Expeditionary Fluid Analysis Capability (EFAC)Phase III

Bob Yurko Spectro Scientific

Bob Appleton Troika Solutions

Purpose of Project

Develop a proposed DoD wide deployment plan for the EFAC oil analysis capability

Problem Statement• Every year the DoD spends ~$71.5 billion on Maintenance

• A large portion of this is the cost of regularly scheduled time-based preventive maintenance• Since 2002, CBM+ has been established policy.

• Studies reveal that 33% - 60% of oil changed on a calendar based schedule is serviceable

• Oil change costs include:

• Oil

• Filter

• Transportation

• Labor hours

• Waste Disposal

Need a reliable method to assess oil condition at the vehicle prior to changing

What Could Be Gained by Oil Analysis

• Estimated DoD cost of changing and disposing of serviceable oil:

– $150-200 Million per year

– 160,000 man days per year

– Additional monetary, environmental, and transportation burdens

• Diagnosis/prognosis of mechanical condition for CBM

– Oil condition can identify mechanical condition

– i.e. USMC LVSR Transfer Case

Or what is lost by failure to analyze lubricating oil

A CY15 study conducted at 8th ESB assessed the fleet of USMC heavy and medium tactical wheeled- vehicles during normally scheduled preventive maintenance periods.

47 LVSRs Assessed

Normal PM Cost (A & B) x 1 yr = $82,822.74

Normal Labor Hours (A & B) x 1 yr = 844

PM Cost with Tier One x 1 yr = $47,252.24

Labor Hours with Tier One x 1 yr = 955*

Avoidance Cost savings with Tier I x 1 yr = $35,570.50

Avoidance Labor savings with Tier Ix 1 yr = (111)

Opportunity cost = Avoidance + HAZMAT+ Transportation cost+ Admin + Overhead= ???

52 MTVRs Assessed

Normal PM Cost (A & B) x 1 yr = $49,999.84

Normal Labor Hours (A & B) x 1 yr = 1042

PM Cost with Tier One x 1 yr = $35,615.01

Labor Hours with Tier One x 1 yr = 850.5

Avoidance Cost savings with Tier I x 1 yr = $14,384.83

Avoidance Labor savings with Tier I x 1 yr = 191.5

Opportunity cost = Avoidance + HAZMAT+ Transportation cost+ Admin + Overhead= ???

For a two-year time frame, regression analysis data suggests recouping 60,809 labor hours and saving $6.5 Million for the two equipment platforms. Similar savings for all enterprise oil-wetted weapons platforms can be expected.

TriVector™ - Complete View of Condition

Is the machine in good condition?• Engine

• Gearbox and Transmission

• Hydraulics

Is it the right oil?• Is the oil still fit for use?

Is the oil clean?• Water & Coolant?

• Dirt?

Three key elements for understanding the health of a machine and its lubrication system

• Spectro’s instruments answer one or more of these questions

• Q5800 provides answers to all, a Complete View of Condition!

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Technical Approach

Tier I: Expeditionary Fluid Analysis in the FieldFluidScan Q1000

Infrared Spectrometer Kinematic Viscometer

Used by MSC, USCG, ARNG, NECC, NAVSEA, USMC, USAF, DOS

and Hundreds of Commercial Customers

Measures Physical Properties and Viscosity of Fuels and Lubricants

NSN 6650-01-615-3416 NSN 6630-01-622-2461

SpectroVisc Q3050

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Tier I: Case History 8TH ESB, Camp Lejeune• On average, 62.3% of all samples analyzed were NORMAL (No Action Required)

• The single most common ALARM is for viscosity (high or low)

• Most common physical property ALARM’s are due to depleted alkali buffer reserve and water

CONDITION QTY FREQUENCY

No Action Required 53 62.30%

Warning 6 7.90%

Alarm 17 22.36%

TOTAL 76 99.9600%

VISCOSITY QTY FREQUENCY

No Action Required 57 75.00%

Warning 5 6.58%

Alarm 14 18.42%

TOTAL 76 100.0000%

PHYSICAL PROPERTIES QTY FREQUENCY

No Action Required 458 97.03%

Warning 6 1.27%

Alarm 8 1.69%

TOTAL 472 100.0000%

Technical Approach

Tier II: Complete Fluid Analysis in the FieldQ5800- Portable Oil Analysis Lab

Used by USAF, NECC, US ARMY, DOS, LOCKHEED MARTIN,

SAUDI ARABIAN NAVY, ITALIAN NAVY and several commercial customers

Man Portable, < 35 lbs.

Measures Chemistry, Viscosity, Contamination and Wear Metals of Fuels and Lubricants

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Tier II Case History: LVSR Transfer CaseQ5800 Analysis Determined S/N 648404 Contained High Wear Metal Concentrations and Extremely High Particle Count

LVSR (S/N 648404)

USMC Labor Cost to Remove $350

USMC Material Cost to Remove $0

Contractor Labor Cost to Repair $6,400

Contractor Material Cost to Repair $3,260

USMC Labor Cost to Re-Install $520

USMC Material Cost to Re-Install $15

Shipping Costs 2X $2,500

TOTAL COST $13,045

Days in Deadline Status 97

Proposed Technology Deployment(Tentative)

NECC Total Units Unit Cost Costl

Tier 1 83 $33,000 $2,739,000

Tier 2 17 $100,000 $1,700,000

Total Cost $4,439,000

Army Total* Units* Unit Cost Costl

Tier 1 289 $33,000 $9,537,000

Tier 2 289 $100,000 $28,900,000

Total Cost $38,437,000

*From DoD Maintenance 2016 Fact Book

USMC Total UnitCost Cost

Tier 1 69 $33,000 $2,277,000

Tier 2 9 $100,000 $900,000

Total Cost $3,177,000

Air Force Totals Units Unit Cost Total Cost

Tier I $33,000 $0

Tier II 241 $100,000 $24,100,000

$24,100,000

USMC Phased Implementation COAs

COA #1 - Tier I Only$33 K x 69 = $2,277,000

(Active Duty Battalions)

COA #3 Hybrid (I & II)$33 K x 69 = $2,277,000

$100 K x 9 = $900,000

(Battalions & IMA or larger)

Total $3,177,000

COA #2 - Tier II Only$100 K x 78 = $7,800,000

• COA #1 - The Tier I capability employed at the organizational level to measure physical

properties and viscosity

• COA #2 - The Tier II capability employed at the organizational level to measure the

physical properties of fuels and lubricants + particle count, wear metals, and

contaminants

• COA #3 – Hybrid of the Tier I and II devices

- Tier I at organizational level and Tier II at the intermediate level (IMA, MCLB, ESD, etc.)

Project Team Participants

• Government– OSD

– JS J4

– USMC I&L

– Army AMSAA

– Navy Expeditionary Combat Command

• Industry– Spectro Scientific

– Troika Solutions LLC

– National Center for Manufacturing Sciences

QUESTIONS