TWV CBM Return On Investment

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TWV CBM Return On Investment
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TWV CBM Return On Investment

• Response to AMC CBM Summit Tasker
• Purpose
• Provide AMC G-3 with the amount of time and
  resources required to conduct a valid test to
  determine a Return on Investment (ROI) for
  Tactical Wheeled Vehicles
• BLUF
• Modest CBM data collection and analysis for
  trucks currently underway.
• Can augment and enhance those activities in
  support of a CBA/ROI study.
• Added Hardware estimates included
• Need CLOE Enablers in place to realize CBM Plus

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TWV CBM Return On Investment

• The Tactical Wheeled Vehicle CBM Challenge High
  Density, High Production Rates, Substantial Aging
  Legacy Fleet
• On-Hand 1st Production Last Production Current
  Production
• HMMWV 141,038 1984 Funded thru FY13 1800/month
• HMMWV RECAP 800/Month
• FMTV 40,128 1991 Funded thru FY15 800/month
• M939 FOV 26,995 1982 1994 N/A
• M800 FOV 4134 1963 1979 N/A
• HEMTT 13,770 1982 Funded thru FY 15
• HET Tractor 2,012 1993 2003 NA
• PLS 4992 1993 Funded thru FY 13
• M915 FOV 7291 1978 Funded thru FY 03 100/month
• HEWATT/TFFT 116 2004 Funded thru 09 4-6/month
• Combined monthly production 400
• Total of Key fleets 209,347 (less M939, M800 FOV)

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TWV CBM Return On Investment
Ballpark Business Case Example
Baseline Costs for Maintaining Todays Truck
Fleet
How much do we currently spend to maintain our
trucks? Based on averaging 2006 2007 worldwide
OSMIS data Vehicle Quantity OS
Costs/yr HMMWV 119k 583 M/yr FMTV
26k 145 M/yr HEMTT 12k 119 M/yr PLS
5K M915 8K
Incl POL
Hypothetically, how much could we save? Vehicle
.5 1 2 5 HMMWV
2.8M 5.8M 11.7M 29.2M FMTV
.75M 1.5M 2.9M 7.3M HEMTT
.60M 1.2M 2.4M 6.0M PLS M915
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TWV CBM Return On Investment

• ROM Estimate of CBM TV Fleet (FMTV, HEMTT, PLS,
  HETS, M915 and HMMWV)
• Option 1
• Collect only existing vehicle data with simple
  data logger 209,347 _at_ 500/ea 104.67M
• Option 2
• Smart data logger to collect and preprocess
  existing data 209,347 _at_ 1500/ea 314.02M
• Option 3
• Smart data logger plus low cost motion pack
  chassissensor suite 209,347 _at_ 3500/ea
  732.71M
• Option 4
• Full vehicle computer to log, process, and link
  (IETM SAMS-E) existing data 209,347 _at_
  5000/ea 1,046.73M
• Option 5
• Vehicle computer plus low cost motion pack
  chassis sensor suite 209,347 _at_ 7000/ea
  1,465.420M
• Option 6
• Vehicle computer, low cost motion pack, plus
  GPS 209,347 _at_ 9000/ea 1,884.12M
• Option 7
• High end engineering level computer, motion
  pack, GPS 209,347 _at_ 20,000/ea 4,186.94M

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TWV CBM Return On Investment

• Simple ROI Calculation for TWV Fleet
• Based on the following
• Fleet of 209,347 TWVs
• Sustainment costs of 1,007M/yr
• Option 3 _at_3500/vehicle (smart data logger and
  low cost motion pack)
• CBM savings rate of 2
• Yearly savings - 2/yr x 1,007M 20.12M/yr
• Hardware costs - 209,347 x 3500 732.71M
• ROI period - 732.71M / 20.12M/yr 36.4 yr
• ROI period can increase or decrease significantly
  based on percent savings applied.
• This example does not include many other CBM
  enabling costs so the ROI period will definitely
  be longer or shorter when all costs are factored
  in.

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TWV CBM Return On Investment

• ROM Estimate of CBM HW Costs Only for OIF/OEF
  FMTV Fleet
• 4300 MTV/LMTVs in theatre
• Option 1
• Collect only existing vehicle data with simple
  data logger 4300 _at_ 500/ea 2.15M
• Option 2
• Smart data logger to collect and preprocess
  existing data 4300 _at_ 1500/ea 6.45M
• Option 3
• Smart data logger plus low cost motion pack
  chassis sensor suite 4300 _at_ 3500/ea
  15.05M
• Option 4
• Full vehicle computer to log, process, and link
  (IETM SAMS-E) existing data 4300 _at_ 5000/ea
  21.50M
• Option 5
• Vehicle computer plus low cost motion
  pack 4300 _at_ 7000/ea 30.10M
• Option 6
• Vehicle computer, low cost motion pack, plus
  GPS 4300 _at_ 9000/ea 38.70M
• Option 7
• High end engineering level computer, motion
  pack, and GPS 4300 _at_ 20,000/ea 86.00M

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TWV CBM Return On Investment

• Simple ROI Calculation for OIF/OEF FMTV Fleet
• Based on the following
• Fleet of 4300 MTVs
• Sustainment costs of 52M/yr
• Option 3 _at_3500/vehicle (smart data logger and
  low cost motion pack)
• CBM savings rate of 5
• Yearly savings - 2/yr x 52M 1.04M/yr
• Hardware costs - 4300 x 3500 15.05M
• ROI period - 15.05M / 1.04M/yr 14.47 yr
• ROI period can increase or decrease significantly
  based on percent savings applied

This example does not include many other CBM
enabling costs so the ROI period will definitely
be longer when all costs are factored in.
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TWV CBM Return On Investment

• Current Efforts Supporting CBM Return on
  Investment Analysis
• AMSAA Data Collection and Study Efforts
• TACOM Failure Analysis in support of Delayed
  Desert Damage and Degradation Studies (4D)
• TARDEC Studies
• PD-TMDE Activities
• PM-TV Activities
• SBCT Proof of Enablers (PoE) Cost Benefit Analysis

Note Review of AMSAA data collection to date has
not yet provided PM-TV data that would result in
changes in maintenance planning and support
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TWV CBM Return On Investment

• How Can AMC Help?
• Funding support for AMSAA
• More varied data acquisition suites
• Expanded data analysis
• Failure mode/PoF investigations
• Diagnostic/prognostic algorithm development
• Funding support for TACOM ILSC
• Expanded data analysis
• Improving data/record keeping interfaces
• Data processing storage
• Funding support for TARDEC
• Expanded data analysis
• Failure mode/PoF investigations
• Diagnostic/prognostic algorithm development
• Sensor selection placement
• Platform HW optimization
• Funding support for PD TMDE
• Smart Wireless Diagnostic Sensor development
• Vehicle Integrated Diagnostic Software
  development

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TWV Supporting Common Logistics Operating
Environment (CLOE) CBM

• Army development and doctrine changes required

At-Platform

• Army development and doctrine changes required

• Maintenance Data Collection - entire
  troubleshooting, maintenance and parts ordering
  session logged and time/date stamped
• Maintainer ID
• Vehicle ID
• DODAAC
• Symptoms
• Tests Test Results
• Diagnostic Path
• Isolated Faults
• Maintenance Action
• Parts Consumed

- Usage of information once received

• PM Can Provide
• - Ability to interface
• Translation of sensor data

CBM Data Warehouse
Digital Logbook
Digital PMCS
FBCB2
SBCT Proof of Enablers (PoE) Cost Benefit
Analysis supports the goodness of TWVs
participating in a common logistics operating
environment
MTS
VHMS
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TWV CBM Return On Investment

• TWV CBM CBA/ROI Phased Approach
• Phase 1
• Identify candidate platform cost drivers and
  component targets
• Identify benefit drivers (Availability, parts
  ordering, automation, etc)
• Develop FMEA/FMECA and other system models from
  existing field and design data.
• Generate CBA/ROI model, identify inputs, and
  formulate assumptions
• Phase 2
• Component level testing in test cells (engines,
  transmissions, alternators, etc)
• Identify fault modes in controlled environment
• Develop diagnostic/prognostic algorithms
• Identify benefits and savings/avoidance potential
• Design field trial for proof of enablers with
  FMTV Truck Fleet SDC
• Feed CBA/ROI model with test cell experiment
  results
• Phase 3
• Equip FMTV Fleet for tiered Sample Data
  Collection
• Conduct FMTV Truck Fleet tiered SDC
• Feed CBA/ROI model with Fleet tiered SDC results

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TWV CBM Return On Investment

• Business Case Analysis Timelines and Costs

FY09 FY10 4.5M 4.5M
AMSAA OMA/RDTE

• POM requests for FYs 10-15 of 4.5M/yr
• Instrumentation sensor improvements
• Data analysis, failure mode analysis
• Diagnostic and prognostic algorithm development
• Data management and organization
• Failure type analysis for 1 year for 4 TWV fleets
  with failure mode analysis for top 5 cost and
  readiness drivers
• Project support execution, data analysis
• Component testing and modeling
• Diagnostic and prognostic algorithm development
• Data analysis, failure mode analysis
• Unfunded requests for FY09 - 4.2M, FY10 - 1.1M
• WDS-A, WDS-D, Smart WDS integration test
• SAMS-E, DLB, VIDS Interface Development

1.5M
TACOM OMA
TARDEC RDTE
6.2M
PD TMDE OMA/RDTE
4.2M 1.1M
16.4M 5.6M
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TWV CBM Return On Investment

• Highlights from Business Case Template for CBM
  Enablers
• Two year timeline of fleet maintenance events,
  dates, resources, downtimes, etc.
• Maintenance related events for each enabler
  eligible component inspections, parts removals,
  parts shipping, scheduled unscheduled
  maintenance, time waiting for parts, actual
  repairs.
• One time costs
• Purchase and installation of enablers
• Development costs of enablers
• Recurring costs
• Repair replacement of enablers
• Software updates
• Cost savings
• Reduced parts orders
• Lower transportation costs for parts
• Correct parts ordered
• Reduced fleet size due to higher vehicle
  availability
• Cost avoidance
• Minimized inspections due to better vehicle
  health visibility
• Reduced repairs by avoiding collateral damage
  equipment failures
• Fewer recovery missions for field failures

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TWV CBM Return On Investment

• Business Case Analysis Timelines and Costs
• Although existing investments in technology
  development and data analysis are being
  leveraged, help is needed in securing requested,
  and new funding. This will support additional
  data gathering and analysis, algorithm
  development and validation, and cost analysis for
  savings or avoidance projections. This is
  estimated to be an 18-24 month effort.

This investment will leverage 20M spent in
this area in the last two years.
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BACKUP Charts
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TWV CBM Return On Investment

• Current Efforts Supporting CBM Return on
  Investment Analysis - AMSAA
• Sample Data Collection
• System Health and Reliability Computer (SHARC)
  data acquisition suite collects GPS, vehicle
  databus, and chassis sensor data
• Multiple vehicle types, locations, terrains,
  climates
• Developing usage profiles, severity indices,
  damage accumulation parameters
• Miniaturization and improvement of data
  acquisition suite
• Lower cost with more installation flexibility
• Development of diagnostic and prognostic
  algorithms
• Seeded fault testing and teardown analysis
• Oil conditioning monitoring
• Data management and correlation techniques
• Linking of component parametric and maintenance
  data

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TWV CBM Return On Investment

• Current Efforts Supporting CBM Return on
  Investment Analysis - TACOM ILSC
• Delayed Desert Damage Degradation (4D) Analysis
• Data mining and failure mode analysis for Top
  50 readiness drivers from SWA across all ground
  fleets
• LIW ILAP Demand and cost data
• OSMIS OPTEMPO/miles densities
• Maintenance deadline info/activity
• AMSAA SDC Parametric data
• TARDEC - Deficiencies database
• C-REPS - LAR database
• FMEA Root causes for failures

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TWV CBM Return On Investment

• Current Efforts Supporting CBM Return on
  Investment Analysis - TARDEC
• MSU nCode Improved Techniques for Vehicle
  Prognostic/Diagnostic
• Data Acquisition, Analysis, and Storage
• On-vehicle HW SW for chassis monitoring
• Analysis, comparison, and correlation of new data
  with existing databases at multiple echelons
• Study effects of re-configuration and compression
  of new data for storage in data
  warehouse/repository
• Global Electronics Advanced Diagnostics for
  Diesel Engines
• Statistical analysis methods for data sets
• Neural network analysis methods for data sets
• Learning system behaviors and development of
  models
• Supporting informed maintenance decisions

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TWV CBM Return On Investment

• Current Efforts Supporting CBM Return on
  Investment Analysis - PD TMDE
• Wireless Diagnostic Sensor (WDS)
• On-vehicle data logging for diagnostic and
  parametric data
• Supports digital databus and/or analog vehicle
  data feeds
• Vehicle Integrated Diagnostic Software (VIDS)
• VIDS-Embedded. On-board data collector and
  analyzer that interfaces to an off-board
  controller such as the MSD
• VIDS-Field. Expert database resides off-board and
  provides linear regression analysis and failure
  predictions (Currently hosted on an MSD)

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TWV CBM Return On Investment

• Current Efforts Supporting CBM Return on
  Investment Analysis PM-TV
• PM-TV AMRDEC effort to reduce
  troubleshooting/diagnostic time of critical
  non-sensored Starting and fuel circuits.
  Automating diagnostics of critical systems
• PM-HTV - Penn State effort to add automated
  diagnostics to vehicle Hydraulic systems

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TWV CBM Return On Investment

• How Can We Augment and Enhance Current Activities
  in Support of a CBA/ROI study?
• AMSAA activities
• Expand Sample Data Collection efforts
• More vehicles, vehicle types, and locations
• Tiered data acquisition suites
• Low budget No new sensors, databus logging,
  virtual sensing
• Medium budget Motion Pack chassis sensors,
  data logging, preprocessing of data
• High budget Motion Pack, data logging, full
  computing, links to IETMs and logistic
  interfaces, GPS
• Support failure mode characterizations w/vehicles
  components
• Seeded/induced fault testing
• Component teardown and analysis
• Investigate advanced analysis techniques
  methods
• Continue component model algorithm development

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TWV CBM Return On Investment

• How Can We Augment and Enhance Current Activities
  in Support of a CBA/ROI study?
• TACOM ILSC activities
• Create new effort to
• Target TWVs for data analysis
• Expand beyond SWA theater of operation
• Leverage database correlation tools
• Investigate modifying current maintenance action
  record keeping
• Help develop interfaces between CBM data, IETMs,
  and SAMS-E

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TWV CBM Return On Investment

• How Can We Augment and Enhance Current Activities
  in Support of a CBA/ROI study?
• PD TMDE activities
• Smart Wireless Diagnostic Sensor
• Develop cost effective on-board data
  logger/processor that complements off-board TMDE
  and works with Log C2 SW
• Vehicle Integrated Diagnostic Software
• Mature and expand VIDS-E and VIDS-F analysis and
  reporting capabilities
• Allow porting of third party algorithms into VIDS

Test PM-TV efforts on selected vehicles
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TWV CBM Return On Investment

• How Can We Augment and Enhance Current Activities
  in Support of a CBA/ROI study?
• TARDEC activities
• MSU nCode Improved Techniques for Vehicle
  Prognostic/Diagnostic Data Acquisition, Analysis,
  and Storage
• Leverage 4-D Analysis or 4-D follow-on effort
• Global Electronics Advanced Diagnostics for
  Diesel Engines
• Coordinate with AMSAA SDC, failure mode, and
  algorithm development activities
• Correlate RAM testing data and analyses with CBM
  activities