Ship Maintenance on the Horizon

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Ship Maintenance on the Horizon

• RADM Clarke Orzalli
• Director, Fleet Maintenance
• 21 October 2009

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Discussion Topics

• USFF 2010 N43 Initiatives
• Norfolk Waterfront
• MSMO way ahead
• Process Improvement
• Best Practices
• Maintenance History
• Reach Expected Service Life

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USFF 2010 N43 Initiatives

• 1. Partner with OPNAV, NAVSEA and other
  stakeholders to reduce warship Total Ownership
  Costs (TOC).
• Specific initiatives
• Incorporate recent reductions of submarine
  life-cycle maintenance requirements into workload
  leveling efforts in public and private shipyards.
• Award Spiral II Multi-Ship Multi Option contracts
  that increase incentives for cost control as well
  as continuous process improvement efforts.
• Co-ordinate with operational schedules to level
  load ports and more efficiently utilize
  maintenance dollars.
• Execute the total FY10 Ship Maintenance
  Requirement within the allocated resources
  through implementation of continuous process
  improvement initiatives.
• Pilot cost reduction efforts in shipyard
  processes that have demonstrated performance in
  Intermediate Level activities.

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USFF 2010 N43 Initiatives
2. Establish an integrated strategy for Navy
Logistics IT systems. Approve Navy
Logistics IT strategic plan that is resourced in
POM-12. 3. Partner with OPNAV, NAVSEA and
other stakeholders to improve requirements
definition for surface ships to achieve expected
service life. Surface ship
requirements reflect needed maintenance to
support expected service life and funding
requirements are well understood and support the
PPBS process.
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Norfolk Waterfront
NSSA PRIVATE SECTOR WORKLOAD
Preliminary projections based on ship schedules
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MSMO Timeline
2009 2010 2011
Dec Jan Feb Mar Apr May Jun Jul Aug Sep
Oct Nov Dec Jan Feb Mar Apr May Jun Jul
Aug Sep Oct Nov Dec Jan Feb Mar
Spiral 2 Industry Day (Washington Navy
Yard) Norfolk DDG Docker Norfolk DDG
Non-Docker Mayport CG/DDG (New) San Diego LPD
17 (New) Norfolk LPD 17 (New) Norfolk
LHA/LHD PAC NW FFG/DDG San Diego CG

Spiral 2 Roll-out

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Spiral 2 Contract Structure Changes (Enhanced
Cost Control Mechanisms)

• Spiral 1 (FY05-09)
• Competitive awards
• CPAF
• Not exercising options
• Denial of sub-ktr consent
• TAR process

• Spiral 2 (FY10-14)
• Competitive awards
• CPAF/IF
• Not exercising options
• Denial of sub-ktr consent
• Strengthened TAR Process
• Contractor Purchasing Review System places
  ceiling on AF pool at 80
• Corrects bad teaming behavior
• EVMS cert ktr value decision only
• Cost incentive (IF) in lieu of additional Small
  Business incentive fee
• Perf-based AF progress payments
• 1-year Rate Caps (in RFP)
• Invoke excessive fee on fee limitation clause
  in all contracts
• Pre-priced standard work-items

• Navy also drives cost outcomes
• Port loading, AIT erosion, process differences
• Recognized and vigorously managed C-RMC, MCIT,
  ASN Policy (proposed)

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Process Differences
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Continuous Process Improvement
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DDG-51 Class Depot Maintenance Programming History
Rusting trunk and deck in DDG-53 Engine Room
1 Intake Uptake trunk (01-174-0-Q).

• PR-91 through PR-97 Engineered Operating Cycle
  Maintenance Strategy
• PR-99 thru PR-09 Progressive Maintenance
• POM-10 Beyond Return to more rigorous
  requirement determination to enable ships to
  reach ESL

Deep Maintenance was Deferred for the Last Decade
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Life Cycle Maintenance
DDG Life Cycle Maintenance
K-mandays
DDG-51 was designed for 30 years but has an ESL
of 40 years
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SSLCM Mission/Vision

• Mission SSLCM Activity shall provide
  centralized surface ship lifecycle management
  including life cycle maintenance engineering,
  class maintenance planning and management closely
  aligned to the Fleet, Surface Warfare Enterprise
  (SWE), and NAVSEAs needs and priorities.
• Vision SSLCM Activity will significantly
  influence, shape, and provide the engineering
  rigor for the maintenance, repairs, and
  modernization of the surface Fleet to ensure
  ships achieve Expected Service Life (ESL).

SUSTAINED COMBAT READINESS REQUIRES SUSTAINED
MATERIAL READINESS
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SSLCM Activity - 2012
SSLCM Act LNO (1) NWRMC

SSLCM Act Headquarters (70) Portsmouth, VA

SSLCM Act Det (6) Norfolk, VA

SSLCM Act Det (9) San Diego, CA
SSLCM Act Det (2) Mayport, FL

SSLCM Act LNO (1) HRMC

Manning Build (combined MIL/Govt/KTR) June
09 FY09 FY10 FY11 45 52 72 92
SSLCM Act LNO (1) JRMC

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Surface Ship Maintenance Continuum
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BAWP to AWP Process
Process Business Rules Continuous Process
Improvement Metrics are Essential
Increase Process Discipline, Work Package
Visibility, Document Deferred Risk
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Product Lines Planning Factors

• Product Lines
• Tech Foundation Paper is a CLASS specific
  requirement
• (TFP) establishes technical requirements and
  supporting notionals
• Notionals in terms of MAN-DAYS
• SHIPSHEET (cost sheet) is link between CLASS
  notional and specific hull requirements
• BAWP is ship specific oriented agreement /
  contract with TYCOM ISO life cycle plan
• A-720 thru execution (SSLCM Act builds from
  ICMP/delivers to CLASSRON at A-360)
• AWP is hull/availability specific ISO CNO
  availabilities
• Refined costs and requirements
• A-360 thru execution and close-out (CLASSRON
  oversight and execution feedback)
• SSLCM Activity supports deferral process with
  CLASSRON/TYCOM/RMC
• Planning Factors
• ABS Study and Tank Void Team Link (Plus)

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Technical Foundation Paper (TPF) DDG-51

• Develop Long Range Maintenance Schedule (LRMS)
  based on technical requirements.
• Historical Maintenance Required
• Midlife Period Reset
• All CNO availabilities for the life cycle
• Utilize standard costs to model the costs of the
  AVAIL.
• Complete analysis by AVAIL type to establish RCM
  categories.
• Complete Write Up.

LRMS based on technical requirements is Key
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Technical Foundation Paper (TPF) DDG-51
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TFP DDG-51 EDSRA Tab
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Ship Sheet DDG-51

• Capture deferred technical requirement by ship
  after the last AVAIL.
• RCM Centric
• TA 1, TA 2 and TA 3 Jobs not completed
• Capture corrosion jobs that were placed in TA 4.
• NSWC-SSES database
• CLASSRON
• Capture CLASSRON major issues
• Validate requirements at the SSLCM Activity
• Add deferral to notionals
• Submit Ship Sheet

Hull Specific by AVAIL Ship Sheet
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SSLCM Activity DDG-51 Plans

• Draft Surface Ship Sheet Developed.
• NAVSEA 04 RM will analyze the UTR (Unfunded
  Technical Requirement) by hull.
• The DDG-51 CLASSRON will determine if there are
  any large deferred works (major issues) that need
  to be corrected.
• SSLCM Activity will lay in the Technical
  Foundation Paper requirements and adjudicate by
  hull the requirements for FY 12.

DDG-51 Ship Sheets will support FY 12 AVAILs.
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ICMP Surface Ship

• Pushed Over 5,000 Scheduled ICMP Tasks for Tanks
  Voids (G1N5) and Corrosion Hot-Spots (G1N6).
• Conducted Pilot with Underwater Hull Divers
  (Seaward Marine) Using ICMP Assessment
  Qualified Repair Tasks.
• Direct Link Created Between ICMP Assessment and
  Qualified Repair Tasks (Q-Tasks) for Above
  Efforts.
• ICMP Improvements Enabled Under SSLCM Activity
• 674,000 Records Managed for 13 Classes by Team of
  12
• ICMP/MRS Team (NSLC) Assimilated into SSLCM
• Increased Manning at SSLCM for ICMP Management
• Life-Cycle Engineering to Support ESL
• Systems Engineering for Maintenance Task
  Development

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