Modern Business Platform for Improvements to Manufacturing and Sustainment Operations

NCMS Project #: 142098

Problem: Support of older technologies lacks a modern industrial base to perform new manufacture or remanufacture demands effectively.  Companies that sustain legacy technologies are often faced with multi-generational infrastructure (e.g., industrial equipment, business systems, materials processing methods).  This industrial base is relied upon to maintain and sustain tens of thousands of critical aviation components.  Recapitalization efforts are replacing older tools and equipment to retain production line supportability and improve efficiency.  However, these recapitalized production lines are not leveraging the data available from modern industrial equipment, causing inefficiencies that leads to delays, increased costs, and unavailability of assets.

Benefit: Optimized data analytics combined with maintenance and sustainment solutions within aircraft fleets serving the general public can provide cost reductions, enhanced and more reliable aircraft systems, reduced mean times between failure, and lower system failure rates.  Incorporation of lessons learned from this evaluation and demonstration will be leveraged by the industry participant efforts for future business within the aerospace maintenance industry.  Small businesses that provide aerospace maintenance will be able to leverage this effort to avoid custom solutions and large capital investment. 

Solution/Approach: Using a United States Air Force (USAF) Depot organization charged with maintenance and sustainment of many legacy components and assemblies as a test bed, this initiative will demonstrate the benefits of integrating various Commercial Off the Shelf (COTS) Industrial Internet of Things (IIOT) data collection and Machine & Process Analytics  
(M & PA) capabilities.  By providing connectivity, data collection, and data analytics for maintenance process and equipment management – and providing the legacy maintenance planning Information Technology (IT) systems with near real-time information on production – will demonstrate improved performance, reduced cost, and the highest quality of output.

Impact on Warfighter:

  • Enhance cybersecurity and lower IT operating costs 
  • Increase equipment and critical part availability  
  • Reduce maintenance and sustainment costs  
  • Enhance data exchanges and decision-making

DOD Participation:

  • Warner Robins Air Force Base, Commodities Maintenance Group (CMXG)

Industry Participation:

  • Siemens SGT
  • NCMS

Benefit Area(s):

  • Cost savings
  • Repair turn-around time
  • Maintenance avoidance and reliability
  • Obsolescence management and continued maintenance capability
  • Safety
  • Improved readiness
  • Reliability improvement

Focus Area:

  • Business IT and analytics