1. Equipping the American Forces with a Reliable and Robust Condition Based Maintenance Plus Capability
Colonel Sarah J. Smith, USAF
Military Deputy to ADUSD
Materiel Readiness & Maintenance Policy

2. How do I monitor what is going on inside these components?
CBM+ Origin
“I check
everything
because
I don’t know
Anything!”
Reactive
How do I monitor what is going on inside these components?
Predictive
LUBE
ORDER
M1A2
TANK
AOAP
1961
OBD-II
To Predict Failure I need…
Sensors
Management Unit
Decision Mechanism
Refinement
OBD-I
White Truck
1900
1917
1941
1955
1982
1988
2004
2015
2025
2050
PREVENTIVE
CONDITION
MONITORING
PROGNOSTICS

3. Overview
The need for effective policy and doctrine to underpin the emerging capabilities of integrated mechanical diagnostics/ prognostics and advanced maintenance systems
• Optimizing platform readiness, safety and reliability to ensure maximum capability
• The challenges in creating and implementing policy for new and emerging maintenance technologies and systems
• The US DoD requirements for effective maintenance systems
• The impact of HUMS/future maintenance systems within the operational and logistical command chains
• The effects on future logistic and maintenance based policy and doctrine

4. Condition Based Maintenance Plus
Why?
Decrease maintenance burden on the warfighter
Increase platform availability and readiness
Reduce Operations & Sustainment costs
What?
Maintenance capabilities:
Enhancing diagnostics…
Evolving to predicting remaining component life…
Then to proactive supply transactions
Derived from near real-time assessment and analysis of data from:
Embedded sensors
Platform maintenance environments
Weapon system and supply historical data
How?
Interactive electronic technical manuals, portable maintenance aids, other enabling tools and technologies
Diagnostics, sensors and prognostic algorithms & techniques
Reliability-centered maintenance concepts and practices
Statistical and engineering analysis processes
Condition-driven maintenance plans
Integrated maintenance and logistics processes & reporting systems
“Note that without prognostics, the CBM+ initiative looks a whole lot like RCM.” USAF Aircraft Maintenance Officer 19

5. Overview
The need for effective policy and doctrine to underpin the emerging capabilities of integrated mechanical diagnostics/ prognostics and advanced maintenance systems
• Optimizing platform readiness, safety and reliability to ensure maximum capability
• The challenges in creating and implementing policy for new and emerging maintenance technologies and systems
• The US DoD requirements for effective maintenance systems
• The impact of HUMS/future maintenance systems within the operational and logistical command chains
• The effects on future logistic and maintenance based policy and doctrine

6. Current CBM+ System
“The best current CBM+ system is a well-trained, well equipped, very experienced maintenance technician who has the time and inclination to correspond in meaningful terms with the AFETS and Engineering people. Don't take that wrong. What I mean is that the closest thing we have to a system that can predict when a system will fail is the dedicated, expert technician.” USAF Aircraft Maintenance Officer

7. Air Force Initiative: Instrumentation of Critical Life Areas in Aircraft
One of the lessons we learned,…is that we do not have sufficient reliability and structural integrity information to determine the correct course of action relative to the future of our aging fleet.
…the uncertainty in reliability and structural integrity in that fleet
We have the means and methods for achieving a data driven analysis across our fleet.
We have extraordinary fleet reliability experts…, extraordinary data analyzers….the Fleet Viability Board….
What is needed now is to provide [them]…the right information….

8. Overview
The need for effective policy and doctrine to underpin the emerging capabilities of integrated mechanical diagnostics/ prognostics and advanced maintenance systems
• Optimizing platform readiness, safety and reliability to ensure maximum capability
• The challenges in creating and implementing policy for new and emerging maintenance technologies and systems
• The US DoD requirements for effective maintenance systems
• The impact of HUMS/future maintenance systems within the operational and logistical command chains
• The effects on future logistic and maintenance based policy and doctrine

9. CBM+ Elements and Enablers
Sensors and algorithms
Condition status reporting
Data collection techniques
Automated Information Technology
Serialized Item Management
Troubleshooting
Unique Identification
Diagnostics
Radio Frequency Identification (RFID)
Prognostics
Fault Isolation
Health monitoring & management
Systems integration
Interactive training
Reliability Centered Maintenance (RCM)
Analog condition extenders
Built In Test (BIT)
Asset visibility
Integrated information tools & systems
Portable maintenance aids (PMA)
Interactive electronic technical manuals
[Systems & Sustaining] Engineering analysis

10. Legacy and Aging Weapon Systems
Can CBM+ be implemented on legacy and aging weapon systems, and…
is it cost-effective to do so?

11. Overview
The need for effective policy and doctrine to underpin the emerging capabilities of integrated mechanical diagnostics/ prognostics and advanced maintenance systems
• Optimizing platform readiness, safety and reliability to ensure maximum capability
• The challenges in creating and implementing policy for new and emerging maintenance technologies and systems
• The US DoD requirements for effective maintenance systems
• The impact of HUMS/future maintenance systems within the operational and logistical command chains
• The effects on future logistic and maintenance based policy and doctrine

12. Weapon Systems Supported by DoD Maintenance
Maintained by:
678,000 DoD personnel
Private sector companies
100,000+
Ground Combat/
Tactical Vehicles
 900
Strategic Missiles
Marine Corps Depot
Marine Corps Field
0.9 (<1%)
49.9 (7%)
Navy Depot
20.9 (3%)
Army Field
220.8 (33%)
Navy Field
 280 Ships
14,000
Aircraft/Helicopters
173.6 (26%)
+ 250K+ Wheeled Vehicles
+ Comm/Electronics Equipment
+ Support Equipment
+ ...
Army Depot
7.2 (1%)
Air Force Depot
15.1 (2%)
Air Force Field
National Defense PP&E is valued at
 $700 Billion
186.8 (28%) 1 1
Maintenance cost: ~$63B per year

13. Improving Materiel Readiness: Reliability, Cycle-Time, Cost
Life-cycle cost
(acquisition + O&S)
More
Drive reliability
up to
optimum level
reliability
Sustainment cycle-time
Less
Drive
sustainment
cycle time
down to
optimum level
(O&S only)
Higher $
Lower $
Cost of Readiness
R&D/ACQ Only
R&D/ACQ/O&S
Lowest $

14. Sustained Materiel Readiness
ISSUE:
WAY AHEAD:
Concentrate on achieving and sustaining SPG/CPG readiness
Balance safety, reliability, and maintenance activities to achieve readiness at best cost.
Optimize TIME-ON-WEAPON SYSTEM and repair TURN AROUND TIME
Promote End-to-End (E2E) materiel readiness value chain perspective across DoD
Optimize materiel condition reliability sustainment
Optimize maintenance cost, cycle time
Translate SPG/CPG capabilities to weapon system/materiel requirements
Foster and promote Continuous Process Improvements (CPI)
Reliability
Condition Based Maintenance Plus (CBM+)/Reliability Centered Maintenance (RCM)
Cycle process discipline
Lean, Six Sigma, Theory of Constraints, etc
Develop cause and effect predictive models
Institute integrated budgets (engineering, logistics, industrial) 7

15. CBM+ Policy CBM+ key policy tenets…
Need-driven, reliability centered maintenance
Embedded diagnostics and prognostics
Automated maintenance information generation
Trend-based reliability and sustainability process improvements
Integrated information systems providing logistics response based equipment condition and tasking
Smaller maintenance and support footprints
Improved Operational availability US
Army Policy
17 AUG 05

16. CBM+ Select Programs Army Navy Air Force Marine Corps
Future Combat System (FCS)
Apache
Stryker
Navy
Maintenance Effective Reviews (MER)
Engineering for Reduced Maintenance (ERM)
Integrated Condition Assessment System (ICAS)
Smart Ship
Air Force
C-17
JSF
Marine Corps
Expeditionary Fighting Vehicle (formerly AAAV)
Light Armored Vehicle (LAV)
Defense Logistics Agency
Service Parts Ordering Tool (SPOT) – AWACS
DLA Reliability Initiative

17. CBM+ Implementation Phases
IOC 2011
FOC 2015
FOC 2015
FY 05-07
FY 08-15
FY 16+
Phase 1 – Concept Development
Proof of Principle
Develop Data Warehouse
Develop Prognostics
Assess Impacts to DOTMLPF
Assure Interoperability With:
GCSS-A
CLOE
LMP
PLM+
Phase 2 - Implementation
CAB Pilot Fielding
Continuous Data Analysis
Refinement of Prognostics
Changes to DOTMLPF
Examine New Technologies
Phase 3 - Operations
Sustain CBM+
Continuous Data Analysis
Refine Prognostics
DOTMLPF Improvements

18. Overview
The need for effective policy and doctrine to underpin the emerging capabilities of integrated mechanical diagnostics/ prognostics and advanced maintenance systems
• Optimizing platform readiness, safety and reliability to ensure maximum capability
• The challenges in creating and implementing policy for new and emerging maintenance technologies and systems
• The US DoD requirements for effective maintenance systems
• The impact of HUMS/future maintenance systems within the operational and logistical command chains
• The effects on future logistic and maintenance based policy and doctrine

19. CBM+ Program Focus: Benefits for Warfighters
To Battlefield Commanders, CBM+ Is:
Ability to Meet Mission Requirements With Proactively Driven Maintenance
Ability to Optimize Competing Demands of Warfighting & Planned Maintenance
To The Warfighter, CBM+ Is:
Maintenance Instructions Based on Actual Condition and Usage
Greatly Enhanced Diagnostics and Troubleshooting
Fewer Maintenance Manhours
Physical Inspections Are Reduced or Eliminated

20. Potential Benefits to Warfighters
AH-64 Block III Fleet
10 Parts
Readiness +4.9%
Maintenance Burden reduced by 41,000 Maintenance Manhours (MMHs)
Equates to an additional AH64 Battalion
UH-60 M Model Fleet
9 Parts
Readiness +3.4%
Maintenance Burden Reduced by 26,000 MMHs Annually

21. CBM Enabled Army Aircraft
South Carolina
National Guard
2 AH -
64A
Korea
US Army
15 UH
60A/L
Kentucky
Ft Campbell
160 th
SOAR
6 MH
60K
Alabama
8 UH
3 CH
47D (P)
Missouri
1 AH
17 AH
64A (P)
12 UH
60A/L (P)
California
NASA Ames
1 UH
60 Test
Aircraft
ATTC
1UH
60A/L, 1 AH
64A,
64D, 1 CH
47D
Arizona
WAATS
5 AH
15 AH
Iraq
8 AH
64D
North Carolina
60A/L(P)
Tennessee
IRAQ/Kuwait 60 •
Over 33 Systems supporting the war
fighter In IRAQ
Over 40,000 Flight Hours Experience
60A/L,
16 AH
30 UH
60L
4 AH
PA National
Guard/EAATS
1 CH

22. Overview
The need for effective policy and doctrine to underpin the emerging capabilities of integrated mechanical diagnostics/ prognostics and advanced maintenance systems
• Optimizing platform readiness, safety and reliability to ensure maximum capability
• The challenges in creating and implementing policy for new and emerging maintenance technologies and systems
• The US DoD requirements for effective maintenance systems
• The impact of HUMS/future maintenance systems within the operational and logistical command chains
• The effects on future logistic and maintenance based policy and doctrine

23. CBM+ Related Efforts Defense Advanced Research Projects Agency (DARPA)
Advanced Concept Technology Demonstrations (ACTD)
Commercial Technologies for Maintenance Activities (CTMA)
Joint Oil Analysis Program Technical Service Center (JOAP-TSC)
Military Flight Operations Quality Assurance (MFOQA)
Modeling and Simulation
Industry
Academia
Sports and Entertainment
Corrosion Control
Allied Military Services

24. CBM+ Future & Summary
Reality Check #2
When do you reach a critical Mass?
CBM+ is a long term commitment!
Reality Check #3
Need some low hanging fruit…or bridging strategy
Reality Check #1
Technology is here…but…facing real constraints
CBM+ is proactive maintenance based on evidence of need performed by maintainers with the right knowledge, tools and support at the optimal time.

25. Contact Information
Colonel Sarah J. Smith
OSD-ATL (MR&MP)
3500 Defense Pentagon, Room 5A712A
Washington DC
(703)
OSD CBM+ Website: