1. Maintenance and Availability Data Warehouse (MADW)
and Cross-Cutting Study
Briefing to JTEG
Greg Kilchenstein Eric Herzberg
28 November, 2017
Cleared For Public Release

2. Outline Background Structure and Conversion Current Capabilities
MADW origin
Structure and Conversion
Sample record
Machine learning
Work breakdown structure (WBS)
Current Capabilities
High level data views and various examples
Cross cutting study
Future Capabilities
Cost per day of availability metric (C/DA)
Predictive capabilities – DoD Maintenance Strategic Plan support
Food for thought – superordinate goal

3. MADW Origin
Started in FY2005 as a result of Congressional interest in reducing
impact of corrosion on DoD weapons systems, infrastructure and facilities
Contains over 1 billion maintenance records – approximately 40 billion
data elements. Over 300 million supply and materials purchase records.
Cost data back to FY04, availability data to FY08
Includes value added data elements such as:
1) Object – solved through machine learning ) Preventive/corrective
2) Action – solved through machine learning ) Parts/structure
3) Standard work breakdown structure ) Environmental severity
4) Reconciled availability and costs in the same record ) Labor and materials records
Involves obtaining all maintenance records, costs and non-availability results

4. MADW – Sample of Data Record (10 of the approximately 40 labor data fields showing)
Foundational data!
All weapon systems studies now being executed
on a yearly basis – soon to move to quarterly
All yearly maintenance costs accounted for
relative to these systems
Standardized data structure across DoD
The NMC totals equal the reported totals for each Service by
weapon system by EIU (tail or serial number).
Contains both labor (task) and materials (parts) detail. Parts are linked
to labor through the job control number.
Results can be determined to the action and object level of detail

5. MADW - Data Conversion Process (Object and Actions Text Search)
For objects – use NIIN, text, then codes
For actions – use text, then codes
Using Natural Language Processing (NLP) machine learning to apply to the maintenance records

6. MADW - Aviation Work Breakdown Structure (AWBS)
Other comments:
1) The AWBS (Aviation), GWBS (Ground vehicle) and SWBS (Ships) codes are assigned after the fact by LMI analysts –
maintenance technicians have no additional work.
2) The WBS codes are embedded into each maintenance record
3) Codes are assigned by identifying the object worked on first and then mapping to the WBS structure. Objects are determined
through parts requisitions (mapped to WBS structure by FSC), use of text descriptions of work, and then service codes as
a last resort
4) The typical structure is a total of 7 end item types (1st character of code), 14 maintenance actions (2nd character of code),
19 end item systems (3rd and 4th character of code) and up to 10 subsystems (5th character of code)
5) The WBS structure eliminates the verb/object conflict which is resident in each service WBS code structure. Example -
Air Force work unit code “03” scheduled inspection or “04” special inspection, Navy ships “631” paint, etc.
Exec Overview - All

7. Current Capability - High Level Data View

8. Current Capabilities - Examples
What is the annual maintenance cost of electronic components for
which there is “no fault found”? What are the 10 best IFIDS candidates by service?
What is the annual maintenance cost of fuel tank leaks for C-130, C-5 and
F-16 aircraft in the Air Force? Is the severity of the environment a factor?
What is the cost of the Navy FA-18 high flight hour depot maintenance package?
Does it have an economic payback??
What are the causes of low availability on the MV-22B and CV-22B aircraft?
Why do the HMX-1 and VMM-365 squadrons have good availability results?
What are the best opportunities for technology insertion that across
all DoD weapon systems platform? (Cross cutting study)

9. Current Capability – Cross Cutting Study Approach to Determine Technology Insertion Opportunities for DoD
Tool: LMI Maintenance and Availability Data Warehouse Metric: Cost per day of availability (C/DA). C/DA is the historical maintenance spending used
to generate one day of availability for a readiness reportable weapon system.
Starting point: One of the three options below. Begin with all DoD readiness reportable weapon systems as
the scope.
Step 1) Determine C/DA by EI Commodity
Step 1) Determine C/DA by Action
Step 1) Determine C/DA by System
Rotary wing
Inspect/test
Engines
Fixed wing
Replace
Body, frame or hull
Ground vehicles
Repair
Axles, landing gear
Common equipment
Treat, paint
Electrical and power generation
Clean, blast, wash
Fuel system
Modify
Communications systems
9 others
14 others

10. Using EI Commodity to Determine C/DA
Tool: LMI Maintenance and Availability Data Warehouse
Metric: Cost per day of availability (C/DA)
Step 1) Determine C/DA by EI Commodity (FY12-FY14)
The other four EI Commodities have no availability reporting and are therefore excluded from this initial approach:
E – Engines M - Missiles
V - Vessels
S - Submarines

11. F and R EI Commodities Combined to Determine C/DA by AOC
For EI Commodity “F” and “R” Combined, Determine Highest C/DA by System (FY12-FY14)
Determine C/DA by EI Commodity (FY12-FY14)
For EI Commodity “F” and “R” Combined, Determine C/DA by AOC for Highest C/DA Systems

12. How Do We Tell if We Are Winning or Losing in Maintenance?
Goal: “Achieve target availability at the lowest cost”
Achieved availability
is above target
C/DA A B C
C/DA
C/DA
Availability target E
C/DA D F
Achieved availability
is below target
C/DA = the maintenance cost per day of availability

13. How Do We Tell if We Are Winning or Losing in Maintenance?
Examples of Weapons Systems Health Scorecard

14. MADW Future Capability – Predictive Modeling
What were the results? 14
What will the results be?
- Predictive modeling with two initial capabilities
- Reduce cost by x% while minimizing impact on availability
- Improve availability by y%
while minimizing impact on costs
- Data warehouse approach
- Standard data structure
- Availability and cost in same data records
- Environmental severity
Current Capability
Future Capability

15. Thoughts to Leave You With
MADW is a powerful tool to help our community focus our technology (and other) efforts
The cost per day of availability (C/DA) metric can transform how success is measured in maintenance as well as inform the superordinate goal of “achieve target availability at the lowest cost”
The predictive capability in development will be a powerful enhancement to the MADW
Your support and advocacy for the MADW will enhance its’ use as an enterprise level tool to help leaders at all levels spend the next maintenance dollar effectively and efficiently

16. Backup

17. MADW - Authoritative Data Sources (Army Ground Vehicles)

18. MADW - Authoritative Data Sources (Air Force example)

19. MADW - Authoritative Data Sources (Army Aviation and Missiles)

20. MADW - Authoritative Data Sources (Navy Vessels)

21. MADW - Authoritative Data Sources (Navy and Marine Corps Aviation and Missiles)

22. MADW - Authoritative Data Sources (Marine Corps Ground Vehicles)