Wire System Maintenance Reporting Codes Pall B. Arnason Team Leader, Advanced Development Programs Wiring Systems Branch Aging Aircraft IPT / AIR

Navy Has Three Levels of Maintenance for Aircraft : – Organizational “O” Level - on Aircraft Maintenance – Intermediate “I” Level - off Aircraft Maintenance and Occasional on Aircraft Maintenance When Required – Depot “D” Level - Industrial Based “Heavy” Maintenance and Refurbishment Background: Navy Maintenance Levels

All Three Levels of Maintenance Governed by One Document: OPNAVINST NAMP  Establishes Central Maintenance Data System to Record Data About -Equipment Maintainability and Reliability -Equipment Configuration, Including Alteration and TD Status -Equipment Mission Capability and Utilization -Material Usage -Material Non-Availability -Maintenance and Material Processing Times -Weapon System and Maintenance Material Costing Background: Naval Aviation Maintenance Program

Many Combinations of Reports May Be Generated From Maintenance Data, Including: -Maintenance Actions by Component or Aircraft Serial Number -Repair Cycle Data -Monthly Equipment Mission Capability -Man Hours Expended and Cost Data -Top Level Logistics Data Background: Maintenance Data

The Maintenance Data System Requires the Establishment of Codes for the Recording of Data on Maintenance Action Forms: Work Unit Code ( WUC) - A one, three, five or seven character numeric or alpha/numeric code. It identifies a system, subsystem, set, major component, repairable subassembly, or part of an end item. 11XXXXXAirframe 14XXXXXFlight Controls 42XXXXXElectrical Systems Background: Work Unit Codes

 WUCs are assigned and controlled by the Naval Air Technical Engineering Services Command (NATEC) under the direction of the Commander, Naval Air Systems Command (NAVAIR). There are three categories: (1) Aircraft, Missiles, and Drones (2) Aircraft Trainers (3) Aeronautical Support Equipment.  Each aircraft type has an independent WUC manual. Each WUC identifies the system in the first two positions and sub-system elements in the third, fourth, fifth, etc... 42XXXXXElectrical Systems 428XXXXAircraft Wiring 428W0Warn. & Emergency Wiring (C-9) 428W1Fire Det. Wiring (C-9) Background: Wiring System Codes (In Theory)

There are multiple codes employed during maintenance transactions. The cumulative data set tells a story about each maintenance transaction: Work Unit Code Malfunction Description Code When Discovered Code Action Taken Code Type Maintenance Code Transaction Code Type Equipment Code Background: Cumulative Data Set

 All Codes and Data Are Entered in Specified Fields on the Visual Information System / Maintenance Action Form (VIDS/MAF)  The VIDS/MAF Contains Multiple Fields for Data Entry Before During and After Maintenance Actions  Navy Now Uses Electronic Format for VIDS/MAF Known As NALCOMIS  NALCOMIS Permits the Maintenance Activities to Track VIDS/MAF Information From Cradle to Grave and Communicate With Supply Electronically  NALCOMIS Data Is Backed up on Tape and Tapes Are Forwarded to Mechanicsburg, PA for Entry Into the Central NALDA (Logistics) Data Base VIDS/MAF And NALCOMIS

Multiple Reports Can Be Generated Through NALDA to Provide Analysis Information for Virtually All Aspects of Maintenance NALDA Data Is Used to Identify Top 10 Readiness Degraders The Navy Safety Center Tracks Hazardous Material Reports by Work Unit Code NAVAIR Developing A Metrics Program For Aircraft Wire Systems (AIR-4.4.7) How We Use The Data

Current Work Unit Codes Identify Subsystem Wiring and Give No Indication of Zone or Area of Failures (Hot Spots) Generic or Not Otherwise Covered (NOC) WUC’s Are Used Too Often Current Malfunction Codes Do Not Provide Adequate Information to Determine Actual Failures Occurring or Conditions That Lead To Failure (Degenerative Conditions) NALDA Data Is Limited In Its Utility For Reliability Centered Maintenance (RCM) Analysis For Wiring Systems Problems With Wire System Reporting

Work Unit Code Guide for Aeronautical Equipment Changed 8 March 2002 Directing Location Based WUC’s for Wiring and Fiber Optic Wiring (Implementation Controlled By Fleet Support Teams) Change Committee Has Approved Special Wiring Malfunction Codes The Change (Drum Roll Please)

New Wiring WUC Structure

Old WUC Example Electrical Power System Wiring New WUC Example 4257D - MPDB AC Power Wiring FS RH Old Mal Code Example Shorted Broken Wires, Defective Connection New Mal Code Example W00 - Chafing against combustible/bleed air lines W01 - Chafing against structure/components/non-combustible line W02 - Chafing against control cables/flight control components W03 - Chafing against other wire/WBA W46 - Arced/burned/shorted wiring – due to chafing against structure, equipment or fluid/pneumatic lines (including overheat detection elements) W47 - Arced/burned/shorted wiring – due to unknown or other causes (including overheat detection elements) W48 - Broken/open wiring (including overheat detection elements) W49 - Broken splice W50 - Broken terminal lugs/studs * Conditional (Non-Failure)

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Actual Failures Identified Conditional (Non-Failure) Flaws Identified Quickly Highlights Troublesome Areas of the Aircraft Better Metrics For RCM Analysis and Planned Maintenance Benefits

Future Plans NAVAIR Wire System Metrics Program: Verified Failures Mission Aborts (Before-Flight and In-Flight) Non-Mission Capable Hours Partial Mission Capable Hours Zonal and Component Tracking / Wiring Specific RCM Analysis Direct Links to Wiring Diagnostics Identification of Training Deficiencies Joint Council On Aging Aircraft (JCAA): Investigating Joint Service Methods to Improve Wire System Reporting