2 TWV CBM Return On Investment Response to AMC CBM Summit TaskerPurpose: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 VehiclesBLUF: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 includedNeed CLOE Enablers in place to realize CBM “Plus”
3 TWV CBM Return On Investment The Tactical Wheeled Vehicle CBM Challenge: High Density, High Production Rates, Substantial Aging Legacy FleetOn-Hand 1st Production Last Production Current ProductionHMMWV 141, Funded thru FY /monthHMMWV RECAP /MonthFMTV 40, Funded thru FY15 800/monthM939 FOV 26, N/AM800 FOV N/AHEMTT 13, Funded thru FY *HET Tractor 2, NAPLS Funded thru FY 13 *M915 FOV Funded thru FY /monthHEWATT/TFFT Funded thru /monthCombined monthly production 400Total of Key fleets 209,347 (less M939, M800 FOV)
4 TWV CBM Return On Investment “ Ballpark” Business Case ExampleBaseline Costs for Maintaining Today’s Truck FleetHow much do we currently spend to maintain our trucks?Based on averaging 2006 & 2007 worldwide OSMIS data:Vehicle Quantity *O&S Costs/yrHMMWV ~119k ~$583 M/yrFMTV ~ 26k ~$145 M/yrHEMTT ~ 12k ~$119 M/yrPLS ~ 5KM915 ~ 8K*Incl POLHypothetically, how much could we save?Vehicle % % 2% %HMMWV $2.8M $5.8M $11.7M $29.2MFMTV $.75M $1.5M $ 2.9M $ 7.3MHEMTT $.60M $1.2M $ 2.4M $ 6.0MPLSM915
5 TWV CBM Return On Investment ROM Estimate of CBM TV Fleet (FMTV, HEMTT, PLS, HETS, M915 and HMMWV)Option 1Collect only existing vehicle data with simple data logger $500/ea = $104.67MOption 2“Smart” data logger to collect and preprocess existing data $1500/ea = $314.02MOption 3“Smart” data logger plus low cost “motion pack” chassis sensor suite $3500/ea = $732.71MOption 4Full vehicle computer to log, process, and link (IETM & SAMS-E) existing data $5000/ea = $1,046.73MOption 5Vehicle computer plus low cost “motion pack” chassis sensor suite $7000/ea = $1, MOption 6Vehicle computer, low cost “motion pack”, plus GPS $9000/ea = $1,884.12MOption 7“High end” engineering level computer, “motion pack”, GPS $20,000/ea = $4,186.94M
6 TWV CBM Return On Investment Simple ROI Calculation for TWV FleetBased on the following:Fleet of 209,347 TWVsSustainment costs of $1,007M/yrOption (smart data logger and low cost motion pack)CBM savings rate of 2%Yearly savings - 2%/yr x $1,007M = $20.12M/yrHardware costs ,347 x $3500 = $732.71MROI period - $732.71M / 20.12M/yr = 36.4 yrROI 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.
7 TWV CBM Return On Investment ROM Estimate of CBM HW Costs Only for OIF/OEF FMTV Fleet~ 4300 MTV/LMTVs in theatreOption 1Collect only existing vehicle data with simple data logger $500/ea = $ 2.15MOption 2“Smart” data logger to collect and preprocess existing data $1500/ea = $ 6.45MOption 3“Smart” data logger plus low cost “motion pack” chassis sensor suite $3500/ea = $ 15.05MOption 4Full vehicle computer to log, process, and link (IETM & SAMS-E) existing data $5000/ea = $ 21.50MOption 5Vehicle computer plus low cost “motion pack” $7000/ea = $ 30.10MOption 6Vehicle computer, low cost “motion pack”, plus GPS $9000/ea = $ 38.70MOption 7“High end” engineering level computer, “motion pack”, and GPS $20,000/ea = $ 86.00M
8 TWV CBM Return On Investment Simple ROI Calculation for OIF/OEF FMTV FleetBased on the following:Fleet of 4300 MTVsSustainment costs of $52M/yrOption (smart data logger and low cost motion pack)CBM savings rate of 5%Yearly savings - 2%/yr x $52M = $1.04M/yrHardware costs x $3500 = $15.05MROI period - $15.05M / $1.04M/yr = yrROI period can increase or decrease significantly based on percent savings appliedThis example does not include many other CBM enabling costs so theROI period will definitely be longer when all costs are factored in.
9 TWV CBM Return On Investment Current Efforts Supporting CBM Return on Investment AnalysisAMSAA Data Collection and Study EffortsTACOM Failure Analysis in support of Delayed Desert Damage and Degradation Studies (4D)TARDEC StudiesPD-TMDE ActivitiesPM-TV ActivitiesSBCT Proof of Enablers (PoE) Cost Benefit AnalysisNote: Review of AMSAA data collection to date has not yet provided PM-TV data that would result in changes in maintenance planning and support
10 TWV CBM Return On Investment How Can AMC Help?Funding support for AMSAAMore & varied data acquisition suitesExpanded data analysisFailure mode/PoF investigationsDiagnostic/prognostic algorithm developmentFunding support for TACOM ILSCImproving data/record keeping interfacesData processing & storageFunding support for TARDECSensor selection & placementPlatform HW optimizationFunding support for PD TMDESmart Wireless Diagnostic Sensor developmentVehicle Integrated Diagnostic Software developmentAssistance and funding support for IT/Comms Definitions & SolutionsSpur User Involvement forInterpretation/quantification of benefits/usefulnessRequirements generation
11 TWV Supporting Common Logistics Operating Environment (CLOE) & CBM LOGSALIWSAMS-2ESAMS-1ESARSSOperatorMaintainerCAISISAMS-IESAMS-DLBArmy development and doctrine changes requiredEmbeddedAt-PlatformArmy development and doctrine changes requiredMaintenance Data Collection - entire troubleshooting, maintenance and parts ordering session logged and time/date stamped:Maintainer IDVehicle IDDODAACSymptomsTests & Test ResultsDiagnostic PathIsolated FaultsMaintenance ActionParts ConsumedSAMS-E- Usage of information once receivedPM Can Provide:- Ability to interfaceTranslation of sensor dataCBM Data WarehouseDigital LogbookDigital PMCSFBCB2SBCT Proof of Enablers (PoE) Cost Benefit Analysis supports the goodness of TWVs participating in a common logistics operating environmentMTSVHMS
12 TWV CBM Return On Investment TWV CBM CBA/ROI Phased ApproachPhase 1:Identify candidate platform cost drivers and component targetsIdentify 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 assumptionsPhase 2:Component level testing in test cells (engines, transmissions, alternators, etc)Identify fault modes in controlled environmentDevelop diagnostic/prognostic algorithmsIdentify benefits and savings/avoidance potentialDesign field trial for proof of enablers with FMTV Truck Fleet SDCFeed CBA/ROI model with test cell experiment resultsPhase 3:Equip FMTV Fleet for tiered Sample Data CollectionConduct FMTV Truck Fleet tiered SDCFeed CBA/ROI model with Fleet tiered SDC results
13 TWV CBM Return On Investment Business Case Analysis Timelines and CostsFY09 FY10$4.5M $4.5MAMSAAOMA/RDTEPOM requests for FYs of $4.5M/yrInstrumentation & sensor improvementsData analysis, failure mode analysisDiagnostic and prognostic algorithm developmentData management and organizationFailure type analysis for 1 year for 4 TWV fleets with failure mode analysis for “top 5” cost and readiness driversProject support & execution, data analysisComponent testing and modelingUnfunded requests for FY09 - $4.2M, FY10 - $1.1MWDS-A, WDS-D, Smart WDS integration & testSAMS-E, DLB, VIDS Interface DevelopmentTACOMOMA$1.5MTARDECRDTE$6.2MPD TMDEOMA/RDTE$4.2M $1.1M$16.4M $5.6M
14 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 enablersDevelopment costs of enablersRecurring costs:Repair & replacement of enablersSoftware updatesCost savings:Reduced parts ordersLower transportation costs for partsCorrect parts orderedReduced fleet size due to higher vehicle availabilityCost avoidance:Minimized inspections due to better vehicle health visibilityReduced repairs by avoiding collateral damage equipment failuresFewer recovery missions for field failuresReduced “exposure” time & resulting injuries for users and maintainers
15 TWV CBM Return On Investment Business Case Analysis Timelines and CostsAlthough 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 month effort.This investment will leverage ~ $20M spent in this area in the last two years.
17 TWV CBM Return On Investment Current Efforts Supporting CBM Return on Investment Analysis - AMSAASample Data CollectionSystem Health and Reliability Computer (SHARC) data acquisition suite collects GPS, vehicle databus, and chassis sensor dataMultiple vehicle types, locations, terrains, climatesDeveloping usage profiles, severity indices, damage accumulation parametersMiniaturization and improvement of data acquisition suiteLower cost with more installation flexibilityDevelopment of diagnostic and prognostic algorithmsSeeded fault testing and teardown analysisOil conditioning monitoringData management and correlation techniquesLinking of component parametric and maintenance data
18 TWV CBM Return On Investment Current Efforts Supporting CBM Return on Investment Analysis - TACOM ILSCDelayed Desert Damage & Degradation (4D) AnalysisData mining and failure mode analysis for “Top 50” readiness drivers from SWA across all ground fleetsLIW & ILAP – Demand and cost dataOSMIS – OPTEMPO/miles & densitiesMaintenance & deadline info/activityAMSAA SDC – Parametric dataTARDEC - Deficiencies databaseC-REPS - LAR databaseFMEA – Root causes for failures
19 TWV CBM Return On Investment Current Efforts Supporting CBM Return on Investment Analysis - TARDECMSU & nCode – Improved Techniques for Vehicle Prognostic/DiagnosticData Acquisition, Analysis, and StorageOn-vehicle HW & SW for chassis monitoringAnalysis, comparison, and correlation of new data with existing databases at multiple echelonsStudy effects of re-configuration and compression of new data for storage in data warehouse/repositoryGlobal Electronics – Advanced Diagnostics for Diesel EnginesStatistical analysis methods for data setsNeural network analysis methods for data setsLearning system behaviors and development of modelsSupporting informed maintenance decisions
20 TWV CBM Return On Investment Current Efforts Supporting CBM Return on Investment Analysis - PD TMDEWireless Diagnostic Sensor (WDS)On-vehicle data logging for diagnostic and parametric dataSupports digital databus and/or analog vehicle data feedsVehicle Integrated Diagnostic Software (VIDS)VIDS-Embedded. On-board data collector and analyzer that interfaces to an off-board controller such as the MSDVIDS-Field. Expert database resides off-board and provides linear regression analysis and failure predictions (Currently hosted on an MSD)
21 TWV CBM Return On Investment Current Efforts Supporting CBM Return on Investment Analysis – PM-TVPM-TV – AMRDEC effort to reduce troubleshooting/diagnostic time of critical non-sensored Starting and fuel circuits. Automating diagnostics of critical systemsPM-HTV - Penn State effort to add automated diagnostics to vehicle Hydraulic systems
22 TWV CBM Return On Investment How Can We Augment and Enhance Current Activities in Support of a CBA/ROI study?AMSAA activitiesExpand Sample Data Collection effortsMore vehicles, vehicle types, and locationsTiered data acquisition suitesLow budget – No new sensors, databus logging, “virtual” sensingMedium budget – “Motion Pack” chassis sensors, data logging, preprocessing of dataHigh budget – “Motion Pack”, data logging, full computing, links to IETMs and logistic interfaces, GPSSupport failure mode characterizations w/vehicles & componentsSeeded/induced fault testingComponent teardown and analysisInvestigate advanced analysis techniques & methodsContinue component model & algorithm development
23 TWV CBM Return On Investment How Can We Augment and Enhance Current Activities in Support of a CBA/ROI study?TACOM ILSC activitiesCreate new effort toTarget TWVs for data analysisExpand beyond SWA theater of operationLeverage database correlation toolsInvestigate modifying current maintenance action record keepingHelp develop interfaces between CBM data, IETMs, and SAMS-E
24 TWV CBM Return On Investment How Can We Augment and Enhance Current Activities in Support of a CBA/ROI study?PD TMDE activitiesSmart Wireless Diagnostic SensorDevelop cost effective on-board data logger/processor that complements off-board TMDE and works with Log C2 SWVehicle Integrated Diagnostic SoftwareMature and expand VIDS-E and VIDS-F analysis and reporting capabilitiesAllow porting of third party algorithms into VIDS* Test PM-TV efforts on selected vehicles
25 TWV CBM Return On Investment How Can We Augment and Enhance Current Activities in Support of a CBA/ROI study?TARDEC activitiesMSU & nCode – Improved Techniques for Vehicle Prognostic/Diagnostic Data Acquisition, Analysis, and StorageLeverage 4-D Analysis or 4-D follow-on effortGlobal Electronics – Advanced Diagnostics for Diesel EnginesCoordinate with AMSAA SDC, failure mode, and algorithm development activitiesCorrelate RAM testing data and analyses with CBM activities