national maintenance program (nmp)– objective: transition the abrams gas turbine 1500 (agt 1500)...
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Sustaining The Transforming ArmySustaining The Transforming Army
National Maintenance Program (NMP)
October 29, 2002
Maintenance Policy Division
Sustaining The Transforming ArmySustaining The Transforming Army
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
Sustaining The Transforming ArmySustaining The Transforming Army
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
Sustaining The Transforming ArmySustaining The Transforming Army
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
Sustaining The Transforming ArmySustaining The Transforming Army
- 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
Sustaining The Transforming ArmySustaining The Transforming Army
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
Sustaining The Transforming ArmySustaining The Transforming Army
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
Sustaining The Transforming ArmySustaining The Transforming Army
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
Sustaining The Transforming ArmySustaining The Transforming Army
Back-up
Sustaining The Transforming ArmySustaining The Transforming Army
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
Sustaining The Transforming ArmySustaining The Transforming Army
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
Sustaining The Transforming ArmySustaining The Transforming Army
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
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