National Maintenance Program (NMP)– Objective: Transition the Abrams Gas Turbine 1500 (AGT 1500)...

Sustaining The Transforming ArmySustaining The Transforming Army

National Maintenance Program (NMP)

October 29, 2002

Maintenance Policy Division


Field Maintenance

Repair and Return to User

Consists of- Unit - Direct Support

Repair and Return toSupply System

Consists of - Organic Depots- Industrial Base- GS Companies/Qualified Below-

Depot Activities

National Maintenance

Unit

Unit Motor Pools

Direct Support (DS)

General Support (GS)

Depot

TO& E Companies

TO& E CompaniesInstallation DOLs

DoD Industrial FacilitiesContractors Facilities

AVUM AVIM Depot

Field Maintenance

SupportsUnit

Readiness

Provides Predictable Reliability

Supports Single Stock Fund

Single Standard forMaintenance

Rightsizes National InventoryExpected Useful Life

Enhances Readiness

The National Maintenance Program

NationalMaintenance

SupportsArmy-WideReadiness

NMP

Transform

ing Army M

aintenance


The Four NMP Tenets

• Develop National Repair Objectives– Repair to National Vice

Regional Need• Establish a Single Standard of

Repair – Repair to the NMP

Overhaul Standard• Qualify Sources of Repair

– Consists of ISO compliance and technical qualification

• Enable a Repair-Based Logistics System

– Repair & Return to Supply

6

NMP Tenets

Recapitalization

Objectives:• Visibility of all Stocks – Division and above

• National Workload Plan• Visibility of Army Maintenance requirement

Objectives• Provide components with an expected useful life

•Publish National Maintenance Work Requirement

Objectives:•Establish Single Quality System

• ISO 9002 Qualification• Skills/ Tools/TMDE to meet the national standard•

Objectives:•Maximize Repair of Serviceable Components

•Match Capacity to Requirements• Maximize repair of serviceable components


Implementation Timeline

NMM Workload•ID Regional & Wholesale Demand•National Production, Planning & Control•Award National Workload to satisfytotal worldwide Army demands

National Maintenance Standard•Conduct Engineering Analysis•Develop Component Specific Maintenance Procedures•Publish National Maintenance Work Requirement

Qualification•NSN Specific Qualification•Capability, Capacity, Equipment, TMDE and Skills•ISO 9002 Compliant

FY 99-02

FY 00-05

FY 02-05

July 99 HQDA Message announces the NMP


- Deliberate Planning Process - Five Steps to Develop Workload

- Supports POM/Budget Process- Involves Army Commodity & Operational Major Commands

Validatesprojectedworkload

Workload Development Process

IdentifyRepair Requirements

Step 1

Assess Maintenance Activity Capability

and Capacity

Step 2

Identifypotential SORs

Step 3

Step 4

ConductWorkloadConference

Step 5

National Repair Objective

6

Draft NMMWorkload Plan


Cost Of Component Repair

High Safety

IRON

ISM National Standards (SOW)

ExpectedLife

Old Definition of OverhaulReliability Centered Maintenance (RCM)

Old Definition of RebuildNMP Overhaul

National Standard

Diminishing Returns Area

ExistingDMWRs

NMWR for FLRsDMWRs for DLRs

NMPIRON-Fix what’s broke, nothing more.ISM SOW-Restore an item to a complete serviceable condition. Normally at below-depot.RCM-Achieve inherent design reliability and safety doing least amount of maintenance.Overhaul-Restore item to a complete serviceable condition. Normally at depot.NMP Overhaul-Restore item to a complete serviceable condition with a measurable (expected) life.Rebuild-Restore an item to a standard as nearly as possible to original or new. Repair or replace all worn or unserv items to OEM specs.

• Existing Technical Documentation • Historical Failure Data• Soldier Input• Sample Data Collection Records

What we are looking at:

Led To:• Engineering Analyses• Physics of Failure Analyses


Qualified National Providers

NMP qualification is a 2 part process:

• Part 1 requires a source of repair to develop, implement, andmaintain a measurable quality system IAW provisions of the ISO quality standard. (Compliance)• Part 2 is a technical certification to validate possession ofnecessary facilities, tools, TMDE, skills, and manpower to perform required maintenance to the NMP overhaul standard.

Repair Source Qualification


National Maintenance Program

• What we would leave you with –

– National Maintenance Program is a linchpin to Army Transformation

– Implementation of the National Standards is expected to reduce O&S Cost, decrease the maintenance burden and produce higher Mean Time Between Failure


Back-up


National Maintenance ProgramIn Action

• National Maintenance Program:

– Objective: Provide Class IX components with an expected reliability

– Goal: Reduce equipment O&S Cost

– Status: NMP Phase I implementation expected to be complete by FY 05

• DS+ Conversion:

– Objective: Transition the Abrams Gas Turbine 1500 (AGT 1500) repair concept from a four level system to two levels.

– Goal: Increase Mean Time Between Failure (MTBF)

– Status: 4th ID (Ft Hood) and 3rd ACR (Ft Carson) to convert in FY 03. Remaining active Divisions complete by FY 05.

• Recapitalization Standards:

– Objective: Support the Recap programs with Class IX components repaired to the National Repair Standard.

– Goal: Sustain lower O&S cost achieved through Recapitalization and Unit Set Fielding

– Status: USAMC developing repair standards in support of Recapitalization.

• 120 Complete

• 826 Required by FY 05

• AMC On-schedule

Why these goals are attainable


MANHOURS/100 MILES

(Since Jan 1997)

7.1

8.89

12

0

2

4

6

8

10

12

14

M1A1 AIM XXI NON AIM

1ST HALF MI 2ND HALF MI TOTAL

AnalysisComparison of M1A1 AIM XXI Experience

$127

$194 $184

$0

$50

$100

$150

$200

$250

M1A1 AIM XXI NON AIM

1st HALF MI 2nd HALF MI TOTAL

NET OMA credit COST PER MILE

(Since Jan 1997)

AIM Recapitalization PoP –Shows Initial reduction in sustainment metrics with a steady increase over time if

supported through status quo Army Logistics System

Source: AMSAA Study TR-698 Dec 2001


0

50

100

150

200

250

300

350

400

450

1 2 3 4 5 6 7 8 9 10

RGB

AGB

TURBINE

DS+ Conversion O&S CostsNotional Division - 253 tanks, OPTEMPO = 800 miles

TACOM MTBF Data(hrs)

DS+ NMPEngine 255 750Fwd Mod 388Rear Mod 776AGB 1275 3750RGB 657 1932

750 Hours turbine MTBF & entireengine replaced for a failed forward or rear mod

Years

Failu

res

Years 3-10 = 58%*reduction in failures

0

5

10

15

20

25

30

35

40

45

50

1 2 3 4 5 6 7 8 9 10Years

COA 1 COA 4

• Positive ROI beginning in year two• Reduction in TOA Requirements • Sustains SEP and AIM Tanks Fielded • O&S Cost Reduction•Potential to reduce NMCM Rates for the Division• Consistent with NMP Policy

Expected Benefits:

Bottom Line

National Maintenance Program (NMP)– Objective: Transition the Abrams Gas Turbine 1500 (AGT 1500)...

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