The Future of Maintenance

Evaluate & Disassemble

Various technologies provide depot floor workers with digital solutions that accelerate teardown and allow real-time operational feedback. The augmented reality headset provides the worker with step-by-step digital work instructions overlaid onto the physical environment to guide in the disassembly of the part of the plane they are working on. Scanning Quick QR codes ensures that the correct part is being removed. By placing the Internet of Things (IoT) sensors on the disassembled parts, the depot workers ensure that all parts and components that come off the plane are accounted for.

Perspectives
Enabling Technologies
Production Managers
Depot Execution Personnel
Depot Execution Personnel
Depot CO & Production Directors
Production Managers
Production Managers
Depot Execution Personnel
Depot Execution Personnel
Depot CO & Production Directors
Depot CO & Production Directors
icon_DigitalTrackingorange_SVG Enterprise Digital Tracking
icon_IoTorange_SVG Sensors / Internet of Things
icon_WearableTechorange_SVG Wearable Technology
icon_ARVRorange_SVG Augmented & Virtual Reality
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Enterprise Digital Tracking

During disassembly, artisans temporarily apply active Radio-Frequency Identification (RFID) IoT sensors to high-value sub-assemblies and parts to provide digital tracking throughout the maintenance process. As the production controller begins to process work orders, they realize that a large sub-assembly is missing from a particular shop work center. Using the digital tracking app on their mobile device the production controller locates the part in another shop. After physically confirming the part’s location, they determine it was mistakenly removed and reroute it based on the designated work order.

Want to learn more? Read more here: Turnkey IoT Accelerators

Perspectives

Sensors / Internet of Things

Throughout the depot, accelerometers, ultrasonic and thermal imaging sensors will be utilized to perform asset condition monitoring such as measuring vibration and heat being generated by equipment. That data will be transmitted to machine health monitoring computers in Plant Maintenance and compared to normal operating parameters. Any deviations noted that are outside normal limits will automatically generate a work order to address the issue. Machine operating hours are automatically tracked and maintenance based upon operating hours is automatically scheduled. In addition, historical condition monitoring information is utilized to make predictions and make adjustments to operating parameters without being explicitly programmed.

Want to learn more? Read more here: Internet of Things Collection 

Perspectives

Wearable Technology

Artisans throughout the depot are equipped with various wearable technologies to monitor performance and well-being throughout operations. Their “connected boots” are equipped with sensors to monitor and collect hazard awareness data such as proximity monitoring, fall detection, and fatigue assessments to alert depot leadership to potentially hazardous work conditions. Throughout the day artisans receive updated work assignments on digital wristbands based upon their certification and skills. Artisans certification are actively monitored and inform artisan and shop supervisors if a required certification is out of date or violated.  Additionally, the linkage between EWP and artisan skills/certification prevents clocking to tasks outside of the artisans approved skills/certification thereby improving quality of the final product. Wristbands are also used to clock in/out and monitor performance. 

Want to learn more? Read more here: Workforce Superpower: Wearables are augmenting employees’ abilities

Perspectives

Augmented & Virtual Reality

Equipped with an augmented reality headset, an artisan receives step by-step digital work instructions overlaid onto the physical environment to aid in disassembly. While removing a sub-assembly, the artisan notices unexpected discoloration and corrosion so she uses her headset to capture several photographs and sends them to engineering support for review. After reviewing the initial photographs, the engineer decides additional review is required and asks the artisan to initiate a one-way video chat so he can get a better view of the anomaly. Using her headset’s telepresence, “see what I see” capability, the artisan and engineer can virtually review the discoloration together and decide to dispose the hardware as scrap and initiate a root cause investigation.

Want to learn more? Read more here: More Real Than Reality: Transforming Work Through Augmented Reality

Perspectives

Welcome to the Future of Maintenance Microsite

The digital transformation of the Nation’s depots, shipyard, and warehouses will leverage next-generation technology for everything from intelligent operations management and advanced manufacturing to digital supply network synchronization. Personnel at all levels will be better enabled to succeed in their roles through the introduction of these technologies. This digitally-transformed infrastructure will establish an architecture for the Navy to lead its mission readiness capabilities into the future.

This tutorial will provide an overview of the Microsite’s functionality to understand the benefits and potential application of these technologies. Click on the slides below to learn how to navigate the site, otherwise close this window to start exploring. Site best viewed in Chrome or Edge browsers.

Digital Aviation Depot Perspectives

Click on the text below to learn more about each role. 

Define my role:Define what I care about (metrics, KPIs):
 
  • Individuals that oversee all Depot Activities (all models within the facility)
  • Responsible for approving overall production schedule and execution budget
  • Meeting Depot cost, schedule, quality, and safety targets
  • Maintaining safe operations
  • Availability of the right skills and supporting infrastructure (equipment, etc.)
Define my role:Define what I care about (metrics, KPIs):
 
  • Responsible for planning, assigning, and monitoring the execution of all work associated with a particular product line
  • Directs adjustments to be made based upon outside factors (i.e., schedule change, material or engineering delay, etc.)
  • Assigns tasks and priorities based on available capacity, materiel availability, and required skills
  • Managing and resolving delays
  • Daily throughput and completion of work orders
  • Availability of the right skills, materiel, and supporting infrastructure (equipment, etc.)
  • Labor and equipment utilization
  • Actual vs. budgeted Direct and Indirect hours

1st Line Supervisors, Artisans, E&Es, and Quality Personnel

Define my role:Define what I care about (metrics, KPIs):
 
  • 1st Line Supervisors – Plans and matches capabilities to work assignments of artisans, monitors quality of artisan’s work, ensures efficient man-loading of tasks
  • Artisans – Performs maintenance/repair tasks as directed by Work Orders
  • E&Es – Tailors Work Order operations based on actual component condition
  • Quality Personnel – Inspects condition of repairs to ensure standards are met
  • Labor and equipment utilization are maximized
  • Work is performed within allotted workload standards
  • Artisan skills and training
  • Completing tasks within the allotted time at a high level of quality
  • Ensuring that parts are returned to the fleet in acceptable repair condition (A Condition)
Enabling Technologies

A key part of digital transformation of the Nation’s depots, shipyards, and warehouses are the enabling technologies that provide the foundation for the various technologies used throughout maintenance and logistics operations. These enabling technologies ensure connectivity, enable enterprise-wide visibility, and provide the security needed for system stability. Click on the text below to learn more about each role.

A 5G network provides the connectivity that is essential when employing a broad web of interconnected technologies. A 5G network increases the speed of data transfer, lowers latency issues, increases the bandwidth capabilities, and increases the capacity of data that can be sent.  
Cybersecurity supports the protection from cyber threats for all internet-connected systems such as the hardware, software, and stored data. Strong cybersecurity systems protect against unauthorized access to the sensitive information stored within military data systems.  
A Product Lifecycle Management (PLM) solution integrates organizational data, systems, and processes. This allows artisans and depot managers to access the technical data and product specifications needed as well as create and monitor digital twins for repaired parts and weapons systems. 
Model Based System Engineering (MBSE) solutions use a model based approach to support the setup of a complex system from initial concept to ongoing operational analysis. Using an MBSE approach supports orchestrating the combination of several complex systems and deepens the understanding of processes through integrated analytics. 
Robotic and Intelligent Automation (R&IA) can drive efficiency across manual and repetitive processes. Automating tasks reduces back logs and creates time for staff to work on more value-add tasks. Given the large number of tasks that need to be performed across the shipyards, depots, and warehouses this will free up the artisans and managers to focus on higher complexity, higher value tasks. Automation can also drive analytics for leadership to make more informed decisions. 
Control Tower provides deep supply chain data visibility through intuitive and innovative dashboards. Control Tower tools enable deep dives of data analysis to understand the reason for changes behind key performance indicators and augment problem solving and continuous process improvement. Control Tower capabilities can help proactively manage supply chains in real time, allowing leaders to focus on the most critical supply chain segments, while the rest of the supply chain can continue functioning in a business-as-usual fashion. A comprehensive Control Tower provides the visibility across the entire shipyard, depot, and warehouse to view the current state of all processes and quick identification of any pain points or areas requiring action by leadership. 

Control Tower

Six months prior to an aircraft arriving at the depot and during normal on aircraft maintenance at the 0-level, depot artisans perform a conditional maintenance inspection of the aircraft. Data from this inspection is used by various maintenance systems to plan for all logistics support required to complete its future heavy maintenance event. It also provides information to production managers concerning the amount of time as well as artisan skill sets required to perform that work. This information is used to determine proper staffing levels for future work. While finalizing the repair plans for that aircraft, the depot production manager receives two automated alerts from the Control Tower regarding potential issues to depot operations. The first alert indicates throughput of an assembly cell has dropped and the second forecasts supply shortages of critical parts needed to fix the aircraft based on the digital aviation supply data feed. Based on the alerts, the production manager addresses critical personnel shortages in the assembly cell and coordinates with other agencies to develop a plan to alleviate the projected parts shortages.  

Want to learn more? Read more here: The Supply Chain Control Tower

Perspectives