinements which were completed under this project. Upgrades were made to hardware, firmware, test procedures as well as adding new capabilities.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 available
September 2016

Automated Process & Inspection Guide (AP&IG) – Phase I
The Commercial Technologies for Maintenance Activities (CTMA) Automated Process & Inspection Guide (AP&IG) Phase I project standardized both the inspection data and the inspections process for depot maintenance facilities. It utilized Aspire Solutions, Inc (ASI) commercial off-the-shelf (COTS) software application combined with COTS ultra-mobile PC technology to guide the user through the inspection process (improve accuracy) and standardize the defect data (enhance analysis capabilities),

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Automated Process & Inspection Guide (AP&IG) – Corpus Christi Army Depot Pre-Shop Analysis (PSA)
The project was unique in that it involved two pilots centered around a USAF Pave Hawk helicopter to standardize both the inspection data and processes for quality assurance and standardize pre-shop analysis evaluation data and processes. Strong bottom-line results reduced time and provided more consistent and repeatable evaluation processes.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 available April 2016

Automated Process & Inspection Guide (AP&IG) – Data Capture at Rock Island Arsenal
As part of the realignment of documentation from Rock Island to TACOM, this project focused upon how to effectively and efficiently extract meta-data and properly index a digital file to make it easily searchable. It also involved optimizing the file so that file sizes were manageable without impacting optical character recognition quality and readability.

Price per copy: NCMS Members $100.00 available May 2015; Non-members $150.00 available
May 2016

Automated Process & Inspection Guide (AP&IG) In-Process Mobile Paper Replacement Validation Solution (IMPRoVS)
The project replaced inefficient paper-based processes with mobile data capture devices combined with Aspire Solutions, Inc.’s COTS software for Red River’s repair programs. Return on investment for the first year is $373K in combined manpower hours, paper savings, storage space and research hours expended.

Price per copy: NCMS Members $100.00 available June 2015; Non-members $150.00 available
June 2016

Automated Process & Inspection Guide (AP&IG) Summarization
Utilizing Aspire Solutions, Inc.’s commercial off-the-shelf (COTS) software in conjunction with COTS mobile computing devices allowed depots and worksites to realize improved accuracy and standardized inspection results. Strong bottom line results were delivered showing improvements in the cost to inspect/repair systems while reducing the overall number of personnel required.

Price per copy: NCMS Members $100.00 available June 2015; Non-members $150.00 available
June 2016

Automated Rotor Blade Stripping System (ARBSS) Enhancement
In 2009, an NCMS project successfully demonstrated that a laser-based coating removal system could be integrated with a robotic positioning capability to operate within a Navy rotor blade sustainment environment. Currently, however, the ARBSS coating removal process is not formally approved for use on V-22 material. The principal concern was that the copper mesh in the V-22 material may adversely interact with the laser energy to induce heating and substrate damage not observed in the original ARBSS qualification testing. There was no evidence that temperatures within composites processed reach levels that would cause concern nor was there any significant damage to the composite in terms of strength or modulus variations.

Price per copy: NCMS Members $100.00 available September 2015; Non-members $150.00 available September 2016

Automated Test Equipment (ATE) Synthetic Instrumentation – Phase I & II
Since automatic test system test stations are employed throughout the DoD maintenance hierarchy, the transition from traditional instruments to synthetic instrumentation presented a significant opportunity to mitigate hardware obsolescence, reduce the equipment footprint, improve adaptation to emerging requirements and reduce the overall lifecycle cost of automatic test systems. Performance was benchmarked against the legacy U.S. Air Force F-15 Electronic Systems Test Set (ESTS).

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Automated Test Equipment (ATE) Test Program Set (TPS) Migration System
The Test Program Set (TPS) Migration System project was undertaken to provide lower migration costs, for depot Automated Test Systems (ATSs) and their support lifecycles, when equipment modernization is required. ATSs are employed to facilitate diagnosis and repair of failed and suspect weapon system components. These ATSs are being upgraded with modern supportable commercially equivalent test platforms that are developed to take the Air Force repair capability forward for another extensive period. Initially the project evaluated emerging technologies for migrating test applications when ATS are modernized or upgraded. This capability analysis led to a more pragmatic focus on existing commercially available environments that held promise in resolving the cost issues with porting legacy applications to the new generation systems.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Barstow Air Pollution Control System (APCS) Improvements – Phase I
Pollution control equipment for paint lines can be a manufacturing facility’s costliest environmental item and coating facility operators are always interested in better and cheaper ways to achieve environmental compliance. As new manufacturing lines are built, and as old lines are upgraded, the technology must be periodically reviewed to be sure a facility is making the most sensible decision in selecting its pollution control equipment. This project worked with the Barstow Marine depot to identify pollution control technology for their current paint booth as well as a larger facility to be constructed. The results can be applied to a wide variety of military and commercial facilities.

Price per copy: NCMS Members $50.00 now available; Non-members $75.00 now available

Barstow Air Pollution Control System (APCS) Improvements – Phase II
Painting operations release large quantities of solvent vapors into the atmosphere. Painting operations can constitute a facility’s single biggest environmental impact, with the greatest associated environmental compliance costs. This project developed a fundamentally new biological design, from initial concept to a pilot model tested on an operating paint line expected to operate at 25% of the cost of a thermal oxidizer.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Casting Knowledge Reuse-Based Cost Advisor – Phase I
A prototype of an Intelligent Casting Cost Advisory system that reuses existing casting knowledge to provide users with real-time advice on “should costs” and selection of optimal casting process based on part-design criteria was developed. It is a key technological breakthrough that makes capture of practical production information in a knowledge-based system possible having a significant impact in all facets of the design, development, manufacture and support of current and future weapon systems.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Centralized Fleet Management System (CFAMS)
The Centralized Fleet Asset Management System (CFAMS) is a wireless fleet management hardware and software solution designed to optimize operations (both remanufacturing and supply), decrease maintenance costs, while improving equipment readiness, optimize fleet size, reduce vehicle and facility damage, and dramatically improve overall safety. Because CFAMS automatically captures motion hours, as well as movement with load data, the system enables changing to motion, or condition-based preventative maintenance.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Coalition Logistics Interoperability/Joint Logistics Integration (CLI/JLI)
The CLI/JLI project explored, demonstrated, studied, and calculated the benefits of a suite of advanced logistics interoperability enablers. Principal technologies were demonstrated and proven at three separate logistics technology exercises. The events provided unique opportunities to evaluate these capabilities and develop strategies for a way forward.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Collective Mind: Avoidance of Maintenance Cost Through Predictive Trending
The Collective Mind initiative was launched to demonstrate the value of “Big Data” analytics in a maintenance environment. Big data analytic system algorithms are optimized for rapidly scanning and processing data systems to notify maintenance and supply managers about emergence of possible significant problems substantially earlier. The project began to explore the hypotheses and accomplished its limited objective.

Price per copy: NCMS Members $100.00 available June 2016; Non-members $150.00 available June 2017

Composite Materials Substitution Methodology Development
The objective of this project was to provide a standardized methodology to enable DoD depot and field repair facilities to determine suitable substitute materials for weapon system repair and re-manufacture. The project deliverable included assessment of OEM specifications for material substitution issues, draft tests, and procedures to enable organic implementation of science based material substitutions, and a software tool to aid in the implementation of the substitution methodology.

Price per copy: NCMS Members $50.00 now available; Non-members $75.00 now available

Contractor Property Management of Maintenance
A detailed end-to-end study was conducted of the current Contractor Property Management process, taking into account the upgrades planned for the near future. Potential gaps were identified and recommendations were made to correct or alleviate these weaknesses.

Price per copy: NCMS Members $100.00 available June 2015; Non-members $150.00 available
June 2016

Corrective Forming of 701 Skin Panels for F-18 Overhaul
Metal Improvement Company, a subsidiary of the Curtiss-Wright Corporation, has developed an advanced laser peening process that can be used for custom metal forming to predict the laser peening pattern, intensity and coverage required to achieve a needed shape correction in out-of-spec 701 skins. The model has been benchmarked against a rigorous set of small panel tests for which the comparison of model predictions versus measured effect have been remarkably accurate.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 available
February 2016

Corrosion Resistant Solid State Thin-Walled Component Joining for Maintenance and Repair Applications (Deformation Resistance Welding) – Phase I and II
The project sought to develop and test a new solid state joining method called Deformation Resistance Welding (DRW) that did not melt the materials to be joined thus increasing dimensional accuracy, corrosion resistance, and weld cycle time. The solution was constructed and installed on two HMMWV vehicle sub-structures and blast tested.

Price per copy: NCMS Members $100.00 available August 2015; Non-members $150.00 available August 2016

Damage and Wear Assessment Using Condition-Based Monitoring
Traditionally maintenance has followed the philosophy of either run-to-failure or planned maintenance at regular intervals. Each of these approaches has been found to be more expensive and time-consuming when compared to condition-based methods, under which the condition of a machine is monitored and maintenance is only undertaken if conditions warrant it. This method equally applies to manufacturing processes where the settings of some machines or components may need to be altered based on the monitored condition of the process.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Defense Procurement and Acquisition Policy (DPAP) Program Development and Implementation (PDI) Support
This project provided support to the OUSD in their multi-faceted effort to improve business processes in the DoD. The overall objective was to examine the data structures and processes that support essential programs, procedures and policies providing accountability, visibility and interoperability among and between government agencies, industrial partners and international allies.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 available
August 2015

Development and Evaluation of Near-Dry Machine Tools for the Production of Aluminum Components – Phase I
This report summarizes the first of a two-phases of The Development and Evaluation of Near-Dry Machine Tools for the Production of Aluminum Components (Near-Dry) project to determine if the near-dry machining (NDM) process offers enough technical and economic benefits to replace the conventional high-pressure through-the-tool coolant process—the WET process. NDM, which uses small quantities of biodegradable lubricant, circumvents most of the health and safety issues associated with conventional metal-cutting coolants and it is less expensive to own and operate than the WET process.

Price per copy: NCMS Members $50.00 now available; Non-members $75.00 now available

Development and Evaluation of Near-Dry Machine Tools for the Production of Aluminum Components – Phase II
This report summarizes the second of the two-phase project whose objective was to evaluate the achievable benefits from an advanced near-dry production machining process. Machining Enterprises, Inc. (MEI), a parts manufacturer for the automotive industry, piloted the first phase of the program by machining 30,000 GM engine brackets. Data from this pilot project established the technical and economic feasibility for using near-dry technology in a U.S. factory. In comparison to a conventional process incorporating high-pressure coolant delivered through the spindle, the near-dry process was determined to be 8.5% less expensive – even without taking into account the costs of eliminating a central coolant treatment facility as well as the costs of dealing with coolant-related health issues.

Price per copy: NCMS Members $50.00 now available; Non-members $75.00 now available

Digital Pen and Paper for Capturing Maintenance Data
The purpose of the study was to investigate the potential for time and quality improvements by capturing the user’s written data with a digital pen. The study also investigated potential process improvements that could be undertaken as a result of the use of the digital pen. It was found that a median of 7-11 days cycle time reduction could be attained; up to a 6.3% cycle time improvement for a planned 175-day repair process.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Durable Non-Skid Coatings for Carriers
Flight deck non-skid coatings must withstand extreme service conditions, including impact, abrasion and exposure to organic fuels and lubricants. Coatings were developed that met or substantially exceeded all MIL-PRF-24667B(SH) requirements for Type I (High-Durability) and Type V (Extended Durability) non-skid coatings.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

e-CM: Electronic Collaborative Maintenance for Depot Repairs and Manufacturing (e-Collab)
With defense electronic equipment lifetimes of 20 years or more, almost all such systems will, before the end of their useful life, encounter a situation where a component needed for repair is no longer available from routine stock. The current solution is for estimators to spend hours, even days, telephoning potential suppliers. This project sought to develop a web site to which estimators could post lists of parts sought, listed by project, and broadcast notifications of new posts to a list of potential suppliers. Suppliers could then scan the parts list and enter budgetary estimates of part prices for any parts they could supply. The estimator could then provide a much more accurate and timely estimate of the cost to repair a given system.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Embedded Decoupling Capacitance
This collaborative effort advanced the use of embedded capacitance technology for power supply decoupling. The deliverables consisted of materials development and characterization, and board fabrication process development. This 132-page report pre¬sents the results of the tests to evaluate newly developed planar capacitance materials and fabrication processes. More than 135 charts, tables, photographs—many in color.

Price per copy: NCMS Members $50.00 now available; Non-members $75.00 now available

Enabling Interoperability in a NATO Environment through Maintenance and Repair Activities
The goal of this project was to build and test (in a live environment), a system that can facilitate logistics interoperability among and between coalition partners. Commercial off-the-shelf tools were enhanced to facilitate the sharing of maintenance and supply data across the enterprise between coalition allies.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 available
August 2015

Enhanced Wiring Integrity Systems (EWIS) – Phase I
The EWIS project provides improved commercially-available test systems to enhance the troubleshooting and testing capabilities of the maintainers and ultimately improving the overall integrity of electrical wiring systems. This technology is embodied in a handheld, easy-to-use, meter enabling the operator to rapidly connect, detect and locate hard faults in wiring assemblies. The unit performs a test in four seconds, displays the fault location in human readable characters and has computer-based training that requires only 45 minutes to complete. Personal computer-based SWR software utilities provide the ability to download from the meter, via serial bus, test waveforms for analysis.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Enhanced Wiring Integrity Systems (EWIS) – Phase II
Quick identification of the faulty wire path and location of the fault assists greatly in providing increased mission readiness. EWIS I was centered on a reactive maintenance posture that was practiced at all maintenance levels. EWIS I effectively incorporated the use of the EWIS technology in the established reactive maintenance environment. EWIS II, also funded through the NCMS/CTMA Program, targeted implementation of new methods of electrical inspection to help foster a proactive posture. Multiple test protocols and other prognostic test approaches were implemented in EWIS II for feasibility in the DoD maintenance community. The equipment delivered under EWIS II is scalable and open architecture, which enables integration of future test capabilities and technology enhancements.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Enhanced Wiring Integrity Systems (EWIS) at Barstow
Wiring-based systems are the fundamental backbone that supports today’s vital communication, weapons system and related asset control functions. Specific to Barstow, EWIS tools were provided and software developed to test electrical systems for the M1114 Humvee.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 available
January 2016

Enhancing DoD Maintenance Interaction with Industry using Virtual Methodologies
Virtual events cannot replicate every aspect of physical meetings, but given budget constraints and travel restrictions, events using solutions like the one created for this project can prevent cancellations and foster virtual collaborations.

Price per copy: NCMS Members $100.00 available June 2015; Non-members $150.00 available June 2016

Environmentally Friendly Hot Cutting Solutions for Support of the Opacity Initiative – Phase I
This project sought to develop alternative environmentally friendly cutting methods and explore new methods of reducing emissions in order to comply with air operating and water discharge permit requirements at Puget Sound Naval Shipyard & Intermediate Maintenance Facility (PSNS & IMF). It included investigations of alternate oxyfuel gas cutting and equipment as well as alternate cutting processes, such as plasma arc cutting and laser cutting.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Extended Life of Lead-Acid Deep Cell Cycle Batteries Through a Planned Maintenance System using Chemical Battery Corrosion Desulfation
One can double the life expectancy of rechargeable lead-acid batteries by a proper planned maintenance system and TBDSCC corrosion desulfation. The end result is a cost avoidance of $5,000 to $12,000 or more for one battery “unit” in prematurely replacing deep cell cycle battery systems. Additional costs can be avoided which would be associated to machinery downtime and labor. Corrosion desulfation with TBDSCC Compound extends the life of the battery and reduces capital expenditures on additional batteries.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Extending Advanced Distributed Learning Initiatives through Maintenance Activity Mentoring Systems – Phase II (MMS II)
The MMS II collaborative project team developed a software application, the MMS, to assist technicians in the repair and maintenance of large, complex mechanisms such as the AV-8B Harrier aircraft engine, MMS II tested the effectiveness of distributed learning technologies for maintenance activities for workforce productivity improvements when overhauling the AV-8B Harrier Rolls Royce engine at the Marine Corps Air Station (MCAS) NADEP Cherry Point, North Carolina. .

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Fast Field Fluid Assessment Support Tools (3 FAST) – Phase I-III
The joint collaborative project was established in order to supply specifically a handheld infrared spectrometer with an integrated viscometer reporting kinematic viscosity at a fixed temperature. The project resulted in successful deployment of two handheld products for the analysis of fluid condition and contamination properties of lubricants and some fuels.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 available
January 2016

Heat Induction Removal of Special Hull Treatment (SHT) using Exoskeleton and zeroG® Arm Technology
This study proved that using human augmentation to accomplish shipyard tasks involving heavy tools can improve productivity while mitigating a significant cause of worker injury. The study addressed both quantitative measures of productivity (residue removal rate) and qualitative measures of productivity (worker fatigue, ergonomics, etc.)

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 available
August 2015

Heat Transfer Classification for Production Tooling and Composite Repairs
This project is leading to a paradigm shift in the approach to the autoclave curing of composite parts. Improvements in computer power and sensors now enable higher quality composite manufacturing, and greatly reduced scrap as well. This project developed and tested tools to manage heat transfer for ovens and autoclaves used in the production and repair of composites.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

High-Density Chip-on-Board (HDCOB
The purpose of this project was to develop the assembly process and to test the reliability of using the emerging higher-density surface-mount technology (SMT) devices and the chip-on-board (COB) die on the same printed circuit board with conventional SMT parts. Because of the much smaller and tighter traces and solder pads of this technology, development of the rework/repair processes is a significant capability need for industry and the DoD depot community. This report documents the results of designing, manufacturing, populating, assembly rework and reliability testing of printed circuit boards populated with the variety of high-density components using advanced SMT.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

High Performance 3D Scanning Systems
This project resulted in the development of high-speed commercial metrology grade digital shape scanning system. The system does not require special lighting, or use of coatings in many applications, to enable inspection at the point of need without transporting parts to dedicated central inspection areas. Cycle time reductions gained resulted in the need for less pipeline inventory and greater availability. Accuracies of 0.002” were attained to improve quality and reliability. The system is applicable to many other depot and commercial applications.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

High Throughput Production Processing (HITHRU) Aluminum Part Deployment
In HITHRU deployment a demonstration was conducted for the conclusive benefits by using Cimskil™ to develop processes for three F-15 real production parts for Warner Robins Air Logistics Center. Programming time was tracked and production metrics captured for comparison to the original processes reinforcing the lessons learned in HITHRU.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

High Throughput Production Processing of Five- (5) Axis Aluminum Components (HITHRU) –
Phase I
In Phase I an older software system automatically recognized turning and 3 axis milling machined features and automatically created NC code was updated. Feature recognition for 5 axis features typically found in aerospace structural components was developed. Dynamic characteristics of the Cincinnati Machine Lancer V5 vertical 5 axis machining center were measured and cut tests performed to map safe operating zones that maximized the use of spindle power while avoiding chatter zones. Based on those results an algorithm was devised to calculate axial and radial depth of cut plus spindle rpm for high productivity machining. Feature recognition and cutting processes were validated by using the software on actual aerospace parts. In Phase II the formerly Unix only system was ported to MS Windows and a new user interface developed that allows users to modify feature recognition and method generation rules.

Price per copy: NCMS Members $50.00 now available; Non-members $75.00 now available

High Throughput Production Processing Five- (5) Axis Titanium Components III (HITHRU III)
In Phase III cutting processes were developed for components made of titanium, 5 axis feature recognition improved, and provision was made for embedding in automated NC output special functions such as torque controlled machining and probing cycles.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Implementation of New Commercial Hard Chrome Plating Tooling at Naval Air Systems Command Depot North Island
The objective of this project was to introduce new electrodeposited hard chrome plating equipment into Naval Air Systems Command (NAVAIR) Depot North Island maintenance activities, including advanced racks, fixtures, and anodes. New prototype tooling was designed, fabricated and tested and changes in production parameters, including costs and process steps were measured and documented. The results of this project will enable plating facilities to produce higher quality parts with substantially less time and effort than was possible with previous technology.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Implementation of Innovative Hard Chromium Plating Tooling at Corpus Christi Army Depot – Phase I
Conventional chrome plating process is slow and expensive. Parts must first be masked so that only the desired areas are plated, a time-consuming task that must be performed by skilled artisans. Chrome in a standard plating setup is deposited slowly and unevenly, requiring extensive machining to bring parts back into tolerance. The extra labor contributes significantly to the overall turnaround time and cost of aircraft refurbishment. This project demonstrated the ability of a new development, “no-mask” tooling, to eliminate labor for masking, and to achieve much faster plating times and more uniform chromium deposits. The quality improvement and cost savings were so dramatic that no-mask tooling was adopted for standard production while the project was still underway.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Implementation of Innovative Hard Chromium Plating Tooling at Corpus Christi Army Depot – Phase II
The no-mask concept is relatively new to chromium plating. It involves the design/fabrication of a rack and anode fixture, which are customized to particular parts. The main advantages of this approach are reduced labor for masking, faster plating times and more uniform chromium deposits. Hard chromium plating provides superior wear resistance for a wide variety of surface geometries. During Phase II, custom no-mask anodes were designed, fabricated and implemented for an additional six frequently plated aircraft parts (two during Phase I and six during Phase II), plus design changes were made to one of the Phase I anodes. Also during Phase II, generic tooling was developed for several less frequently plated parts.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Implementation of Predictive Modeling in Support of USMC Systems Command – Product Group Nine (PG 09)
The Total Life Cycle Systems Management Assessment Software Tool (TLCM-AT™) was used to run “what if” scenarios on maintenance, logistics, policies, removal of parts for repair; and spare consumption for return on investment in terms of readiness and costs for secondary repairable items.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Improved Stealth and Lower Cost Operations for U.S. Naval Ships using High-Performance Cordage (HPC) Deck Edge Netting (DEN)
The primary objective for this project was to extend the use of High-Performance Cordage Deck Edge Netting (HPC DEN) in lieu of nylon strap netting by installing developmental square HPC DEN Spectra/polyester cordage aboard a U.S. Navy test vessel.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Increased Reliability of Full Authority Digital Engine Control (FADEC) System – Phase I
Intermittent electrical failures are driving acquisition and Operations & Sustainment costs in rotary wing aircraft. The purpose of this initiative was the definition of a reliable testing protocol that quickly and consistently identifies electrical issues associated with degradation of reliable performance by FADEC systems on both the MH-47G and MH-6M. The initiative used the Automatic Wire Test Set (AWTS) developed by Eclypse International to develop and successfully execute FADEC testing protocols.

Price per copy: NCMS Members $100.00 available December 2015; Non-members $150.00 available December 2016

Inspection & Repair Preparation Cell (IRPC) – Phase I
Phase I of the project identified computer controlled advanced technologies including digitizing, shearography, ultrasonic photo imaging, microwave, mechanical impedance that can be integrated into an automated work cell to detect defects, moisture, and delaminating with the capture of historical data in digital form. While the IRPC project focused on the C-130 Radome, the work cell will be applicable to the repair of many different types and sizes of large composite structures such as helicopter side panels.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Integrating Sensors & Predictive Maintenance Systems with Performance Support Technology to Achieve Increased CH-53E Readiness & Reliability – Phase I and II
The Electronic Performance Support System (EPSS) provides CH-53E helicopter maintenance technicians with a seamless prognostic, diagnostic, and repair suite that measurably increases the readiness and availability of the aircraft while reducing or eliminating associated maintenance expenditures. Phase II of the project further developed EPSS content pertaining to three additional CH-53E systems: Flight Controls, Propulsion, and Transmissions (TM series 140, 220, and 260 respectively).

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Integration of Laser Coating Removal for Helicopter Blade Refurbishment – Phase II
The primary objectives in Phase II were to overcome scale-up and technical integration issues and to deliver an operational ARBSS for test, evaluation, and eventual production. This report summarizes the work conducted under the Phase II effort summarizing the design requirements and overall system design, then provides details of the laser workhead, the integrated robotic system, and the user interface.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Interactive Visualization
Visual simulation technology has been available in the market for several years, and has been used selectively in high-end graphical applications. Use of the technology for practical applications has typically been limited in deployment due to the traditionally high costs of these types of systems, as well as previously awkward methods (special viewing glasses or lenses or sometimes in sacrifice of quality of the image) of being able to easily “view” the results. The Interactive Visualization project achieved the goal of understanding where and how to apply the enhanced visualization technology for benefit in targeted applications areas, while also identifying areas of improvement or modifications of the technology that would better enhance the objectives of the individual projects.

Price per copy: NCMS Members $50.00 now available; Non-members $75.00 now available

Intermittent Fault Detection Isolation System (IFDIS) Central air Data Computer (CADC) Test Program Set (TPS)
Capabilities were provided to Hill AFB to test F-16 chassis circuitry for intermittent faults, open circuits and short circuits directly addressing the no-fault found problem currently costing the DoD as much as $10B annually.

Price per copy: NCMS Members $100.00 available June 2015; Non-members $150.00 available
June 2016

Isotropically Conductive Adhesives (ICA)
This project sought to develop a novel replacement for lead- (Pb) based solders. The focus of the material for development was a copper- (Cu) based ICA for use in the Electronics Industry, since there was a resolute market drive to eliminate lead-containing solders from all commercial electronics. During this ICA project, the team investigated two different methods to apply the ECORAP (electrically-conducting, oxidation-resistant adhesion promoter) coating without agglomerating the particles using scaleable processes. The successful demonstration of a scaleable vapor process was pursued with a fluidized bed reactor, while the solution coating process was demonstrated using a stirred-tank reactor.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Item Unique Identification (IUID) Markings for Legacy Parts
The Department of Defense (DoD) in 2003 mandated that all parts meeting specified criteria receive Item Unique Identifier (IUID) marks. The mandate can be relatively easily implemented for new acquisitions, but the non-recurring engineering (NRE) cost for updating the technical data for hundreds of thousands of legacy National Item Identification Numbers (NIINs) and physically marking millions of legacy parts in inventory is a daunting task. To address at least a significant portion of the total legacy part issue, an automated IUID Engineering Change Order (ECO) process was successfully developed under this IUID project.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

IUID Data Utilization Strategy and Policy Initiative for Sense & Respond Logistics Total Lifecycle Management (TLCM)
This project took a two-pronged approach to examine several key areas in the rapidly changing logistics landscape. The first was an analysis of current Marine Corps practice and policy regarding Total Lifecycle Management and Sense & Respond Logistics with particular attention to Item Unique Identification. The second element of this project was exploration of the potential benefits to be obtained by integrating mobile computing into the logistics information infrastructure, as well as an examination of the hurdles. The benefits of the mobile computing approach were demonstrated at the Marine Corps ExLog Wargame where Marines were trained in the use of the platform. A proposed policy document was submitted suggesting future Marine Corps policy based upon the lessons derived from this project.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 available April 2016

IUID Marking for Legacy Parts – Navy Pilot
DoD mandates that all parts and subassemblies valued over $5,000 receive Item Unique Identifier (IUID) markings for life cycle tracking purposes. IUID marking technology is mature so the mandate imposed no significant challenge for new items. For legacy items, however, tech data must be modified to specify how and where to mark the part. For legacy parts already in inventory, the non-recurring engineering (NRE) cost is prohibitive. This project demonstrated a cost saving solution for parts falling under the mandate that already have data or name plates. Shape search provided a means of using a name plate shape as a template to find the plate in the body of a drawing.

Price per copy: NCMS Members $100.00 available June 2015; Non-members $150.00 available
June 2016

Joint Maintenance Enterprise Interoperability
Successful modern logistics depend upon information technology (IT). The various Service components, departments and organizations with the DoD have embraced IT to achieve the many individual goals of each. In order for these programs to reach their maximum benefit particularly in the joint environment, IT applications must become interoperable across platforms, Services components, nations and industrial partners. This project pursued meaningful steps toward enabling that necessary interoperability.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 available
August 2015

Joint Test Protocol for Gas Turbine Engine Materials
The project examined natural and manufactured sands and dusts to determine key features needed in a manufactured CMAS test media. A new test media was developed that appears to form CMAS glass with the concurrent formation of water, sulfate, and chloride vapor. It took a model of what the test media should behave like and developed a real, testable, material that can be used in laboratory and for full-scale testing.

Price per copy: NCMS Members $100.00 available August 2015; Non-members $150.00 available August 2016

Kinetic Spray Metal Deposition Technologies for Corrosion Protection
Restoration of metallic surfaces plays a significant role in maintenance activities for both military and commercial applications. A variety of technologies are used in an effort to thwart corrosion. Kinetic spray technologies overcome a number of traditional spray “shortcomings.” Kinetic spray deposition does not rely upon molten droplets that impact the surface and then solidify. Instead, the particles are accelerated, impact the surface, deform plastically, and cold fuse to the surface. This results in a better surface coating with less oxidation and higher density. Centerline’s Fusion Series 3800 system was successfully evaluated for this project. Additionally, the technology is amendable to portability, meaning the potential to use this technology in intermediate and field operations.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Laser Coating Removal Systems for Helicopter Blade Refurbishment – Phase I
The removal of paint from H53 and H60 main helicopter rotor blades is a labor intensive, expensive and environmentally sensitive operation. Determined to improve this process with advanced laser and vision systems, the Automated Robotic Blade Stripping System (ARBSS) team developed a proven automated robotic laser paint stripping technology that strips helicopter blades 75% faster than traditional methods, with practically zero error.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Laser Engineered Net Shaping Solutions (LENS™) Solution for Commercial and Defense Manufacturing Repair and Overhaul Applications – Phase I
This project pursued the merits and feasibility of a material deposition repair technology called Laser Engineered Net Shaping (LENS™). The collaborative project participants produced a commercialized version of the LENS™ equipment and proceeded to determine both technical and economic feasibility on commercial and military applications.

Price per copy: NCMS Members $50.00 now available; Non-members $75.00 now available

Laser Engineered Net Shaping Solutions (LENS™) Solution for Commercial and Defense Manufacturing Repair and Overhaul Applications – Phase II
As tanks, ships, submarines, and aircraft continue to operate beyond their intended life, part obsolescence management becomes an increasing challenge for asset sustainment, compromising military readiness. This project further developed the additive metal process, laser engineered net shaping, into a more robust system designed to repair a wider variety of parts vital to weapon systems readiness.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Lasershot Peening of Landing Gear Components
A variety of landing gear components are failing without having reached their desired service lives. The failures are due primarily to stress corrosion cracking (SCC) and fatigue. The objective of this project was to improve the fatigue life and SCC resistance through the application of laser peening technology to selected components.

Price per copy: NCMS Members $50.00 now available; Non-members $75.00 now available

Leak Test Technology Development (LTTD) & Prove-out
The project identified and evaluated a number of advanced technologies at national laboratories and universities in an effort to find a viable solution for leak testing in today’s manufacturing environment. Four technologies were selected for research and development. Three primary objectives drove the project: cycle-time reduction, sensitivity, and simultaneous leak location. Secondary objectives were: robustness, cost effectiveness, and ease of use. The metrics used by the industrial participants to evaluate these new technologies were: long-term facilities cost savings, headcount savings, quality, and overall efficiency of the leak test operation.

Price per copy: NCMS Members $50.00 now available; Non-members $750.00 now available

Legacy Lifecycle Management (LLM)
To assist ballooning processes, the project team developed intelligent Optical Character Recognition (OCR) technology with a dictionary that includes General Dimensioning and Tolerancing (GD&T) symbols as well as both machine generated and handwritten alpha-numeric symbols. Artificial intelligence built into the OCR technology allows it to “learn” with use so that recognition accuracy improves over time. A key feature of the solution is that it divides the drawing into zones, separating drawing from title and notes blocks, which enables the use of specialized dictionaries for each zone, also improving recognition accuracy. To demonstrate a secure supplier collaboration environment, the project team leveraged learning from the Transatlantic Secure Collaboration Program (TSCP) which had already defined the requirements and architecture for a web-enabled system.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Legacy Test Program Migration Organization
During the project, Analysis, Integration & Design Inc. (AIDI) accomplished the design and generation of an ITA based on the migration of a selected Common Automated Support System (CASS) legacy test program onto a new commercial test platform using ConVEx® implementing the resource pre-allocator and the ITAG tool. Cost and scheduling results showed drastically reduced test program set (TPS) migration times and significantly faster ITA design and generation times that lowered average costs incurred via engineering efforts.

Price per copy: NCMS Members $100.00 available June 2015; Non-members $150.00 available
June 2016

Light Armored Vehicle (LAV) Condition-Based Maintenance (CBM) Life Cycle Logistics Support Tool – Phase I
Efficient logistical support and timely effective repairs, while critical to ensure that equipment is combat read, have become increasingly complex and difficult to manage. This project delivered advanced sensor and energy management technology installed on two Light Armored Vehicles (LAVs). An off-board diagnostic tool demonstrated the capability of performing a “health check” on the vehicle. Also demonstrated was on-LAV communication via an on-board capability to send “health check” data to the Depot Data Center for immediate action on the affected vehicle.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Light Armored Vehicle (LAV) Sense & Respond Support System – Phase II
The Phase II project objective was to develop, demonstrate and evaluate tools and techniques necessary to support Sense & Respond concepts in the LAV community. Asset health monitoring was refined and a support infrastructure was established to being to make use of the data collected. The results of the LAV II project have moved us markedly closer to the ultimate goals which are developing reliable prognostics, realizing true CBM, providing greater situational awareness at every level, and increasing operational availability across the fleet.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Light Armored Vehicle (LAV) Sense & Respond Support System – Phase III
LAV III was the third phase of the PM-LAV strategy to embrace Logistic Modernization and build on knowledge gained during the LAV Condition-Based Maintenance (CBM) Life Cycle Logistics Support Tool project. Asset health monitoring and the required support infrastructure were refined to enable scalable and web-based access to the end user. Sense & Respond saw the maturation of the Joint Asset Management Information Support System (JAMISS) as a tool designed to enable presentation of vehicle data in a coherent fashion in a scalable format for the end user. LAV III validated the “Best in Breed” selection of hardware, software and firmware designed to meet the PM’s requirements for a system designed around flexibility and reliability in the end-to-end Enterprise architecture environment.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Light Armored Vehicle (LAV) Sense & Respond Logistics – Phase IV
During this project the CTMA team worked to expand the concept of asset health monitoring; build an understanding of what data, and how much data is useful; explore means of translating data to knowledge; and disseminating that knowledge to those who need it, in a usable format. The project was unexpectedly stopped prior to completion “for the convenience of the government” causing inconclusive results and incomplete deliverables through no fault of the CTMA team. Although the project was truncated, significant progress was made in many of the technologies that will be necessary to enable CBM+ and Autonomic Logistics.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Logistics Master Data Management Proof-of-Concept Capabilities-Based Assessment and Data Storage & Utilization Strategy
This CTMA project determined the capabilities required to store the data, identified the person¬nel and organizational requirements needed to support data warehouse requirements, and the proof-of-concept identified and validated the requirements for mining and visualizing the data stored in the proposed data warehouse.

Price per copy: NCMS Members $100.00 available June 2015; Non-members $150.00 available
June 2016

Low Heat Input Mobile Manufacturing and Repair Systems with Thin Wall Structures with PMD™ Flat Wire Deposition Process – Phase I
The team developed, built, and tested for basic functionality a prototype Mobile-PMD™ system for repair and reclaiming damaged large thin wall engine or large curved surface components. This technology is geared towards larger area repair and portability. The initial tests of Phase I Mobile-PMD™ process prove the feasibility of the system of performing the intended repair/reinforcement operations on large components with suitable mechanical and metallurgical characteristics.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

MAGTF Logistics Support Systems (MLS2) Interoperability Demonstration and Capabilities-Based Assessment
The introduction of an integration strategy for MLS2 maximizes training, mission readiness, sustainment, combat readiness and logistical support for deployed MAGTFs. By focusing on capabilities, rather than functions or systems, the strategy defined is able to provide a holistic approach for providing logistics support to the MAGTF.

Price per copy: NCMS Members $100.00 available June 2015; Non-members $150.00 available
June 2016

Maintenance and Supply Accountability and Process Efficiencies – Marine Corps User Experience and Systems Operational Improvement for GCSS-MC
The goal of this project was to assist the Operational Advisory Group (OAG) in identifying areas of concern, creating a way ahead, and devising improvements upon the systems, processes and procedures associated with Global Combat Service Support Marine Corps (GCSS-MC) as identified by HQMC to include but not exclusive to combat service support operations in CONUS and deployed environments. The actions of the project included the identification of technology, training, processes, policy and skill sets needed to increase effectiveness and efficiency in the Marine Corps Maintenance and Supply Operations.

Price per copy: NCMS Members $100.00 available August 2016; Non-members $150.00 available August 2017

Manual Arc Welding Control
In a project recently supported by the National Center for Manufacturing Sciences (NCMS), the enabling technology for weld flaw avoidance was successfully developed and transitioned into a commercial product. The cost-sharing Commercial Technologies for Maintenance Activities (CTMA) program has brought new and needed welding control technology to the Albany depot. Control leads to reduced costs and process cycle times by reducing flaws and rework. The technology has been adapted for uses in the Albany weld shop to not only reduce costs, but also to train welders and provide a source of documentation required by the depot to meet ISO-9000 audit requirements.

Price per copy: NCMS Members $50.00 now available; Non-members $75.00 now available

MARFORRES Material Readiness Analysis and Logistics Information Management
The focus of the effort was to improve the Marine Forces Reserve inventory accuracy including data entry along with providing greater visibility of inventory status and readiness throughout the Forces. A new tool was developed to track, evaluate and analyze ground equipment and personnel data. While training was ongoing, the dashboard tool was developed with seven of the 11 readiness metrics, refined and tested in collaboration with Marine Forces Reserve G-4 and G-8 Information Management/Knowledge Management.

Price per copy: NCMS Members $100.00 available August 2016; Non-members $150.00 available August 2017

Marine Corps Distribution IT Portfolio Proof-of-Concept and Business Case Analysis
The project assisted in identifying and refining the Marine Corps logistics community’s IT requirements as well as buying down the Marine Corps requirements and acquisition risk. The tasks defined in this project improve operating forces and supporting establishment distribution systems, application, processes and asset visibility positively impacting weapon system readiness.

Price per copy: NCMS Members $100.00 available June 2015; Non-members $150.00 available
June 2016

Marine Corps Logistics Portfolio – Information Technology Portfolio Baseline and Proof of Concept
The project team used a multi-step process to get baseline statistics on the Log IT systems and applications to uncover both redundancies and gaps in the capability coverage, and to create a vision for future Log IT management that shows what could be possible given proper tools and information. The results derived from this project will allow the Marine Corps visibility into the portfolio at levels far beyond any effort to date.

Price per copy: NCMS Members $100.00 available August 2016; Non-members $150.00 available August 2017

Marine Corps Logistics Portfolio Consolidation Proof-of-Concept Business Case Analysis and Demonstration
The project solidly established the foundation and framework to baseline the current Marine Corps LOG IT Portfolio. This will allow the Marine Corps to optimize its LOG IT Portfolio which will lead to increased agility to respond to changing requirements and to reduce LOG IT system sustainment costs.

Price per copy: NCMS Members $100.00 available June 2015; Non-members $150.00 available
June 2016

Marine Corps Total Life Cycle Management Support – Phase I & II
Support was provided to perform gap analysis, improve process flows, conduct forums to develop cross-functional governance, and undertake projects to analyze specific problem areas to recommend solutions for the Marine Corps to effectively support development of the proposed “Middle Weight” Corps.

Price per copy: NCMS Members $100.00 available June 2015; Non-members $150.00 available
June 2016

Metal Finishing Development Program – Phase I & II
A comprehensive computer-based training program (The Basics of Hard Chrome Plating) was designed to educate and train the depot metal finishing workforce in basic electroplating and other metal finishing processes. Three supplemental modules were also developed: Electroplating Electro-Chemistry Bath Simulator, Current Density Calculator and Electroplater Troubleshooting Guide. The ease-of-access and availability to the training and online reference materials by the shop floor artisans has been an invaluable tool.

Price per copy: NCMS Members $100.00 available August 2015; Non-members $150.00 available August 2016

Mine Resistant Ambush Protected (MRAP) Predictive Analysis Support
The Total Life Cycle Systems Management Assessment Software Tool (TLCM-AT™) is a high-resolution, discrete event, stochastic simulation platform designed specifically for representing the full-system life cycle of vehicle fleets. It was utilized for this project to determine provisioning needs for a fleet of vehicles during specific operations and scenarios.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Model-Based Definition for Aircraft Launch, Recovery, and Support Equipment
This project established new processes utilizing only 3D data versus the traditional two-dimensional (2D) representations of the 3D data. The new 3D Technical Data Package (TDP) conveyed the design intent to the manufacturing artisans with significantly greater fidelity

Price per copy: NCMS Members $100.00 available May 2015; Non-members $150.00 available
May 2016

Modernization of Nickel Electroplating at Depots
The latest in a series of four projects involving implementation of revolutionary commercial electroplating methods that results in improved product quality and major cost savings at military depots. The initial three projects successfully applied approaches to hard chrome plating, while this project successfully extended the concept to nickel electroplating. During the project, innovative masking and nickel electroplating methods were designed and tested on aircraft parts requiring refurbishment.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Modernizing Technical Data Packages – Phase I
The project scope concentrated on developing a methodology with limited capabilities for the ISMLT (Intelligent system for Modernizing of Legacy Tech-Data) prototype. The project led to development of unique software tools that showcased the capability of “stitching” together raster drawings and extracting shapes out of the raster images.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Multi Axis Simulation Table Environmental Enclosure (MASTEE)
When this project began, the U.S. Army Tank Automotive Research, Development and Engineering Center (TARDEC) had in its Physical Simulation Laboratory (PSL) a Multi-Axis Simulation Table (MAST) capable of emulating shock and vibration conditions at levels exceeding anticipated OCO conditions. It did not, however, have an integrated environmental chamber capable of fully emulating the environment. This project was launched to correct that deficiency. The Multi-Axis Simulation Table Environmental Enclosure (MASTEE) designed is roughly a six foot cube, designed to hold complete electronics systems and test them under extremes of environment, vibration, and shock.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 available
November 2015

Multi-Beam Laser Additive Manufacturing (MB LAM) for Efficient Part Manufacture and Repair
A unique multi-beam laser additive manufacturing system has been designed, built, tested and demonstrated using powder materials and substrates of interest to the depots. The technology is based on two low power beams, each precisely controllable and with a minimum heat input incorporating the latest high-brightness diode laser technology.

Price per copy: NCMS Members $100.00 available October 2015; Non-members $150.00 available October 2016

Next Generation Inspection Systems – Phase III
The project targeted the need to replace manual operations with automated dimensional measurement, and numerical control machining, for the repair of compressor airfoils. Machining studies were performed to develop tooling and machining approaches. A five-axis machining center was built and successfully tested. Long delays were experienced in attempting to resolve data transformation problems and the project was terminated

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Operation Enduring Freedom (OEF) Warfighter Maintenance and Implementation and Operations Support
Assistance was provided to the Operational Advisory Group in identifying areas of concern, creating a way ahead, and devising improvements upon the systems, processes and procedures associated with Global Combat Service Support Marine Corps (GCSS-MC) as identified by Headquarters Marine Corps (HQMC) to include but not exclusive to combat service support operations in CONUS and deployed environments. The focus was improved performance, capabilities, functionality, and user understanding of GCSS-MC in its current and future state as it relates to maintenance and supply activities, directives, policies, and operations.

Price per copy: NCMS Members $100.00 available may 2015; Non-members $150.00 available
May 2016

OptiCAM and I-POMX Phase I – Point-of-Maintenance Execution Tools for Optical Model Generation and Process Automation
Whether it is a crucial broken part where no computer model or even drawings are available, or a maintenance technician in a tight airframe crawlspace needing information to diagnose a new problem just identified, the problem is timely access to technical data. The OptiCAM/I-POMX project focused on two seemingly disparate functions; 3D imaging for reverse engineering applications (OptiCAM) and the integration of a powerful tool for mobile access to an information system that can deliver work control documents and technical data to the point-of-maintenance (I-POMX).

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

OptiCAM/I-POMX Phase II – Point-of-Maintenance Execution Tools for Optical Model Generation and Process Automation using Condition-Based Monitoring
The OptiCAM portion of this project made significant advancements during Phase II. Scan accuracy was improved from 0.025 to 0.012 inches and the reverse engineering process itself was significantly improved. The I-POMX system was enhanced for the pilot by adding software that allowed a user to disconnect from the network, perform work using a local database as if he/she remained connected, and then automatically synchronizing both local and network databases on reconnection to the network.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Optical Generation of 3D Models for Computer-Aided Manufacturing (OptiCAM) – Phases III & IV
With weapons systems held in service well beyond their originally intended lifetime, parts fail or wear to the point of rendering the system mission incapable. Depots often find themselves needing to make replacements. All too often the technical data for a needed part is either missing or incomplete. For those cases, the depot must reverse engineer the part, constructing a Technical Data Package sufficient to manufacture the part. The project achieved three goals: Portable, rugged and low cost but accurate scanner; Easy transformation of “Cloud of Points” to 3D solid model; Development of a complete Reverse Engineering environment.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Portable/Handheld Oil Assessment Devices – Phase I
A lack of immediate knowledge about oil quality leads to heavy costs when oil is changed either too soon or too late. Changing oil at the right time can only be done if the physicochemical properties can be determined accurately and precisely at the time the condition merits it. The objective of this project was to develop a commercialized product marketable to both DoD and the private sector. Successful development of a field-ready, commercialized, marketable portable/handheld oil assessment device suitable for real-time oil assessment by mechanics in the field was a project result.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Portable Large Shape Inspection System
The project resulted in development of a commercial metrology guide scanning system that has been successfully installed for production applications. The commercial scanning system is based on the use of Accordion Fringe Interferometry (AFI). The chief advantage of AFI over conventional scanning approaches is that AFI allows simple, lightweight high-performance scanning systems to be produced that can be used to scan a broad range of surfaces under a range of shop lighting conditions.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Process Substitution Methodology for the Repair of Composite Materials
The Process Substitution Methodology project for composite materials provided immediate benefit to the Department of Defense (DoD) war fighting capability during missions in Afghanistan, Kosovo and Iraq. The primary goal of this project was to develop and install the basic tools required to support material state management approach upon which the substitution methodology is based. The rapid revision of the processes that allowed for expansion of the Predator mission is just one example of how this technology can be applied. The material state management approach provides production personnel and support engineers with visibility on the effects of changes in process on the cure rate and cures state of the composite.

Price per copy: NCMS Members $50.00 now available; Non-members $75.00 now available

Product Life Cycle Management (PLM) for Aircraft Sustainment and Support – Phase I & II
In today’s Fleet Readiness Centers (FRCs), the lack of a single controlled environment for required technical information challenges their capability to maintain and service aircraft. The result of this project was an enhanced maintenance and logistics process which naturally created significantly shorter lead times, provided data to stakeholders in an organized format and ultimately supports the Navy’s goal for fleet readiness.

Price per copy: NCMS Members $100.00 available May 2016; Non-members $150.00 available
May 2017

Product Lifecycle Management (PLM) for Six-Sigma Quality – Phase I and II
Current life cycle data management processes dictate manual handoffs, delegations, and follow-through, which is a compromise in terms of productivity entitlement and lead to quality oversights. Industry is struggling to demonstrate a successful marriage of CAD engineering definition with the complete manufacturing process data in a PDM environment. The project piloted the integration of three technologies that together provide a means of automatically extracting all engineering requirements (GD& T plus specification and standards references) from UG-NX drawings and storing them under configuration management in the Teamcenter™ PLM system. The result can take management of characteristics (engineering requirements) from the 3 to the 6 Sigma level, virtually eliminating quality escapes.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Product Lifecycle Management (PLM) for Six-Sigma Quality – Phase II
This project addressed major opportunities for improving the way in which product design data is linked to Quality Plan and Manufacturing Information throughout the Supply Chain and product lifecycle from initial design to depot maintenance. The work done during project execution to under the depot requirements sets the stage for broader deployment of the product lifecycle management (PLM) tools that were successfully demonstrated. Based on the pilot results, the total quality and productivity-related savings opportunity for an OEM is estimated to be between $11-13M per year.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Rapid Access to Readiness-Essential (RARE) Parts through Rapid Manufacturing and Repair (RM&R) – Phases II-IV
This Rapid Access to Readiness-Essential (RARE) Parts program recognized the importance of additive manufacturing to the DoD and its organic and industrial maintenance base and built an active industry-government network that has a nationwide scope and reach. It has been meeting the challenges of bringing this capability to maturation and adoption within the DoD, with its public-private partnership’s sharing information about the number and type of rapid production systems within the U.S., where these systems are located (i.e. industry, government, academia) and skills in the form of lessons-learned with respect to equipment installation, user training, materials properties databases, three-dimensional digital file creation, parts certification and inspection. Over 126 parts were fabricated in the contiguous RARE Parts program with a $7.12M in annual cost savings as compared to acquisition costs or legacy production costs, and up to 90% cost savings per part. As well 1,479 weeks cumulative time savings over part acquisition time and quoted delivery schedules, or legacy production time (based on a 40 hour week), up to 80% time savings per part. Over the course of this program 16 machines were installed in participating DoD maintenance facilities and another 12 in collaborating industry partners’ facilities during multiple phases. Additionally, DoD members purchased and installed an additional 22 machines during the course of the program.

Price per copy: NCMS Members $100.00 available June 2016; Non-members $150.00 available
June 2017

Rapid Manufacturing & Repair (RM&R) Technologies – Phase II
Additive technologies allow part design freedoms not possible with traditional fabrication methods. Complex-multiple part configurations can be constructed in a single build, thus allowing reduction in the numbers of component parts needing assembly. Forty parts were fabricated and 17 provided sufficient data on cost and readiness benefits resulting in $2.03M annual cost avoidance and up to 80% in time savings.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Rapid Prototyping Technology Advancement for Maintenance Activities (RPTA)
The 4-year Rapid Prototyping Technology Advancement (RPTA) project transferred skills, inserted technologies, and increased the use of RP in DoD maintenance depots. Activities included conducting pilot demonstrations ad case studies using RP technologies installed in both industry and DoD depot locations. Benefits to participating DoD depots included knowledge transfer, part design simplification, material and process improvements, lead time and man-hour reductions in part repair/replacement and associated cost avoidance. Over 30 case studies documented savings in excess of 600 man-days and $2.2 million.

Price per copy: NCMS Members $50.00 now available; Non-members $75.00 now available

Rapid Response Computer-Aided Manufacturing of Printed Wiring Boards (RRCAM)
The objective of this program is to demonstrate and install a computer-automated alternative to the conventional plate-and-etch technology for producing printed wiring boards. The process is based on newly developed metallo-organic decomposition chemistry for direct, additive metallization of holes and printing of circuit traces. The new technology, named Parmod®, has been used to prepare demonstration circuits with pure copper conductors on laminate substrates which are believed to be the equivalent of conventional plate-and-etch circuits.

Price per copy: NCMS Members $50.00 now available; Non-members $75.00 now available

Recent Alternatives to Chromate Conversion Coatings
This study extends and updates an earlier NCMS study completed in 1995. This new study compares the performance of 18 conversion coatings, including 17 chromate-free alternatives and 1 chromate-based control, from seven suppliers, on six aluminum alloys. Data from side-by-side testing is provided for three typical tests: salt spray corrosion resistance, contact electrical resistance, and paint adhesion.

Price per copy: NCMS Members $50.00 now available; Non-members $75.00 now available

Replacements for Hexavalent Chromium in Surface Finishing Processes (Tri-Chrome)
For many years, researchers have sought chromium-free substitutes for hexavalent chromium processes, driven by toxicity concerns. However, there remain many applications for which no suitable substitute for hard chromium has yet been developed, and for which there is no immediate prospect of a replacement. These processes remain in use, despite well over a decade of attempts at replacement. Most process engineers are convinced that hard chromium plating is going to remain a necessity for some time to come. This project is based on the recent development of a new trivalent chromium electroplating process that will provide an alternative to the use of hexavalent chromium to achieve hard functional coatings. The project objective is to optimize the new process to meet military and industrial specifications and evaluate its performance.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Retrograde Part Identification Using 2nd Generation Permanent Marking Techniques (Parts ID)
Direct part marking is in widespread use in commercial aerospace, automotive, electronics, semiconductor, and pharmaceutical industries. The Data Matrix (ISO 16022) is the dominant barcode symbology used to place a permanent machine-readable code directly into material surfaces i.e., not using labels or tags. The challenge is to determine which marking method is acceptable for material types, so that the resulting symbology will survive (remain readable) after enduring harsh environments and therefore last the life of the part.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Robotic Automated Coating Removal Systems (RACRS)
Developed performance specifications for an enhanced version of the Automated Rotor Blade Stripping System and a concept of operations for fully stripping a V-22 fuselage using laser/robotic technologies.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Robotic Painting Optimization for Military Vehicles
Chemical agent resistant coatings (CARC) camouflage application to military land-vehicles is currently a labor-intensive process that requires the applied of a single-color base coat, followed by manually drawing the camouflage pattern in chalk to allow the application of the final two colors. The project approach involved combining vision and robot technologies to advance the state-of-the-art using an interface between the vision system and the robot. The project was designed to first assess the feasibility of the approach and to demonstrate the concept, prior to launching into a full-scale robotic painting implementation

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Robotic Systems Joint Program Office (RSJPO) – Interoperability for Micro Robot Weight Class Unmanned Ground Systems
The RSJPO launched a program to reduce the deficiencies through development and application of an Interoperability Profile (IOP) standard. An IOP-compliant system decouples operator control unit (OCU) and UGV development.

Price per copy: NCMS Members $100.00 available June 2015; Non-members $150.00 available
June 2016

Robotic Systems Joint Program Office (RSJPO) – Interoperability for Tactical Robot Control
The project demonstrated two government-owned operator control unit applications controlling two separately developed IOP v0-compliant UGV, with the implication that either of the demonstrated applications is capable of controlling any IOP compliant UGV.

Price per copy: NCMS Members $100.00 available June 2015; Non-members $150.00 available
June 2016

Shareable Operational Resource Tool (SORT)
When U.S. and Allied Forces deploy to operations and exercises, additional/redundant equipment and sustainment items are continually deployed with little ability to cross-service support from friendly forces in theatre. The Shareable Operational Resource Tool (SORT) provides a web-based capability for facilitating coalition planning, execution and drawdown for shared visibility of offered national items and services.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 available
October 2015

Smart Machines Pilot Project – Phase I
Cincinnati Lamb, LLC developed a Field Reliability Evaluation Electronic Log (FREEDOM E-LOG) system to monitor equipment health and process effectiveness of its machine tool installations. It captures data automatically (without human intervention), stores it, processes it, and in some installations automatically sends data to Cincinnati Lamb for archival. It can be tailored to accommodate virtually any factory equipment and/or manufacturing process. The project team piloted the technology in a variety of industrial and depot maintenance applications.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Smart Machines Pilot Project – Phase II & III
The problem addressed in this project was online access to real-time and historical process status and equipment health information. Phase II provided previously unavailable visibility into the status and health of shop floor equipment. Phase III deployed condition monitoring in a production environment on equipment assets making status available over the site enterprise network.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Static Event Detection (SED) Initiative
The objective of this project was to determine the feasibility of developing a Static Event Detector (SED) Health Monitoring System. This system would alert inspectors or equipment operators to an electrostatic discharge (ESD) event that may have inflicted latent or catastrophic damage to critical electronic components resulting in a weapons system’s degraded performance. A SED is a device that detects the passage of an electrostatic discharge event. It can be as simple as a fuse or a metal-oxide semiconductor (MOS) device, both are single use devices. A magneto-optic static event detector (MOSED) is a subset of SEDs. It is resettable and thus reusable and is the type of SED developed during this project.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Track Test Machine
The Army’s physical simulation effort for ground vehicles at the Physical Simulation Laboratory (PSL) and the Tire, Run-Flat, and Road Wheel Simulation Laboratory (TR2SL) regularly tests HMMWVs, MRAPs, Strykers, and trailers, among other vehicles, to validate and verify the durability of whole-vehicle and component systems, such as armor, frames, suspensions, run-flats, tires, and road wheels. However, the PSL lacked two important capabilities: the ability to perform active testing of electronics at extremes of temperature, humidity, vibration, and shock and also the ability to test track systems such as that of the M1A2 tank at extremes of speed and load. This project through the CTMA program closed the track testing gap by providing PSL with the needed capabilities.

Price per copy: NCMS Members $100.00 available June 2015; Non-members $150.00 available
June 2016

Technology Roadmapping for United States Marine Corp Maintenance Depots
The result of this technology roadmapping pilot facilitation at Albany and Barstow proved this methodology of roadmapping was a valuable and useful tool for the long range planning and sustainment of Maintenance Depots. The pilot demonstrated the ability of technology roadmapping to identify critical customer needs, capabilities, technologies, and skills to meet those needs in the depots. The roadmapping process also identified gaps in meeting those needs, and helped define plans to fill the gaps.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Thermal Spray Coatings Booth Equivalency Unit
The Commercial Technologies Maintenance Activities (CTMA) Thermal Spray booth Equivalency project was launched to address a critical need in the plasma spray coatings industry—variances from booth-to-booth or cell-to-cell for parameters which affect the plasma plume, and hence, the resultant coatings. This project developed a portable booth monitoring system that allowed the user to optimize spray booth conditions and translate these conditions easily to other booths.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Ultrasonic Consolidation of Titanium Alloys for High Performance Aircraft Damage – Phase I
The project focus was to specifically demonstrate the feasibility of electric current augmented ultrasonic consolidation of titanium for the repair of structural components made of titanium alloy (Ti-6-4). The development of a satisfactory tool steel sonotrode became a major hurdle in the accomplishment of the project goals. The specific repair-oriented application explored were: Feature Restoration (Damage Repair) of Metal Airframe Features; Damage Repair of (Forged) Aircraft Structural Components; Pumps, Tubing, Heat Exchangers, Reaction Vessels; and Armor

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Validation of Functional Trivalent Chrome Plating Process – Phase II and IIA
Traditional chromium plating releases a mist of highly corrosive droplets that pose a risk to process operators. Hexavalent chromium has been implicated in long-term health effects, including cancer. In Phase II, an extensive series of tests was performed on samples produced using Faraday’s trivalent chrome process. The samples were able to successfully pass several key tests and performed comparably to hexavalent chrome. In Phase IIA encouraging results were achieved by modifying process plating parameters and select tank additives, a potential increase in platable current density range.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Validation of Functional Trivalent Chrome Plating Process – Phase IIB
Traditional chromium plating releases a mist of highly corrosive droplets that pose a risk to process operators. Hexavalent chromium has been implicated in long-term health effects, including cancer. The objective of Phase IIB was to expand on the knowledge gained in Phases II and IIA and to better understand/expand the effective of additives on the range of current densities that produce a dense, hard, wear resistant chrome coating. Hull Cell experiments were used to assess the range of applicable current densities obtainable with each additive.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 available
February 2016

Validation of Functional Trivalent Chrome Plating Process – Phase IIC
Building on earlier project phases, the objective of Phase IIC was to complete the experimentation work to optimize the Faraday Technology trivalent chrome process as well as complete the testing and pass standardized tests from industry and the depots and determine the potential of additives to extend the range of current densities that produce a dense hard chrome coating from Faraday’s environmentally benign process. The new plating process was able to pass all wear resistance tests.

Price per copy: NCMS Members $100.00 available November 2015; Non-members $150.00 available November 2016

Virtual Workplace Simulator – Phase I & II
Through the use of simulation technology and physical dynamic interface in the Virtual Workplace Simulator, Pendaran delivered accelerated, problem-based learning to individuals staffed at all levels of the organization. The intense, “live-fire” simulation provided the context for physical, psychological and intellectual experiences that lead to long-term learning retention.

Price per copy: NCMS Members $100.00 available June 2015; Non-members $150.00 available
June 2016

Volumetric Accuracy for Large Machine Tools (VALMT) – Phase I
VALMT pioneered an innovative process in volumetric error compensation for large machine tools. VALMT will save ship and aircraft manufacturers millions of dollars. Machine tool calibrations used to take an entire week. VALMT allows the same process to be performed in a day. The benefits of this technology aren’t just time savings; it will allow for more accurate parts, reducing or eliminating expensive re-work during assembly.

Price per copy: NCMS Members $100.00 now available; Non-members $150.00 now available

Work Process Automation with Automatic Status Reporting
The Automated Work Process Planning project was formed between industry and the Tobyhanna Army Depot (TYAD) to address industry and depot needs to shorten cycle times, reduce out of stock rates while lowering pipeline inventory requirements, provide improved visibility of in process orders and enhance resource planning capabilities. The specific goal was to develop, and demonstrate, a cost effective, automated workflow planning system through development of a business process-driven Information Technology (IT) architecture with the capability to continuously respond to change as tasks are performed. This required the integration of legacy Workflow, PDM and Project Management systems.

Price per copy: NCMS Members $50.00 now available; Non-members $75.00 now available

ZeroG™ Arm Technology Transfer to DoD Depots to Reduce Injuries and Reduce the Cost of Maintenance
This project conducted a productivity assessment to evaluate the benefits of applying zeroG® technology to assist depot workers as they used a variety of tooling (e.g. sanders, drills, grinders, etc.) that require periods of prolonged use. The assessment reviewed both quantitative measures and qualitative measures of productivity (worker fatigue, ergonomics, etc.). Designed to carry the weight of heavy tools, zeroG® allows the completion of arduous tasks with a higher degree of quality while eliminating most of the physical stress and fatigue experienced by the workforce.

Price per copy: NCMS Members $100.00 available August 2016; Non-members $150.00 available August 2017

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