125264541 Crosthwaite G and McClure J 27 Nov 2012 F 22 ASIP Roadshow Benefits on Overall ASIP...

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12/3/2012

Birthplace, Home & Future of Aerospace

F-22 System Program Office

F-22 ASIP Roadshow:

Benefits on overall

ASIP Execution

DEC 2012

1

George Crosthwaite & John McClure

AFLCMC/WWUE


12/3/2012


Background

• Started in 2008 due to field communication

issues, and to track down reasons for missing

data

• Currently there are 7 AFBs operating the F-22

– Scattered among several MAJCOMs: ACC,

PACAF, AETC, AFFTC and ANG

– Visit 1 per quarter

2


12/3/2012


Format

• Brief OG and MXG commanders on usage and

overarching topics

• Meet with AMUs and FSs to discuss issues on

the unit level

• Meet with the LO shop to go over any coatings

issues and stripping techniques

• Meet with the NDI shop to discover any

complications with tools or procedures

• Meet with ACC representatives to cover not

only base issues but the fleet as a whole* *Only occurs at ACC HQ base

3


12/3/2012


Purpose

• Present current usage and discuss ways to

alleviate severity

• Make sure commanders are knowledgeable

about who we are and what we do

– Rotate ~ every 2 years

• Provide communication channels for any

future problems

• Alert field of any upcoming/ongoing issues,

find out any issues the field is experiencing

unbeknownst to the SPO

4


12/3/2012


Data

• Achieving 90+%

fleet average on

data download rates

– Back in 2008 the

worst jet download

rate was 65%

– In just 4 years that

jet is still the worst

but now over 80%

5

50.00

55.00

60.00

65.00

70.00

75.00

80.00

85.00

90.00

95.00

100.00

Perc

en

t

Ho

urs

Aircraft

Sortie Time

Sortie Time Received


12/3/2012


Integrity Data Collection Trend

6

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

Inte

gri

ty D

ata

Ca

pu

tre

Ra

te

IAT Report Number

Data Capture Rate

Required Capture Rate

Ju

ly 2

00

4

Ju

ly 2

008

De

c 2

00

6

De

c 2

00

9

Se

p 2

01

2

ASIP Road

Shows Begin


12/3/2012


Usage

7

Control Point CPH-0014A

FS610 Bulkhead

LHS Lower Wing Attach Lug

• Represents fatigue critical structure

• Correlates well to wing loads and

NzW (primary fatigue driver)


12/3/2012


Usage

8

0

200

400

600

800

1000

1200

1400

0 200 400 600 800 1000 1200 1400

Eq

uiv

ale

nt

Fli

gh

t H

ou

rs

Actual Flight Hours

TrainingNon-…

More

Less

Severe


12/3/2012


Usage Trends

• Compare quarterly and current year trends

9


12/3/2012


Engine Usage

• Not affiliated with ASIP

• Organized visits already in place

• Engine SPO can

relay the timeline

for major engine

maintenance

based on current

usage

10

Increased

Usage


12/3/2012


Rotation

• Aircraft Fatigue

Severity Ranking

– Semi-annual

– Base Specific

• Allows Rotation of

Severe Missions

11

EFH AFHSeverity

RatioAFH

Severity

RatioAFH

Severity

Ratio

933 735 1.27 62 1.56 50 3.50 5366

1011 829 1.22 52 0.87 10 0.90 5546

746 627 1.19 48 1.50 56 0.74 5977

880 765 1.15 55 1.64 45 0.72 6077

1258 1233 1.02 37 1.22 46 0.70 6585

1023 974 1.05 45 1.12 71 1.25 6596

856 823 1.04 47 1.12 46 0.76 6836

1142 1142 1.00 32 1.02 64 0.71 6858

1028 1018 1.01 56 0.82 33 0.54 6893

1172 1203 0.97 89 0.97 34 0.74 7036

935 935 1.00 47 0.69 22 0.84 7065

785 785 1.00 41 1.04 56 1.03 7215

729 729 1.00 42 0.93 55 0.88 7271

488 488 1.00 25 0.64 33 1.21 7512

958 1038 0.92 41 1.21 48 0.37 7709

724 772 0.94 56 0.76 40 0.37 7810

646 691 0.93 52 0.89 39 1.17 7917

486 523 0.93 48 0.66 49 0.56 8122

652 732 0.89 38 0.63 45 0.51 8325

628 740 0.85 54 0.80 39 1.00 8803

713 937 0.76 63 1.18 53 0.79 9795

435 573 0.76 18 0.68 94 0.77 10093

606 847 0.72 48 0.55 56 0.45 10583

431 604 0.71 53 1.33 47 0.60 10776

510 784 0.65 42 0.89 79 0.43 11779

All Usage through June

20122nd Quarter 2012 1st Quarter 2012

Time

Remaining

to Reach

8000 EFH

at Current

Avg. Rate

Data is for illustration – not actual values


12/3/2012


Weight Reduction

• Reducing weight by removing stores to

minimum requirements

– 4% life savings, which works out to ~2 more

years of service

• Saving high G maneuvers until later in flight

– Lower fuel weight

12


12/3/2012


Flight Procedures

• Distance to range restrictions

– Range is close to base, less chance to burn fuel

weight before maneuvering

• G warm-up maneuvers

– Accounts for 10% of all high Nz events

– Recommended performing at higher altitude to

lower wing loads

13


12/3/2012


Flight Procedures

• Syllabus

– Mission types that are more severe are generally

higher priority

• 11 mission profiles

• Air-to-air training the most severe and highest priority

• Jet availability

– Less Ao the more focus on BFM

– Scheduling with depot inductions and overfly

requests around PMPs

14


12/3/2012


Tank Carriage

• External fuel tank usage was exceeding the anticipated 10%

– Bases stated their lack of flying with tanks

– Restructured calculation of base usage to exclude Ferry Flights

0%

5%

10%

15%

20%

25%

30%

Fleet Base A Base B Base C Base D Base E Base F

External Tank Usage

Total Tank Usage

TO Base = Landing Base

15


12/3/2012


Software

• Software update added an ICAW from Over-G

monitoring that was not in previous OFPs

– Field started seeing ICAWs, mostly during demo

flights, and was unaware of the cause

• Further update resulted in a “nuisance” Over-

G Hard Landing ICAW that asserted on startup

– Happened randomly and only on some jets

• Meeting with the field/pilots allowed us to

address the changes in the flight software so

they were aware and could alter their planning

accordingly

16


12/3/2012


Corrosion

• Ongoing problem with F-22

– Corrosion on the cockpit floor being the most

recent find

– Make sure they are pro-actively looking for and

preventing corrosion

17


12/3/2012


Coating Issues

• Keeping them on the lookout

18


12/3/2012


Tooling

• Provide MX community with new tools to demo

shortly after they make the approved list

– EVC Quick Skive Pneumatic Removal Tool

– Pneumatic Pencil Grinder

19


12/3/2012


NDI

• Ultrasonic inspections were shut off to protect

aircraft safety

– TOD was generically created and for old UT

systems

– Ensure that bases were submitting an AR to get

proper procedures

– AR database can be accessed to match

inspections without submitting new request

• Tasks currently being reworked

– Provide the NDI personnel at the base the

burndown schedule of the rework

20


12/3/2012


SPO Benefit

• Better physical understanding of the jet

21


12/3/2012


Summary

• Link Operations with Usage Tracking Data

• Identification of Maintainer Issues

– TO Clarification

– NDI Readiness

– Aircraft Downtime Drivers

– Emerging Repair Issues

– Data Collection Challenges/Procedures

22


12/3/2012


Conclusions

• Necessary to have direct contact with the field

to keep communication lines open

• Warfighter Understands Impact of Flying

Profiles and Usage Variation Has on Service

Life

• Identify and Mitigate Emerging Maintenance

Issues to Optimize Aircraft Availability

23

Communication is the key to successfully

sustaining any product for the warfighter


12/3/2012


Acknowledgements

• Lockheed Martin

– Suresh Patel

– Pete Caruso

• Engine SPO

– Gary Burns

– Mike Duffy

• SSO

– Dave Nielson

24


12/3/2012


Questions?

25

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125264541 Crosthwaite G and McClure J 27 Nov 2012 F 22 ASIP Roadshow Benefits on Overall ASIP...

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