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September 26, 2018 | International, Aerospace

US Air Force turns to data analytics to solve B-1, C-5 maintenance challenges

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WASHINGTON — The U.S. Air Force is making changes to the way it sustains the B-1B Lancer bomber and C-5 Super Galaxy cargo plane, moving to a maintenance approach that will allow it to use data analytics to predict problems, the acting head of Air Force Materiel Command said.

Both the B-1 and C-5 fleets transitioned to a conditions-based maintenance model last month, Lt. Gen. Robert McMurry, commander of the Air Force Life Cycle Management Center, told Defense News in a Sept. 18 interview.

“Given the aging fleet situation that we have, we probably need to be using data better to take care of it — which is a drive toward what most everyone right now is saying is the right way to manage fleet sustainment, which is through condition-based maintenance and data analytics,” he said. “So we're trying to bring that on.”

The approach — which involves using algorithms to predict the need for repairs rather than waiting for a part to break — is a standard practice in the commercial airline industry to help reduce maintenance-related delays or cancellations, but has been less common in the Air Force.

AFMC determined it needed to make a greater push toward conditions-based maintenance as a result of servicewide reviews triggered by rising concerns about the number of aviation-related mishaps.

The first review, directed by Air Force Chief of Staff Gen. Dave Goldfein, involved a one-day standdown that would give flying and maintenance units a chance to communicate potential safety concerns up the chain of command. Gen. Ellen Pawlikowski, then the head of AFMC, also directed the organizations under her command, like the Air Force Sustaiment Center, to evaluate its own data.

The reviews have since concluded, with the Air Force finding “two systems ... where high risk was accepted,” said McMurry, noting that “operational security does not allow us to identify them.”

“Our process is dealing with those responsibly,” he added.

The B-1 and C-5 were chosen as pilot programs for the conditions-based maintenance approach because they are sustained by airmen and have older, relatively small inventories, making for a more manageable data set.

But the planes have something else in common — a recent history of well-publicized mishaps. The C-5 has sustained a number of nose landing gear malfunctions that led to a standdown and maintenance assessment in 2017. But despite a fix being put in place, there have still been problems with the gear, such as a March 2018 event where one C-5 landed on its nose at Joint Base San Antonio-Lackland, Texas.

Meanwhile, the B-1 fleet was temporarily grounded in June after a safety investigation board found problems with ejection seat components while investigating a May 1 emergency landingwhere the ejection seats did not deploy.

Full article: https://www.defensenews.com/digital-show-dailies/air-force-association/2018/09/25/air-force-looks-to-data-analytics-to-help-solve-b-1-c-5-maintenance-challenges/

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  • F-35 Lightning II: A 21st century concept

    December 5, 2019 | International, Aerospace

    F-35 Lightning II: A 21st century concept

    by Alan Stephenson The F-35 Lightning II is not only a fifth-generation fighter aircraft, but a 21st century tooth-to-tail concept. I recently had the privilege to join a Canadian media trip sponsored by Lockheed Martin to visit the F-35 production facility in Fort Worth, Texas, as well as the 63rd Fighter Squadron, at Luke Air Force Base, Ariz., which is responsible for F-35 pilot training. Industry executives and F-35 operators presented detailed briefings on the latest aircraft improvements, maintenance concepts and operational considerations, as well as a tour of the production line and an up-close look at the aircraft itself. Without a doubt, the F-35 system represents a progressive leap in technology and life cycle management. Design concept Although some have questioned the very idea of a “fifth-generation” designation, the F-35 is the result of an evolutionary process in the design of low-observable (stealth) fighter aircraft for the United States Air Force (USAF). It draws upon the experiences of creating and operating the F-117 Nighthawk and the F-22 Raptor fighters. The lessons learned went beyond simply enhancing aircraft performance; the F-35 ameliorates fundamental life cycle cost issues through leveraging emerging technologies and leading-edge concepts to maximize readiness, logistic and maintenance efficiencies. In effect, the F-35 is built for sustainment. The fighter aircraft makes use of a modular avionics architecture with fusion technology, rather than a federated architecture where Line Replaceable Units (LRU or “black boxes”) are placed in a sequence. In this manner, maintainers no longer need to remove the first and second boxes to replace the third; they simply replace an easily accessible modular LRU. Roughly 95 per cent of the LRUs are first line removeable and virtually all first line maintenance functions are accessible through the weapons bay doors, nose wheel well, and behind panels that can be opened and closed without causing any low observable skin repairs. Ease of maintenance is further achieved from simple redesigns such as a front-hinged canopy that facilitates ejection seat removal without the need to remove the canopy. ALIS, the state-of-the-art Autonomic Logistics Information System, provides real-time digital information that also significantly reduces maintenance demands. “ALIS integrates a broad range of capabilities including operations, maintenance, prognostics, supply chain, customer support services, training and technical data,” according to Lockheed Martin. Maintenance staff can quickly determine the health of the aircraft upon landing through Prognostic Health Management (PHM) and quickly resolve any anomalies, increasing the serviceability rate and minimizing technician fault-finding time through fewer maintenance steps. PHM is a maintenance system that monitors the actual condition of an aircraft to decide what maintenance needs to be done. As all aircraft fleet operators know, unscheduled maintenance and lack of spare parts increases manpower demands and decreases aircraft availability. ALIS is designed to reduce maintenance hours, increase readiness, and decrease labour related costs by offering greater control in sustainment functions and providing actionable information to military decision-makers. Cost drivers From an initial reported cost of over US$100 million, the per-unit costs for the F-35 have fallen to US$77.9 million for Lot 14 fighters. The nine-nation co-operative development and the economies of scale of 12 current customers have greatly contributed to bringing life cycle costs closer to those of contemporary fourth-generation fighters. Costs have been lowered in assembly of the aircraft through use of an automated production line, designed to produce 180 aircraft per year, which has seen a 75 per cent reduction in “touch-labour” since 2010. Each aircraft is personalized by purchase order, allowing all three models to be produced in tandem, and unlike other fighters, the jet is essentially combat-ready when it leaves the production facility, having complete indigenous offensive and defensive avionic suites. With respect to sustainment, the F-16 had 24 different stovepipes supporting worldwide operations. ALIS logistics functions are networked with all F-35 users and supports a consolidated global supply chain that aggressively sources and produces the most cost-effective parts available, making them available as required and thereby minimizing costly inventory. A mandated Reliability and Maintainability (R&M) program has established metrics within automated processes designed to ensure constant systemic evaluation and facilitate continuous improvements that lower support costs and expedite fleet upgrades. At a reported six hours of maintenance per flight hour, the F-35A is at the forefront of fighter operations. Conscious design features such as internal weapons carriage and the use of pneumatic (air pressure) weapons ejection rather than explosive cartridges has significantly reduced maintenance personnel hours required to clean and service fourth generation weapons delivery systems. Another example of manpower savings occurs in routine checks on the fuel tanks and valves, where only one F-35 technician with a Portable Maintenance Aide (a laptop computer the technician connects to the F-35) is now required to conduct the same task that requires six maintainers to perform on the F-16. In manpower savings alone, anecdotal evidence suggests a 60 per cent reduction in personnel to perform routine maintenance functions. Operations At the flight line, significant changes have occurred to USAF military occupations and employment through innovative maintenance developments such as the Blended Operational Lightning Technician (BOLT) and the Lightning Integrated Technicians (LIT) programs. The BOLT program combines six USAF technical trades into two streams. The Air Vehicle stream includes crew chiefs, fuels, and low observable technicians, while the Mission Systems stream focuses on avionics, weapons, and egress trades. This streaming not only economizes manpower but allows deployed operations to be conducted with a smaller personnel footprint. In addition, the LIT program was introduced to increase maintenance efficiencies and effectiveness by integrating these two streams into one co-ordinated team through establishing commonality in training and dedicating each team to a single aircraft. The low observability of the F-35 is more than just a means to penetrate adversary defences; it is a “nose-to-tail” concept that increases performance and survivability from reduced drag and a low platform electromagnetic signature. The embedded antennas in the radar absorbent skin, internal fuel tanks and weapons carriage, and full line-of-sight radar reflection blockage not only help define the F-35 as a fifth-generation fighter, but the addition of an advanced sensor suite with sensor fusion, an electro-optical Distributed Aperture System (DAS) electronic warfare suite and networked enabled operations cement the fifth-generation classification. The Active Electronically Scanned Array (AESA) radar is a computer-controlled array antenna in which individual radar beams can be electronically steered to point in different directions without moving the antenna. This feature allows the F-35 to perform multiple functions such as detecting, tracking, and attacking airborne targets while simultaneously countering or attacking ground-based radar systems. 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    October 10, 2019 | International, C4ISR

    The data challenge of space-based hypersonics defense

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