Defense Supply Center Richmond

1. Defense Supply Center Richmond Aviation Engineering Reliability and Sustainment Programs Defense Logistics Agency Defense Supply Center Richmond Ms. Edilia Correa Division Chief, Engineering Programs DSCR VE

2. Mission Integrate engineering and technical solutions with DLA Integrated Supply Team efforts to deliver best value supplies and services to the warfighter. Increase item availability Sourcing solutions and alternatives Improve item reliability Fund, manage and field improved products Generate savings to DoD Coordinate efforts with emphasis on life cycle cost savings across all aviation weapon systems

3. Reliability Improvement Program DSCR Manages DLA�s Reliability Program for Aviation Supply Chain consumables Reliability improvements deliver maintenance benefits Flexibility to integrate across engineering, logistics and maintenance communities DLA and Services sharing costs; Services realize benefits In today�s environment of global change, the Services are tasked to do more with less while continuing to operate existing equipment and systems. There are numerous initiatives and contractor support options which provide incentive to reduce operating costs through reliability improvements which the Services are actively pursuing. The Sustaining Engineering Center of Excellence is aimed at responding to this challenge by offering reliability improvements for DLA aviation consumable items. The approach being used at DSCR involves direct contact with customers including program offices and suppliers to identify candidate items. Business case analyses are used to evaluate the candidates identified and projects are prioritized based on several factors including readiness, safety, return on investment, and total cost. Once an item is selected for improvement, continued coordination with the responsible ESA is required to ensure configuration control and appropriate testing to qualify the new item. To enhance what DSCR personnel can provide, a contractor was hired to provide technical services including documenting the process and preparing business case analyses, providing expert resources, re-engineering parts where needed and being engaged as part of the team.In today�s environment of global change, the Services are tasked to do more with less while continuing to operate existing equipment and systems. There are numerous initiatives and contractor support options which provide incentive to reduce operating costs through reliability improvements which the Services are actively pursuing. The Sustaining Engineering Center of Excellence is aimed at responding to this challenge by offering reliability improvements for DLA aviation consumable items. The approach being used at DSCR involves direct contact with customers including program offices and suppliers to identify candidate items. Business case analyses are used to evaluate the candidates identified and projects are prioritized based on several factors including readiness, safety, return on investment, and total cost. Once an item is selected for improvement, continued coordination with the responsible ESA is required to ensure configuration control and appropriate testing to qualify the new item. To enhance what DSCR personnel can provide, a contractor was hired to provide technical services including documenting the process and preparing business case analyses, providing expert resources, re-engineering parts where needed and being engaged as part of the team.

4. Benefits to Services DLA can bring a focused solution to bear on troubled parts while maintaining a broader perspective on potential opportunities By addressing bad actors at the part level, the lifecycles of existing weapon system architectures can be extended Solutions applicable to broad part families can be addressed for the entire supply chain. Examples: Battery improvements - NiCad to lead acid conversions Hydraulic actuators seals upgrades � change out older, nitrile rubber seals for more durable, fluorocarbon-based material seals. DLA can bring a focused solution to bear on troubled parts while maintaining a broader perspective on potential opportunities By addressing bad actors at the part level, the lifecycles of existing weapon system architectures can be extended Solutions applicable to broad part families can be addressed for the entire supply chain. Examples: Battery improvements - NiCad to lead acid conversions Hydraulic actuators seals upgrades � change out older, nitrile rubber seals for more durable, fluorocarbon-based material seals.

5. Typical Reliability Projects

7. Services Funding Total funding and estimated savings per each Service Total funding and estimated savings per each Service

8. Source Development Reverse Engineering: The process of performing in-depth physical analysis of an item with the intent of developing the technical data (physical and material characteristics) required for development of engineering drawings. If the Government funds a reverse engineering project, it will normally own the subsequent engineering drawings and data. The drawings can then be used for fully competitive procurement purposes. If a contractor funds the engineering effort, it will normally own the data and the Government cannot use it for competitive procurement. Reverse Engineering: http://www.dscr.dla.mil/userweb/ve_engineering/ReverseEngineering.htm Points of Contact Mr. Ralph Newlon, DSCR-VEA, 279-5226 Mr. Ed Lilly, DSCR-VEA, 279-5863 Reverse Engineering: The process of performing in-depth physical analysis of an item with the intent of developing the technical data (physical and material characteristics) required for development of engineering drawings. If the Government funds a reverse engineering project, it will normally own the subsequent engineering drawings and data. The drawings can then be used for fully competitive procurement purposes. If a contractor funds the engineering effort, it will normally own the data and the Government cannot use it for competitive procurement. Reverse Engineering: http://www.dscr.dla.mil/userweb/ve_engineering/ReverseEngineering.htm Points of Contact Mr. Ralph Newlon, DSCR-VEA, 279-5226 Mr. Ed Lilly, DSCR-VEA, 279-5863

9. Research & Development Weapon System Sustainment: Logistics support to aging weapon systems is costly, and characterized by many processes whose efficiency and effectiveness could be improved.� This program will pursue high risk, high payoff projects to develop policies, methods and techniques to increase the productivity and effectiveness of DLA�s support to the Services. Program has four initiatives which can be grouped as: Process improvement to provide faster response to customer requirements. The program will deliver improved stocking policies for relatively low demand items in Land and Maritime supply chains, earlier visibility into upcoming demands from maintenance actions, and techniques to link retail and wholesale requirements. Sustaining engineering, including analyses of materials, components, tooling; reliability analysis and failure trends; creation, maintenance and modernization of technical data; value engineering; reverse engineering; and source qualification.Weapon System Sustainment: Logistics support to aging weapon systems is costly, and characterized by many processes whose efficiency and effectiveness could be improved.� This program will pursue high risk, high payoff projects to develop policies, methods and techniques to increase the productivity and effectiveness of DLA�s support to the Services. Program has four initiatives which can be grouped as: Process improvement to provide faster response to customer requirements. The program will deliver improved stocking policies for relatively low demand items in Land and Maritime supply chains, earlier visibility into upcoming demands from maintenance actions, and techniques to link retail and wholesale requirements. Sustaining engineering, including analyses of materials, components, tooling; reliability analysis and failure trends; creation, maintenance and modernization of technical data; value engineering; reverse engineering; and source qualification.

10. Aviation Forging & Casting Assistance Team AFCAT = (Aviation Forging & Casting Assistance Team). This program is ManTech funded, industry cost-shared, DLA program (American Metalcasting Consortium (AMC) and Forging Defense Manufacturing Consortium (FDMC)) has teamed with VEA to address these items, with engineers from these organizations on-site at DSCR working side-by-side with VE, FA, SBO, etc. personnel. Castings and forgings are currently poorly identified as being contained in items. Data analysis of �rock-pile� back orders/UFOs indicated 19% of the 100 oldest backorders contained C/F although C/F are estimated to be contained in only 5% of the 1.3 million DSCR (S9G) items. This % reconfirmed in UFO analysis in summer 2007, looking at Aviation Supply Chain (ASC) items. In addition, diminishing C/F sources and specialty material shortages/extended delivery times have compounded production lead time issues. This team, AFCAT, has, with input from FA participants via IPTs developed a number of tools to assist Product Specialists and Procurement personnel. The AFCAT website, databases with information on confirmed and suspected casting and forgings, and the location of tooling, and communications tools have been developed to insure transfer of information easily to both DLA and supplier customers. BSM: A significant effort has focused on providing data into BSM that makes its way both into the Material Master (MM03) for internal usage and the POT/solicitation/contract for bidder and contractor awareness of C/F content. We have the Unique Material Requirements (UMR) field in the Classification Tab under MM03. Tables: We�ve also have Table A1202 that was placed into the Purchase Order Text (POT) of all suspected items with cast and/or forged content. We now have two definitive tables, one for Castings (ZD003) & one for Forgings (ZD004) The AMC and the FDMC provide access to industry technical experts (their own team application engineers) and are conduits to best-in-class, responsive C/F suppliers. Awareness by DSCR tech/quality and procurement personnel of the intricacies of C/F is another focus of AFCAT. Tech transfer and benchmarking site visits (Bus trips) provide DSCR personnel with an awareness of lead time issues and process/material differences To date 200 DSCR personnel have participated in these training events (with next event scheduled for April 2008). AFCAT efforts have recognized that their customers are both internal (DLA) and external (the industrial supply chain). Activities continue to address the needs of both of these groups. AFCAT = (Aviation Forging & Casting Assistance Team). This program is ManTech funded, industry cost-shared, DLA program (American Metalcasting Consortium (AMC) and Forging Defense Manufacturing Consortium (FDMC)) has teamed with VEA to address these items, with engineers from these organizations on-site at DSCR working side-by-side with VE, FA, SBO, etc. personnel. Castings and forgings are currently poorly identified as being contained in items. Data analysis of �rock-pile� back orders/UFOs indicated 19% of the 100 oldest backorders contained C/F although C/F are estimated to be contained in only 5% of the 1.3 million DSCR (S9G) items. This % reconfirmed in UFO analysis in summer 2007, looking at Aviation Supply Chain (ASC) items. In addition, diminishing C/F sources and specialty material shortages/extended delivery times have compounded production lead time issues. This team, AFCAT, has, with input from FA participants via IPTs developed a number of tools to assist Product Specialists and Procurement personnel. The AFCAT website, databases with information on confirmed and suspected casting and forgings, and the location of tooling, and communications tools have been developed to insure transfer of information easily to both DLA and supplier customers. BSM: A significant effort has focused on providing data into BSM that makes its way both into the Material Master (MM03) for internal usage and the POT/solicitation/contract for bidder and contractor awareness of C/F content. We have the Unique Material Requirements (UMR) field in the Classification Tab under MM03. Tables: We�ve also have Table A1202 that was placed into the Purchase Order Text (POT) of all suspected items with cast and/or forged content. We now have two definitive tables, one for Castings (ZD003) & one for Forgings (ZD004) The AMC and the FDMC provide access to industry technical experts (their own team application engineers) and are conduits to best-in-class, responsive C/F suppliers. Awareness by DSCR tech/quality and procurement personnel of the intricacies of C/F is another focus of AFCAT. Tech transfer and benchmarking site visits (Bus trips) provide DSCR personnel with an awareness of lead time issues and process/material differences To date 200 DSCR personnel have participated in these training events (with next event scheduled for April 2008). AFCAT efforts have recognized that their customers are both internal (DLA) and external (the industrial supply chain). Activities continue to address the needs of both of these groups.

11. Collaboration and LeveragePartnering for Best DoD Solutions DLA is positioned to maximize opportunities DoD wide DLA has joint visibility for entire parts families DLA is positioned to leverage technologies from many sources DLA is positioned to maximize opportunities DoD wide DLA has joint visibility for entire parts families DLA is positioned to leverage technologies from many sources

12. Summary