APG63V1 Radar Upgrade

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• APG-63(V)1 Radar Upgrade
• F3I Lifetime Contractor Support (FLICS)
• Concepts

Last Rev. 5/10/99 by DFW
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FLICS Requirements

• Implement F3I
• Guaranteed radar mission capability rate
• Support peace and war time scenarios
• USAF/Contractor forms partnership for sustainment
  over the system life cycle
• Affordable cost to USAF
• Must offer Government fall-back position

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FLICS Implements F3I Requirements

• Performance based specifications
• Form, Fit, Function Interface (F3I)
• How to responsibility given to Contractor
• Contractor Depot Maintenance
• Helps mitigate the risk of short lived
  technologies
• Contractor has configuration control internal to
  LRU
• Facilitates technology insertion
• Utilizes Trigger Based Item Management (TBIM)
  Process
• Provides for trends and targets actions that
  provide high payoff
• Proactive rather than reactive management

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Elements of FLICS(Continued)

• Proper O level maintainer training and technical
  information
• Tech Pubs updated (MSIP APG-70) during EMD
• CFR/CFI system update deployment during OTE
• All technical information evaluated vs as
  designed
• Inclusive Diagnostic System at all levels of
  assembly
• Automated configuration management required
• For tracking
• Base Aircraft LRU SRU
  Critical Component
• Manage parts inventory
• Tracking of bad actor hardware, remove when
  necessary

FLICS Implements F3I Criterion
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Availability When you need it you will have it!
Actual On-Aircraft Mean Repair Time (MRT)lt 45
Minutes
BASE SUPPLY
Base X Flightline
Shipping Receiving
5 Hrs
- Receives Bad LRU - Generates DIFM via CAMS
Removal Defective LRU
Install Good LRU
- Issues Spare - Picks Up Bad LRU - Sends Bad LRU
to Shipping
Maint. Tech Exchanges Bad LRU for Spare
8 Hrs
AMU Support Section
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Shared Responsibility is Key to Success

• Contractor - Provide adequate spares based upon
  MTBMA
• USAF and Contractor - Minimize Mean Down Time
  (MDT)
• USAF - 45 Minute MTTR
• Contractor - 5 Hour stores replenishment time
  (for spares)
• USAF - 8 Hours for local transportation,
  preparation of
• maintenance action and
  requisition forms,
• pack and ship
• Technical Performance Measurands will be
  implemented to help the FLICS IPT manage the
  program, minimize MDT

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Maintenance ConceptOrganizational Level Tasks
Serial Numbers BIT Matrices
DTM Transfer
Skill LvL 3 Technician

• Remove/Replace
• Failed LRU
• Perform Additional
• Troubleshooting Procedure
• and Repair System
• Perform System Verification

CFRS/CFI
1) CFRS - Determine existence of fault. 2) CFI
- Determine most likely cause of fault. Identify
corrective action to be performed.
PMA
Maintainer Always Receives Positive Action From
Technical Data (e.g. Next Action).
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CFR/CFI System
PMA
CFR/CFI System Wiring Diagram on the Fly
CFRS/CFI
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CFRS EnhancementsFunctional Requirements

• Automated Fault Detection
• Provided by on-aircraft system BIT and
  supplemented with CFRS
• Accomplished via updates to WIN-95 CFRS
• Automated Fault Isolation capability
• Provides POSITIVE ACTION to maintainer
• Electronic automated tool implementation includes
  Digital Wire Diagrams
• Currently done with paper manuals today
• Automated data collection
• Enables collection and manipulation of data
  collected
• Includes maintenance corrective action and
  parametric information

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Advantages of Enhancements

• CFI data base can readily be updated in 1-2 weeks
  time frame
• Not Tech Pubs update dependent (months/years time
  frame)
• Maintainer now gets real time data to help
  isolate failures
• Portable Maintenance Aid (PMA) compatible
• Deletes paper Fault Isolation/Wiring Diagram
  (FI/WD) manuals

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HUGHES REPAIR DEPOT PROCESS
LVPS RSC - HAC SC
BAD LRU RETURNED FOR REPAIR
RDP - NEWPORT BEACH
CFRS/CFI
2 DAYS FROM ALASKA
ASC RE ESN - R15
BAD SRU
TRANSMITTER ESN - S25
R15
CONFIRM FAILURE REPLACE BAD SRU LRU TEST
CONFIRM FIX INSPECT
ASSET MANAGEMENT PREPARE TASK ORDER
PACKAGE TRACK REPAIR OBTAIN SHIPPING
INSTRUCTIONS PROCESS GFP DOC.
SRU REPAIR
LRU REPAIR 7 DAYS AVERAGE
SHIPPING RECEIVING
SRU SPARES
SPARE PARTS
2 DAYSTO ALASKA
RSC returned to Hughes South Carolina. All
other LRUs Returned to Hughes El
Segundo, California for Repair.
SRU REPAIR 60 DAYS
RFI LRU SHIPPED PER ASSET MANAGEMENT INSTRUCTIONS
REPAIRED SRU
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FLICS Asset Manager (Middleware Merge Engine)
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Asset Manager Development Plan

• Development Phases
• Database Evaluation
• In-work
• User Evaluation / Input-Output Definition
• In-work
• Initial Testing (El Segundo - Local)
• Aug 99 (early)
• On-Site Testing (St. Louis ECS)
• Aug. 99 (late)
• Remote Testing (ECS core sites Test Bases)
• Sept. 99 (early) WPAFB, WRALC Nellis AFB
• Deployment (Elmendorf)
• Dec. 99 (with first Radar Installation)

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Planned Asset ManagerField Level Metrics

• System Readiness or Availability Rate
• System MTBMA (less -120 Antenna)
• Mean Down Time per Radar Maintenance Action
• LRU Demand Rates
• System CND Rate
• Average Duration from JCN Issue to Part Received
  by Commercial Shipper
• Percent JCNs Awaiting Parts - Off Station
• Average Active Maintenance Time for
  Troubleshooting and Repair
• Average Repair Turn-Around Time Base Dock to Base
  Dock

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Planned Depot Metrics

• LRU Repair Rates
• Number of broken warranty seals on returns
• Number of Units in Pipeline
• Average Duration of LRUs in Transit
• Average Turn-Around Time by Facility
• BCS/RTOK Rates
• Depot Test Voids/Total Test Required
• Number of Parts Produced by Single Source
• Technology Obsolescence Projections
• Number of Obsolete Part Types in Field
• Percent JCNs Awaiting Parts
• Current Value of Repair Inventory
• Repair Station Availability Rates Excess
  Capacity
• Number of Open Engineering Investigations
• Number of Outstanding BIT ECRAs and Time
  Outstanding

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ECS Network
Elmendorf AFB
DOS/Windows and Macintosh OS Supported
Nellis AFB
Edwards AFB
SPO WPAFB
MDA
Langley AFB
Hughes
SPO RAFB
Eglin AFB
Honeywell
Tyndall AFB
ECS Attachments
ECS backbone and attachments as of June 1996
Nellis AFB
Nevada
Eglin AFB
Florida
California
Edwards AFB
Langley AFB
Virginia
Tyndall AFB
Florida
Hughes Aircraft
California
Honeywell
Florida
Elmendorf AFB
Alaska
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ECS Current Configuration
St. Louis, MO
Hughes LAN
C O N CENTRATOR
Clients
SMTP GW
E T H E R N E T
Servers
SNA Network
MDA-East
Local Post Office CCMail
E T H E R N E T
Firewall
Local Post Office Group Wise
3172
E T H E R N E T
Novell 3.12 Environment
Concentrator
Firewall
File Server ECS-HAC-FS1 NetWare 3.12
Servers
Router
128KB
T-1
El Segundo, CA
Local Post Office MS Mail
Router
Clients
64KB PVC, 128KB Port
Novell 3.12 4.10 Environment
128KB
128KB
128KB
128KB
Dayton, OH
Warner Robins, GA
Elmendorf AFB
Router
Router
Router
Concentrator
Concentrator
Concentrator
SPO-RAFB LAN
SPO-WPAFB LAN
Base LAN
Local Post Office MS Mail
Firewall
Firewall
Firewall
Beyond Mail
Local Post Office MS Mail
E T H E R N E T
E T H E R N E T
E T H E R N E T
Servers
SMTP GW
Servers
Servers
ENS Server
CFRS Debrief
SMTP GW
SMTP GW
Clients
Clients
Clients
Base Supply
Windows NT Novell 3.12 Environment
Novell 4.10 Environment
Windows NT Environment
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ECS Upgrade
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Defense Information Systems Network (DISN)