Newly Funded Projects— CTMA’s Record Year in 2017
As part of CTMA’s mission of streamlining technology transfer and enhancing materiel readiness, all maintenance and sustainment efforts are categorized under Focus Areas. These areas have been targeted to work in lockstep with the DoD’s efforts to drive down costs while adopting new technologies. NCMS is excited to be collaborating with the DoD, its industry partners, and academia to find, develop, and demonstrate the most effective technologies at best cost. Over the last three years, the CTMA Program has seen significant growth. There is every reason to believe that the best years are yet to come.
Additive Manufacturing
Development of Laser Additive Manufacturing Repair (LAM-R) Transition Procedures Supporting Maintenance & Sustainment
In partnership with the Army, NAVAIR, Honeywell, Southwest Research Institute, and with assistance from Elevate Systems, NCMS launched a project to develop qualification requirements of a LAM-R for the H-60 Oil Cooler Assembly and T700 Gas Generator Turbine Shaft. Benefits of LAM-R technology makes it possible to repair parts that were previously unrepairable. The knowledge gained on LAM-R repair will be transferred to the public. This project is managed by Dana Ellis.
DoD AM Implementation Strategy Development
In partnership with OSD Maintenance, the Navy, Marine Corps, Air Force, the Army Logistics Information Agency, Lockheed Martin, Penn State University, Raytheon, Boeing, Moog, and LMI, NCMS launched a project to develop a strategy to implement additive manufacturing (AM) capabilities across the Armed Forces. An environment through CTMA enables the maintenance and sustainment community to share relevant information, identify critical issues, discuss key topics, and increase their awareness of DoD maintenance and sustainment initiatives. This project is managed by Debbie Lilu.
Autonomic Processes
Business Improvement Process for Maintenance & Sustainment
In partnership with Air Force, the Defense Logistics Agency, Oracle Corporation, and Definitive Logic, NCMS launched a project to improve business processes around maintenance and sustainment. These solutions will enable the general public and DoD to better understand cost, schedule, and implementation to predict the return on investment and better support their organizations through cost-saving decisions. This project is managed by Dana Ellis.
Development of Operational Transition Procedures & Sustainment Analysis for Global Logistics Integration System (GLIS) Supply & Maintenance Functions
In partnership with the Marine Corps and Anglicotech, NCMS launched Phases III-V to develop transition procedures and conduct analyses surrounding the Global Combat Support System – Marine Corps (GCSS-MC), an enterprise resource planning (ERP) system. The improved efficiencies of logistics systems reduce costs for the companies via reduced labor and transportation expenses; these savings can then be passed on to the consumer by reducing the price of goods. This project is managed by Nicholas Brown.
Technical Studies, Analyses of Innovative Container Operational Concepts, and Expanded Use of Autonomous Logistics Platforms
In partnership with the Department of Defense Strategic Capabilities Office (SCO) and LMI, NCMS launched a project to analyze container operational concepts and expand the use of autonomous logistics platforms. The application of new operational concepts and data management techniques for containers may expand the scope of material that can be efficiently delivered by autonomous delivery platforms, with additional public benefits. This project is managed by Phil Callihan.
Business Processes/ Partnerships
Analysis of Maintenance Expenditures to Optimize Innovation Prioritization and Resourcing for Naval Shipyards
In partnership with the JTEG principals, DASD, Joint Chiefs of Staff –J4, the Navy, and LMI, NCMS launched a project to develop a model and analysis that will assist the DoD with identifying and prioritizing which maintenance technology insertion initiatives can achieve higher efficiency and readiness results. Being able to anticipate maintenance obligations will allow organizations to have the needed inventory on hand, reducing downtime, extra man-hours, and redundant costs. This project is managed by Phil Callihan.
Development of Intermittent Fault Detection Technology Implementation Procedures, Guidance, and Training
In partnership with the Navy and Universal Synaptics, NCMS launched a project to develop implementation procedures, guidance, and training for the Navy for an intermittent fault detection device. An easy-to-use device allows maintenance technicians to locate intermittent faults with little training time. This project is managed by Dana Ellis.
Gantry Hull Welding System Demonstration at a Naval Shipyard
In partnership with the Navy and Encompass Machines Incorporated, NCMS launched a project to explore using automated welding for work on hulls. A reliable weld cut is a safer operation and once programmed, the automated system can work continuously, saving the organization time and money. Automated routine weld cuts would not eliminate jobs, but reassign the complex work to welders who can use their skills in other, more creative and complex work. This project is managed by Debbie Lilu.
Intelligent Management Analysis System (IMAS)
In partnership with the Navy, the Marine Corps, Analatom Incorporated, and the Mercer Engineering Research Center (MERC), NCMS launched a project demonstrating the use of IMAS with the H-60 helicopter fleet. IMAS is a management system whose “associative memory” capability allows it to merge condition-based maintenance (CBM) data sources to identify correlations with which to improve maintenance strategy. Decreasing the failure probability requires a platform sustainment methodology that continually improves the ability to detect and mitigate functional degradation before failure occurs. This project is managed by John Keippala.
Intermittent Fault Detection Technology Pilot Implementation for U.S. Air Force/Air Force Materiel Command
In partnership with the Air Force and Universal Synaptics, NCMS launched a project to implement use of intermittent fault detection devices in the Air Force. Adoption of the advanced technological capability contained in VIFD allows maintainers to identify and then eliminate intermittent NFF, resulting in a positive benefit for the general public. Air Force Materiel Command will realize a significant return on investment by detecting, isolating, and repairing the root cause of intermittence in A-10 wiring harnesses. This project is managed by Dana Ellis.
Maintenance Quality Analysis
In partnership with the Navy and the SAS Institute, NCMS launched a project to develop a reliable method of maintenance data collection and interpretation for NAVAIR. With similar systems, industries could readjust their maintenance schedules and inventory, making them leaner, more efficient, and competitive. Equipment that is properly maintained will last longer, be safer, and cost the company less in replacement and insurance costs. This project is managed by Nicholas Brown.
Mission Analysis Readiness Resource Synchronization Tool
In partnership with the National Guard and MKGCS, NCMS launched Phase III to create a platform that all general staff directorates can operate using the same environment and decision support tools and milestones. In doing so, all directorates and agencies can reap the benefits of a cross-pollinated array of decision support tools. This project is managed by Lisa Stobierski.
Modern Information Technology Portfolio Management Improvement Initiative
In partnership with the Navy, Marine Corps, and RGS Associates, NCMS launched Phase III, which will result in an improved Capital Planning and Investment Control (CPIC) process supporting better portfolio management. Information will become better organized and visible to those who use it for decision-making processes at all levels. This will result in industry being better poised to propose and execute solutions while lowering cost of goods sold to the public. This project is managed by Nicholas Brown.
Strategy and Innovation; Enterprise Innovation Management
In partnership with the Navy and RGS Associates, NCMS launched Phase II to foster and promote the adoption of innovative private- and public-sector best practices. The success of the project will result in reduced sustainment costs, a more transparent future state plan for DON Innovation as a resource constraint mitigation strategy, and improved weapon systems readiness and reliability. This project is managed by Nicholas Brown.
Supply Item Logistics Capability Initiative
In partnership with the Navy and One Network Enterprises, NCMS launched a project to implement an enterprise resource planning system (ERP) for the Navy. The technical, cloud-based ERP platform envisioned can be readily applied to the commercial market, either integrating with existing ERPs or replacing them at a much lower cost. One of its most important aspects is agility, allowing for rapid growth into new markets. This project is managed by Jeff Walker.
Technical Studies, Analyses for Intermittent Fault Detection Isolation System (IFDIS) Implementation Across DoD
In partnership with the Navy, the Air Force, Universal Synaptics, LMI, Eagle Systems, Inc., and Copernicus, NCMS launched a project to build upon the experiences of Fleet Readiness Center Southwest and Hill Air Force Base in utilizing the IFDIS to assess the best strategy to implement this game-changing electronics maintenance capability across the DoD and at all levels of maintenance. The implementation of this IFDIS study equates to more streamlined and productive supply-chain management of electronic systems. This project is managed by Dana Ellis.
CBM+
NAVAIR Expeditionary Fluid Analysis Capability (EFAC) Evaluation
In partnership with the Navy and the Expeditionary Fluid Assessment Support Team (involving all five Armed Services), NCMS launched a project to evaluate a portable tool for performing vehicle oil analysis in the field. Remotely located entities benefit by having a reliable, easy to-use, in-house capability that provides real-time fluid analysis with minimal operating time lost, eliminating the need (and costs) for a mobile laboratory or collecting and shipping samples for analysis. This project is managed by Debbie Lilu.
Reducing Maintenance Costs through Predictive Analytics
In partnership with the Navy, the Joint Service CBM+ Action Group, and General Electric, NCMS launched Phase II to help the DoD leverage OEM-agnostic predictive analytics solutions developed by and for commercial industry to transform from planned to proactive maintenance strategies for its critical equipment. Objectives achieved through this project will allow GE to show how predictive analytic technologies can be used in conjunction with existing sensors and instrumentation to provide advanced warning of major failures. This project is managed by Jeff Walker.
Using Predictive Analytics to Improve Main Reduction Gear Readiness
In partnership with the Navy and the DEI Group, NCMS launched a project to use the Navy’s Integrated Condition Assessment System (ICAS) to improve main reduction gear and propulsion drive train maintenance. Results and technologies derived from this project will provide critical information for maritime engineers so that they may incorporate all relative findings into U.S. seagoing vessels, increasing safety for all those who travel congested shipping lanes and/or are subject to heavy seas. This project is managed by Jeff Walker.
Coatings/ Corrosion Prevention
Coating Layer Consolidation
In partnership with TARDEC and PPG, NCMS launched a project to produce dual-use corrosion protection strategies that represent cost savings and improvements to the DoD and the general public through enhanced asset protection. These technologies will be applicable to both defense and industrial applications requiring substrate protection, including but not limited to ground vehicles, all modes of transportation, aging bridges, buildings, sections of highways, electrical towers, power plants, and numerous other structures This project is managed by Lisa Stobierski.
Integrated Corrosion System
In partnership with TARDEC, PPG, and North Dakota State University, NCMS launched Phase II to provide a new means to store and transport goods while maintaining the original appearance of the product. The new temporary coating will allow easy application to larger products made from a broader array of materials. Elongating the integrity of the initial corrosion coating could make legacy equipment more reliable, thereby enhancing its performance. This project is managed by Lisa Stobierski.
Long Term Tire Storage
In partnership with TARDEC and PPG, NCMS launched Phase II to identify ways to limit degradation of tires in long-term storage. If the reliability of tires could be increased by reducing rotting and decomposition, that could drastically lower the number of injuries and deaths due to accidents. Companies that depend on their tires for commerce could realize significant savings in tire replacement and the cost of inventory. This project is managed by Lisa Stobierski.
Reversible Adhesives
In partnership with TARDEC, PPG, and Michigan State University, NCMS launched Phase II to develop a safe adhesive that works on dissimilar components and is removable and reusable, which would make vehicle research and re-engineering easier and would broaden the possibilities for experimentation. Companies could remove and replace adhesives quickly and easily, greatly reducing the downtime needed for equipment repair. This project is managed by Lisa Stobierski.
T700 1st Stage Turbine Nozzle Sand/ Salt Phobic Treatment Concept Demonstration
In partnership with NAVAIR and Ohio State University, NCMS launched Phase II to demonstrate the sand/ salt phobic treatment for the T700 first stage turbine nozzle. When fully developed and adopted, protective gas turbine engine compressor coatings will make commercial aviation safer, more reliable, and less expensive. The same holds true for the power generation industry. This project is managed by John Keippala.
Maintenance and Safety Improvement for T700 Engine Compressor Airfoils
In partnership with the Navy, Air Force, Army, MDS Coating Technologies, and GE Aviation, NCMS launched a project to develop a coating that could resist erosion and corrosion. A market-ready coating applied widely across the entire commercial gas turbine engine industry from transportation to power generation offers many benefits to the general public resulting from reduced engine maintenance, lower fuel costs, and greater time on-wing. This project is managed by John Keippala.
Energy, Environment, Health & Safety
Advanced Lithium Battery Technology Demonstration for Forklift Trucks
In partnership with DLA, the OSD, Navitas Systems, and Analytic Strategies LLC, NCMS launched Phase II to introduce the use of lithium- ion-battery-powered forklifts. Lithium-ion cells cause little harm when disposed of and cell materials have shown the high ability for recovery and recyclability, so it is expected that lithium-ion recycling rates will rival lead-acid. This project is managed by Marc Sharp.
Assessment and Concept Development of zeroG and zeroG Mag-Mount Systems for Hull Applications at Puget Sound Naval Shipyard (PSNSY)
In partnership with the Navy, Equipois LLC, and Maglogix, NCMS launched a project to introduce magnetic mounts for tool arms in a Naval maintenance setting. By eliminating the strain and fatigue associated with repetitive tasks and making tools effectively weightless, zeroG technology can significantly boost productivity, reduce industry costs, and improve quality of goods and workplace satisfaction. This project is managed by Debbie Lilu.
Improving the Effectiveness of Combat Wounded Warfighters
In partnership with the Army, Archimedes Analytics, and Portable Factory, NCMS launched a project to examine multi-modal forces and vibration on the body and develop a modular vibration mitigation system that will establish a barrier to absorb forces between the injured body and litters for carrying combat-wounded warfighters. The modular design, vibration mitigation, and protection will directly translate to improvements in the civilian sector for remote rescue units, urban casualty transport, and air evacuation scenarios. This project is managed by John Keippala.
Integration of Operational Energy into Training and Education
In partnership with the Navy, the Marine Corps, the OSD, and Booz Allen Hamilton, NCMS launched a project on incorporating operational energy into warfighter training. The general public needs a strategy for effectively educating their workforce on the role of operational energy for
mission success and incorporating the use of energy-efficient technologies and operating procedures (conservation) into policies, doctrine, and other maintenance and sustainment requirements. This project is managed by Marc Sharp.
Lightweight Design for Ground Combat Vehicle Components
In partnership with TARDEC and PPG, NCMS launched a project to investigate lightweighting components for the Army’s ground vehicle components. The intent of this initiative is to use the U.S. Army’s lightweighting goals as a test bed to develop optimized materials that reduce weight without decreasing vehicle safety, and show how such improvements can be transferred to commercial applications. This project is managed by Lisa Stobierski.
Modernized Safety Enclosure for Hazardous Machinery
In partnership with Letterkenny Army Depot, Exact Machine Services, and Keller Industrial, NCMS launched a project to develop new safety equipment for hazardous machinery. Improved worker safety at Letterkenny is the first and most important public benefit of this project, but that benefit can be extended to manufacturers across the U.S. that find themselves in a similar OSHA-deficient state. By retrofitting fully functioning legacy CNC machines with the new safety equipment rather than incurring the cost of new ones, savings can be reallocated toward upgrades or innovation. This project is managed by Nicholas Brown.
Enhanced Inspection
Advanced Mobile Universal Electrical Tester (AMUET) for Maintenance and Sustainment
In partnership with the Air Force, Solavitek, and the Mercer Engineering Research Center (MERC), NCMS launched Phase III to demonstrate that AMUET can be a valuable, cost-effective wiring/electrical systems analysis tool as an alternative to conventional ATE and handheld meters typically used at the Operational-(O) level. Early results from a Phase II BCA showed testing for a moderate subsystem can be completed within 45-minutes (compared to hours using handheld meters), and tens of thousands of dollars in equipment costs and TPS development time can be avoided when compared to conventional ATE. This project is managed by John Keippala.
Item Master Logistics Capability Initiative
In partnership with the Air Force and One Network Enterprises, NCMS launched Phase II to leverage the Marine Corps IT effort by objectively evaluating its Platform as a Service (PaaS) as a Course of Action (COA) for the Air Force. The intent of this initiative is to use the Air Force’s logistics system as a surrogate to industry to demonstrate how improvements to their logistics systems and worldwide distribution networks can benefit local governments to improve and better support services required by the general public. This project is managed by Jeff Walker.
Large Standoff, Large-Area Thermography (LASLAT) Non-Destructive Inspection of Composite Structures
In partnership with NAVAIR and Thermal Wave Imaging, Inc., NCMS launched a project to develop a novel system for thermographic NDI of composite aircraft capable of inspecting a large area in a short time. This technology will greatly benefit the inspection of composite aircraft where geometry is considerably more complex since severe defects may not be visually detectable at the surface. This project is managed by Phil Callihan.
Manufacturing Demonstration Tool Set for Maintenance & Sustainment Support for FRC Southeast and FRC Southwest
In partnership with the Navy and Siemens, NCMS launched a project to provide a centralized data management system for the business enterprise, which will improve overall control of product configuration by enabling all stakeholders to have real-time, on-demand access to the same configuration, product history, and other service-related data. This project is managed by Dana Ellis.
Manufacturing Management System for Aircraft Maintenance, Sustainment, and Support
In partnership with the Navy, Siemens, and Hylasoft, NCMS launched a project to implement a shared PLM system to share data, resources, and manufacturing capabilities in the same environment. Results derived from this project will allow manufacturing, maintenance, and sustainment industries to directly observe how they can produce a higher quality consumer product that delivers more value for the general public in coping with the increasing complexity and engineering challenges of developing new products for the global competitive markets. This project is managed by Dana Ellis.
Product Lifecycle Management (PLM) for Integrating Maintenance and Sustainment Program Requirements Through an Asset’s Lifecycle
In partnership with the Air Force and Siemens, NCMS launched Phase III to create a defined set of project lifecycle information (PLI) for each product made, instead of a loose set of requirements for delivering product data for each weapon system. Maintaining an optimized, single approach with a company enables pooled employees to use a single process across multiple platforms instead of using a unique approach for each product. This project is managed by Dana Ellis.
Rapid and Agile 3D Scanner with Micron Accuracy for NonDestructive Inspection
In partnership with the Army, Navy, Air Force, Automated Precision Inc. (API), and MDS Coatings Technologies, NCMS launched a project to create an agile, high-speed instrument capable of measuring precision surface finish, dimensional feature accuracies as a non-contact device which will change metrology best practices and procedures in virtually every industry. This new capability will far exceed the precision data that the commercial industry currently has available. This project is managed by Debbie Lilu.
Reliability Improvement
Enhanced Environmental Performance for Safety Glass
In partnership with TARDEC, PPG (Aerospace), and Oakland University, NCMS launched Phase III to produce high-quality, glass-laminate, safety glass. The results from this project will better equip commercial industry to produce similar material at an affordable price. This includes applications such as vehicles transporting government and private industry dignitaries; protective screening for bank tellers, convenience store clerks, and law enforcement personnel; and in industrial situations where workers are subjected to a volatile/explosive manufacturing environment. This project is managed by John Keippala.
Membrane Water Filtration System Development
In partnership with TARDEC, PPG, and North Dakota State University, NCMS launched a project to create a membrane-based system for filtering large quantities of water for drinking. Whether the situation is a global, humanitarian problem or a DoD-specific mission, potable water treatment technology helps preserve life and decrease the logistical difficulties and costs of missions. This project is managed by John Keippala.
Minimizing Air Force Vulnerability During Smart Grid Upgrades to Ensure Sustainment
In partnership with the Air Force, Air National Guard, and Booz Allen Hamilton, NCMS launched Phase II to plan improvements to power generation and energy assurance on Air Force bases. A new, smarter grid will offer improved methods for gauging risks and the security posture of real-time distributed control systems, advancing the development and standardization of cybersecurity, including privacy, policies, measures, procedures, and resiliency in the grid. This project is managed by Marc Sharp.
Power and Signal Cable Reverse Engineering and Development to Improve MRAP Maintenance and Readiness
In partnership with TARDEC and Unified Business Technologies, Inc., NCMS launched Phase II of a project to reverse-engineer needed cables on an as-needed basis. The techniques and engineering technologies and skills used here are directly
applicable to cables used in civilian applications so the use of a military test bed to add to knowledge and skills of engineers and technicians is beneficial to the general public. A complete, modern, model-based, USG-owned TDP that can be more universally distributed across DoD will be created. This project is managed by Nicholas Brown.
Removal of Magnetically Attached Devices (ReMAD) Effectiveness and Sustainability Assessment
In partnership with JIDO and Florida State University, NCMS launched Phase II to explore means to repel/ detach unwanted or no longer needed MADs. This capability will be a welcome technology offering the benefit of enhanced safety to the public in general by preventing injury during the detachment process of strong magnetically-attached components. This project is managed by Lisa Stobierski.
The Refurbishment, Re-Engineering, and Testing for Sustainable Re-Introduction of Components into Legacy Systems
In partnership with PEO Submarine, the OSD, and Orbital ATK, NCMS launched a project to re-engineer current warheads. By doing so, rather than developing new ones, the DoD can save millions of taxpayer dollars. By re-tooling, less hazardous materials would be in circulation, which could result in a safer environment. This project is managed by Marc Sharp.
Vehicle Maintenance and Repair Data Acquisition and Predictive Maintenance (DAPM)
In partnership with TARDEC and Ricardo Control Point, NCMS launched a project to collect high quantity and quality vehicle maintenance data for the Army within a single platform. With access to data that can streamline maintenance and instruct personnel when repairs and updates are actually needed, rather than suggested, asset downtime can be reduced, lowering overall maintenance costs. This project is managed by Marc Sharp.