3. 2 SEA 04M1 2000 DoD Maintenance Symposium and Exhibition Applying RCM Principles in the Selection of CBM-Enabling Technologies Kenneth S. Jacobs (SEA 04M1) Director, Maintenance Engineering Naval Sea Systems Command 31 October 2000 Charleston, SC

4. 3 SEA 04M1 CBM – Enabler and Risk Reducer Reduced LCC Decreased Maintenance Reduced Manning 3 Year Deployments New Logistics Paradigm CNO maintenance policy SURFMER AEC MRS Maintenance Education Wireless, distributed Networks “Smart”, self-powered Sensors Materials / Coatings Embedded Training Policy, Processes & Procedure Policy, Processes & Procedure Enabling Technologies Enabling Technologies ACHIEVED WITH BALANCED APPROACH ACHIEVED WITH BALANCED APPROACH Surface Warfare Vision Surface Warfare Vision CBM CBM Transition

5. 4 SEA 04M1 CBM is a Maintenance Philosophy RCM Provides Rules of Evidence RCM Provides Rules of Evidence RCM Is the Hub of CBM

6. 5 SEA 04M1 Proof of RCM Success: n The process l Uses a review based on RCM principles l Examines planned, preventive maintenance (PMS) l Performed by In-Service Engineers (ISEs) s SEA 04M1 provides training and post-training support n Progress to date l SURFMERs 0 - 31 complete l Four-year effort coast-to-coast, starting with Smart Ship n Documented SURFMER savings l Exceeded CNO goal of 30% reduction of maintenance manhours Achieved 40% reduction by Oct 2000

7. Road Map for applying CBM to Maintenance Tasks Step 4: Apply Rules for Applicability TD: Life Renewal Replace/Restore) CD: Health Monitoring FF: Hidden Failure (Find/Repair) S/L: Servicing and Lubrication Is the Existing Maintenance Task Applicable? Task Does Satisfy Applicability Rules Task Does Not Satisfy Applicability Rules NoYes Redesign Improve task “Fix when failed ” Determine/Classify Type Task TIME - CONDITION - FAILURE - SERVICING L UBE DIR.DIR. FINDING (S) (L) (TD) (CD) (FF) Step 3: APPLICABILITY (Second Filter) Restores or Maintains Original Reliability Step 6: Improvement Option Goals Develop Recommendations for Change Continuous Improvement: periodic re-evaluation and adjustment of tasks Step 5: EFFECTIVENESS (Third Filter) Task Is Worth Doing Is the Maintenance Task Effective? Apply Rules for Effectiveness Safety or the Environment (Law) Operational performance (Mission) All other failures Task Does Satisfy Effectiveness Rules Schedule Task Task Does Not Satisfy Effectiveness Rules NoYes Extend periodicity Sample Vs 100% inspection Make situational Redesign task See other options Identify Failure Mode (E.g., seized bearings) Step 1: AGE DEGRADATION (First Filter) Verify Requirement Exists NoYes Step 2: Does a Significant Rate of Age Degradation Exist? No or Acceptably Slow Rate of Degradation Significant Rate of Degradation No task

8. 7 SEA 04M1 Choosing CBM Technology n Can’t afford it all n Wouldn’t all be worthwhile, anyway n How to choose? n RCM is the key

9. 8 SEA 04M1 RCM Criteria for CBM-Enabling Technology n Failures Happen: Dominant Failure Modes l Failure mode is reasonably likely to occur n Applicability l Monitored parameter really correlates to the failure mode; and l Measures the parameter consistently and accurately; and l Measurements serve as an accurate indicator of required repair action; and l There is adequate time for corrective action before functional failure.

10. 9 SEA 04M1 RCM Criteria for CBM-Enabling Technology (cont.) n Effectiveness l Safety: Identifies repair threshold in time to reduce probability of failure to acceptable level; or l Mission: Identifies repair threshold in time to reduce risk of failure (probability times severity) to acceptable level; or l Economics: Identifies repair threshold in time to reduce cost to identify and prevent failure at less cost than repairing after run to failure.

11. 10 SEA 04M1 Other Considerations n CBM does not eliminate the need for maintenance l Deterioration may occur no matter what the maintenance approach l Goal is to maintain or restore reliability at least cost l May allow operator to secure an equipment before occurrence of disruptive and more costly failure n Costs considered in determination of effectiveness l Hardware and software acquisition l Development of operating procedures and parametric values vs. deterioration for monitored equipment l ILS costs, including training

12. 11 SEA 04M1 Conclusions n Application of CBM technology can be crucial to a successful CBM transition n But only worthwhile technology should be applied n A CBM-enabling technology may be worthwhile only if: l There is a specific failure mode that is reasonably likely to occur l The technology produces applicable results related to that failure mode l The technology allows operators and maintainers to take appropriate action that reduces probability of failure (safety), risk of failure (mission), or cost of prevention to acceptable levels

14. 13 SEA 04M1 SURFMER 2 Steam Boilers MK-86 GFCS SLQ-32 CIWS SURFMER 3 Boat Handling/Stowage Flash Type Distilling Exterior Communications MK-23 TAS SURFMER 4 Aux Boilers, Waste Heat Systems, Anchor Handling & Stowage, SQQ-89, AFFF, Sonar Dome Press, Flex Hoses SURFMER 5 Aviation Fuels, HPAC/LPACs, Potable Water, Weapons Elevators, Radar Systems SURFMER 6 Mooring & Towing, Propulsion Diesels, L.O. Systems, Search Radar Systems SURFMER 7 UNREP, Steering, Diesel Generators, F.O. Systems, Small Boats SURFMER 8 LP/HP Air Dehydrators, DFTs, Bow Thrusters/ Fin Stabilizers, Desalinization Plants, SLQ-25, RAST SURFMER 9 Bleed Air, Cranes, Fire Main, Ventilation SURFMER Systems to Date SURFMER 10 Main Feed & Condensate Reduction Gears AC & R SURFMER 11 Tanks & Voids, Motor Controllers, Navigation Aids, Power Conversion, Main Propulsion GT, Cargo Handling, Doors & Hatches, Laundry, Propulsion Control SURFMER 12 Electronic Cooling Water, Sewage & Small Arms, WW Pollution, Oil Pollution, Galley, Laundry, Shop Equip, Solid Waste SURFMER 13 Aviation Support Facility, Damage Control, Drainage & Ballasting, Ladder & Access, Lifesaving Equip, De-watering Gear, Valves, SSGTG, Unrep, Sprinklers SURFMER 14 Aegis, AN/SWY, Electronic Cooling, Harpoon, Power Conversion, Replenishment, Switchboards, Sea Sparrow, Tomahawk, Vertical Launching System SURFMER 15 Small Arms, 5”/54, 25mm Machine Gun, Aegis, 2M, CIWS, PVPCS, Video Mixer SURFMER 16 Aegis, Magnetic Tape, Mine-hunting, Mk 46 Torpedo, Navigation, NAVMAC, Portable Test Equipment, Underwater Fire Control, WSC COMM SURFMER 17 Arresting Gear, C-13 Catapults, ILARTS, Flight Deck Lighting, Cargo Systems, Visual Landing Aids SURFMER 18 AN/USQ, Inflatable Life Boats, NAVMAC, Damage Control, Exterior Communications, Magnetic Tape Systems, Navigation, Transmitting Systems, WSC-3 SURFMER 19 Fire Extinguishing, Salvage Support, Sprinklers, Damage Control, Ventilation SURFMER 20 Torpedo Tubes, Underwater Fire Control, Navigation, Mine Hunting SURFMER 21 CV Specific Systems, Shore Power, 400 HZ, TLI’s, Gas Detection, Shaft Torsionmeter Systems, Weapons Handling Gear SURFMER 22 Oil Coolers, Force Draft Blowers, Countermeasure Washdown, Stern Gate, Air Ejectors, SSTG’s, Mill Machines O2/N2 Plants SURFMER 23 Reduction Gears, Propellers, AN/SPN-46, Reboilers, Small Boats, MOGAS, Diving and Salvage, Medical, Winches, Air Compressors SURFMER 24 Communication, Combat Systems, Missile Systems, Navigation, Underway Replenishment SURFMER 25 Propulsion Boilers, Galley & Laundry Equip, Diver Equip, Damage Control, Pollution Control, Fresh Water Sys SURFMER 26 Weapons Elevators, EOD Equipment, Anchor Handling & Stowage, LCAC Systems, Calibration SURFMER 27 Boat Handling, Distilling Plants, Feed & Condensate, Mooring & Towing Life Saving, Shop Equipment, Sonar Dome, Waste Heat Boilers SURFMER 28 AEGIS, BFTT, PCMS, MK-86, MK-92, Q-70, CEC, Tomahawk, VLS, OCSOT SURFMER 29 SLQ-32, 2M, WQC-2/6, UQN-1/4, Stinger, SLA-10, Electro-optical, SSQ-82, MK 64, USM-465 SURFMER 30 Combustion Air, Deaerating Feed Tanks, Fuel Oil, Lube Oil, Shafting, ICAS, Uptakes and Baffles SURFMER 31 CCTV, Communications, DC WIFCOM, RADIACs, Security Systems, SQQ-108

15. 14 SEA 04M1 The Context of the Problem n Legacy fleet: Ý Is sizable Ý Will be with us for some time Ý Must be supported n New ships & legacy fleet must be totally: Ý Interoperable Ý Compatible Ý Supportable Fiscal Year Surface Combatant Manning [1,000 ] FFG DD DDG CG DD-21 CG-21 LPD-17 LHD LHA LSD LPD-4 / LSD / LST MCM/MHC * * OPNAV N86