Modernizing and Enhancing Facilities Supporting Our Organic Industrial

Base

ModeratorMr. Kevin Stamey

Executive Director, Air Force Sustainment Center

LSE2040: Infrastructure Modernization Vision & Roadmap for the Next 30 years

Attributes1. 100% Data

Availability2. 100% Parts

Availability3. Environmentally

Compliant4. Efficient Depot5. Effective

Workforce6. 100% Process

Control7. Intelligent

Sustainment Infrastructure

8. Resilient Mission-Ready Software Sustainment

9. Energy Efficacy10. Host Installation

Support

Host Installation

Support

10

2

Robotics Strategy

WALK – Mid-Term Outlook

RUN – Game-Changers

• Implement across all weapon systems• Expand to metallic alloys, composites, LO

• De-painting is just the beginning…initiate multi-functional efforts

– Developing Robotic NDI Tool– Basis for CBM+ (Aircraft 3D mapping)

• Robotic Laser De-painting Initiative – Implementing F-16 and C-130 at HAFB – Implementing C-130 at RAFB in FY16

– Qualifying LO platforms and Global Hawk

Reduces cost by 75% Reduces de-paint flow

days by 50% Eliminates hazardous

materials and waste Less fatigue to

substrate

• Multi-purpose robotic systems from one foundation:

– ONE Robotic SYSTEM to NDI and De-Paint– ONE Robotic SYSTEM to Clean and Paint

• Enables next generation maintenance practices

Crawl – Immediate Value

Advanced Metal Finishing

• Automated Process Controls– Pre-programmed plating recipes– Automated hoist for movement of

parts through plating• Worker Protection

– Shielding– Exhaust System

• Acid scrubber• Chrome mist elimination

4

Zinc-Nickel Plating

• Eliminates use of toxic chemicals:

– cadmium – cyanide– hexavalent-chromium

• Environmentally compliant• Improves worker safety• Suitable for automated

process control

5

Effective Alternative to Cad Plating for High Strength Steel

F-22 Inlet Coating Robot Program

6

- 3 of 7 LO Booths modified at HAFB 2016- 3 Val/Vers completed in 2017

- First production Acft completed Jun 2017- Robots apply 10 different coating layers

- $12M investment funded by F-22 SPO

Implementation

Savings Reduces material consumption by 44%

Reduces flow days by 17% Eliminates variability in application, reducing

rework Reduces technician exposure by 50%

Reduces fatigue/injury rate to technicians Eliminates PPE requirement, reducing cost

Future State- Modify robot arm with sanding attachment

- Expand robots to perform external coatings application

Radar Cross Section Test Facility (RCSTF)

• Effort:– Replace non functional turntable within RCSTF– F-22 SPO & F-35 JPO funding, F-22 SPO contract

management– Contract award Dec 2018– IOC 2022, FOC 2023

• Benefits:– Single facility supports both weapon system

(organic capability)– Incorporated new F-35 requirements for RCS

testing– Projected work, 100 A/C per year

• 30 F-22, 70 F-35 7

Facility ModernizationEnergy Assurance/Management

Leveraging third party finances through Energy Savings Performance Contract (ESPC) and Utility Energy Service Contract (UESC) projects

OC-ALC ESPC ($243M):• Awarded on 14 December 2016 with 3.5 year construction period & 21.5 years of service• Steam system decentralization (replacing failing system), chiller plant improvements,

building automation systems, lighting improvements, building envelope modifications, water and sewer conservation systems, heating, ventilation, and air conditioning

• Improves mission reliability through installation of new equipment and infrastructure, i.e., replacement of the B3001 central steam plant (CSP) system

• Enhances safety by replacing aging high-pressure gas distribution systems; improves worker protection through elimination of hazardous environments

• Frees up OC-ALC capital for other mission priorities, avoiding future capital cost requirements for equipment and infrastructure reaching the end of its useful life

• Construction to be completed June 2020• Annual utility and O&M savings of $20M per year• Guaranteed 665,463 MBTU/year energy reduction which is 35% of OC-ALC total

consumption

Major General Craig CrenshawCommanding General, Marine Corps Logistics Command

Mr. James WrzeskiDeputy Assistant Commander for Industrial Operations, Naval Sea Systems

Command

Mr. Martin AhmadDeputy Commander, Fleet Readiness Centers, Naval Air Systems Command

Mr. Mark MorrisonDirector, Industrial Base & Infrastructure Planning, United States Army Materiel

Command