Readiness amp Sustainability through Condition Based Maintenance Plus CBM OSD CBM Senior Leaders Summit CDR Jesse Black 27 November 2018 America s Navy The Next Generation 2 NAVSEA CBM BLUF ID: 768592
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Readiness & Sustainabilitythrough Condition Based Maintenance Plus (CBM+) OSD CBM+ Senior Leaders’ Summit CDR Jesse Black 27 November 2018
America’s Navy: The Next Generation 2
NAVSEA CBM+ BLUFCBM+ is DoD documented policy for maintenance. NAVSEA ensures CBM+ policy is updated regularly.NAVSEA is working to accelerate the implementation of enterprise CBM+ via the modernization of Integrated Condition Assessment System (ICAS) with enterprise Remote Monitoring (eRM) for Hull, Mechanical and Electrical (HM&E) systems. CBM+ has its foundation in the Reliability-Centered Maintenance (RCM) methodology that NAVSEA promulgates for all (Organizational, Intermediate & Depot level) maintenance development. 3
CBM+ Expected BenefitsImprove Equipment Health to Achieve Expected Service Life (ESL) Improve Readiness and Availability of Assets Maximize Efficiency and Reduce Life-cycle Maintenance Costs Through Data-driven Maintenance Decisions 4
DODI 4151.22 Requires CBM+ as a principal consideration in the selection of maintenance plans and also be based on RCM analysis DOD 4151.22-M establishes RCM as method to “ensure effective maintenance processes are implemented” OPNAVINST 4700.7L (Maintenance Policy for US Navy Ships) - Requires NAVSEAs RCM process for shipboard maintenance development OPNAVINST 4790.16B (CBM & CBM+ Policy) – Requires RCM integration NAVSEAINST 4790 . 27A (RCM, CBM, & CBM+ Policy for Ships, Ship Systems and Equipment) – Describes NAVSEA requirements for use of RCM in maintenance development and sustainment MIL-STD-3034A RCM Process – This standard delineates the 12 phase fully detailed RCM Process and includes the associated Data Item Descriptions (DIDs) for each phase. This standard also contains the Backfit RCM process and Appendix F on NAVSEA’s RCM and CBM+ relationship. NAVSEA Established RCM Training &Certification program in 2001 Current NAVSEA RCM & CBM+ Policy NAVSEA CBM+ is Aligned to OSD Policy 5
RCM is the Basis for CBM+Classic RCM is the engineering analysis process used to develop organizational, intermediate and depot level maintenance requirements for new equipment and systems.Backfit RCM is the Continuous Process Improvement review of existing approved organizational, intermediate, and depot level maintenance tasks.Both Classic and Backfit RCM processes are fully described in MIL-STD-3034A and are essential to achieving CBM+. Since 2001, NAVSEA has trained and certified 7676 in Backfit RCM and 4886 in Classic RCM NAVSEA has instituted online training for our Backfit RCM certification via ePMS Gateway: https://epmsgateway.pmsmis.navy.mil CBM+ connects the maintenance tasks that RCM tells us to do with cost-effective technology to assist in evaluating system and equipment performance. CBM+ uses RCM analysis to determine failure modes and aids in sensor placement. CBM+ uses prognostics to schedule maintenance to REDUCE DOWNTIME 6
NAVSEA RCM & CBM+ Relationship 1. RCM Developed Maintenance Requirements Index 4. Do CBM+ Technologies Exist That Can Accurately and Consistently Detect The Onset of the Failure Mode? 3. List and Identify Specific Failure Mode(s) 5. List Each Technology and Link to the Failure Mode(s) Identified Resort to Non-technology CD, TD, or FF Task NO YES 2. Select Preventive Maintenance Task 6. Comparing the Cost and Reliability of CBM+ Technology With Manual PM, Does Any Identified CBM+ Technology Have a Greater ROI Than Existing Low-tech Methods? NO Test CBM+ Technology in Intended Application Before Full-scale Buy or Lease YES NAVSEA CBM+ TECHNOLOGY DECISION LOGIC TREE Source: MIL STD 3034A (Appx. F) CD - Condition Directed TD - Time Directed KEY: FF - Failure Finding PM - Preventive Maintenance 7
Enterprise Accomplishments since Sept 2017RCM supporting CBM+ Revising NAVSEAINST 4790.27A – RCM, CBM &CBM+ Policy Drafting RCM Management Manual revision 21 Classic RCM courses completed 25 Backfit RCM courses completed 6 FLEET Maintenance Effectiveness Reviews completed (Part of NAVSEA maintenance CPI) 9,248 maintenance procedures reviewed 12 Classic RCM workshops (Part of NAVSEA maintenance CPI) 1,783 maintenance procedures reviewed Total trained in NAVSEA’s RCM methodology in FY18 - 1370 8
RCM Supporting CBM+ Promulgate revised NAVSEAINST 4790.27B – RCM, CBM & CBM+ Policy Issue revised NAVSEA RCM Management Manual 29 Classic RCM courses scheduled 37 Backfit RCM courses scheduled 6 FLEETMERs scheduled Plan to review approximately 9,000 maintenance procedures 12 Classic RCM workshops scheduled Review online Backfit RCM Training course Expectations for FY2019 9
California 1/14/19 San Diego (SURPAC) – Classic 1/18/19 San Diego (SURPAC) – Backfit 1/28/19 San Diego (FLEETMER 106) – Backfit 5/13/19 Port Hueneme (NSWC) – Classic5/17/19 Port Hueneme (NSWC) – Backfit 8/12/19 Port Hueneme (NSWC) – Classic 8/16/19 Port Hueneme (NSWC) – Backfit 8/26/19 San Diego (SURPAC) – Classic 8/30/19 San Diego (SURPAC) – Backfit 9/16/19 San Diego (FLEETMER 110) – Backfit New Hampshire 3/18/19 Dover (SUBMEPP)– Classic 3/22/19 Dover (SUBMEPP)– Backfit 9/16/19 Dover (SUBMEPP)– Classic 9/20/19 Dover (SUBMEPP)– Backfit Rhode Island 4/8/19 Newport (NUWC) – Classic 4/12/19 Newport (NUWC) – Backfit Washington 6/3/19 Keyport (NUWC) – Classic 6/7/19 Keyport (NUWC) - Backfit Florida 3/4/19 Panama City (NSWC) – Classic 3/8/19 Panama City (NSWC) – Backfit 5/13/19 Mayport (FLEETMER 108) – Backfit New Jersey 12/10/18 Picatinny (NSWC) – Classic 12/14/18 Picatinny (NSWC) – Backfit Virginia 10/15/18 Chantilly (SEA04RM) – Classic 10/19/18 Chantilly (SEA04RM) – Backfit 11/13/18 Chesapeake (SEA04RM) – Classic 11/17/18 Chesapeake (SEA04RM) – Backfit 10/29/18 Chantilly (SEA04RM) – Classic 11/2/18 Chantilly (SEA04RM) – Backfit 11/5/18 Norfolk (FLEETMER 105) – Backfit 12/3/18 Chantilly (SEA04RM) – Classic 12/7/18 Chantilly (SEA04RM) – Backfit 2/11/19 Chantilly (SEA04RM) – Classic 2/15/19 Chantilly (SEA04RM) – Backfit 2/25/19 Chesapeake (SEA04RM) – Classic 2/29/19 Chesapeake (SEA04RM) – Backfit 3/25/19 Chantilly (SEA04RM) – Classic 3/29/19 Chantilly (SEA04RM) – Backfit 4/29/19 Chantilly (SEA04RM) – Classic 5/3/19 Chantilly (SEA04RM) – Backfit 5/20/19 Chesapeake (SEA04RM) – Classic 5/24/19 Chesapeake (SEA04RM) – Backfit 7/26/19 Norfolk (FLEETMER 109) – Backfit 8/5/19 Chesapeake (SEA04RM) – Classic 8/9/19 Chesapeake (SEA04RM) – Backfit 8/19/19 Chantilly (SEA04RM) – Classic 8/23/19 Chantilly (SEA04RM) – Backfit Pennsylvania 10/22/18 Philadelphia (NSWC) – Classic 10/26/18 Philadelphia (NSWC) – Backfit 1/23/19 Philadelphia (NSWC) – Backfit 2/4/19 Mechanicsburg (NSWC) – Classic 2/8/19 Mechanicsburg (NSWC) – Backfit 5/3/19 Philadelphia (NSWC)– Classic 5/7/19 Philadelphia (NSWC)– Backfit 7/31/19 Philadelphia (NSWC) – Backfit Maryland 9/13/19 Baltimore (USCG) – Classic 9/17/19 Baltimore (USCG) – Backfit South Carolina 7/15/19 Charleston (SPAWAR) – Classic 7/19/19 Charleston (SPAWAR) – Backfit District of Columbia 1/7/19 Washington (SEA04RM) – Classic 1/11/19 Washington (SEA04RM) – Backfit 6/10/19 Washington (SEA04RM) – Classic 6/14/19 Washington (SEA04RM) – Backfit Hawaii 3/18/19 Pearl Harbor (FLEETMER 107) – Backfit Indiana 6/17/19 Crane (NSWC) – Classic 6/21/19 Crane (NSWC) – Backfit 10 Expectations for FY 19 RCM Training
Integrated Condition Assessment System (ICAS) is: Program of Record NAVSEA’s common tool to support Condition Based Maintenance (CBM) for the past 20 + yearsInstalled on over 100 ships across the FleetMonitoring mechanical and electrical systems including:Performing diagnostics, parametric trend analysis and providing condition alerts via Consolidated Machinery Assessment System ashore (CMAS) Gas Turbine Engines Fuel Oil System Main Reduction Gears Propulsion Diesel Engines Potable Water Controllable Pitch Propeller Refrigeration Plants Gas Turbine Generators Lube Oil System Air Compressors Ships Diesel Generators Line Shaft Bearings Distilling Plants Sewage & Waste Water Air Conditioning Units Evaporators NAVSEA CBM+ Program of Record 11
Enterprise Remote Monitoring (eRM)NAVSEA is moving to replace ICAS with eRM beginning FY18eRM improvements over ICAS Include:Government owned/developed system Increased cybersecurity postureEnhanced diagnostics, fault analysis & trendingEnhanced feedback to ships forceHighly scalable, faster data processing Supports rapid development and revision of CBM+ algorithms Phased transition to automated predictive analytics/prognostics Digital Twin capability Linkage to existing and new Navy policy and doctrine, infrastructure, business strategy, architectural framework, RCM, and open systems and data strategy Enterprise Accomplishments Since 2017 NAVSEA CBM+ is Aligned to OSD Policy 12
Expectations for FY 2019 CMAS is in The Early Stages of Realizing Digital Twin Capability for CBM+ 13
ICAS Combatant Hulls Fully Sunset in FY26 Assumptions: LCS Hulls included into Deployment Plan 11 MCM not planned (decommissioning) 9 LPD Hulls to follow Backfit schedule starting FY26. POM-19 REQUIREMENT ICAS/eRM CROSSOVER PLAN FY18 FY19 FY20 FY21 FY22 FY23 FY24 FY25 FY26 Total # of eRM Installs - POM-19 (Cumulative) 0 4 14 33 51 69 88 102 113 Planned eRM Installs per FY - POM-19 0 4 10 19 18 18 19 14 11 Total # of ICAS Installed - POM-19 (Cumulative) 105 102 95 81 71 59 44 32 20 Expectations for FY 2019 to 2026 14
eRM First in Class Roll-Out Plan First in class CG-69 Q3 FY19 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 MS B MS C IOC FRP/FD LCS 1 Var eRM v3.1 CG 69 eRM v3.1 DDG 87 eRM v3.2 LSD 51 eRM v3.2 LPD 28 eRM v3.2 LHD 8 eRM v3.3 eRM v3.1.0 SRR CDR TRR TER DCA SRR CDR TRR TER DCA SRR CDR TRR TER DCA SRD CDR TRR TER SRD CDR TRR TER SRD CDR TRR TER Acquisition Milestones eRM v3.1 eRM v3.2 First In-Class Shipboard Deployments (Key Events) Application Development eRM v3.3 CMAS v1.1 CMAS v1.2 CMAS v1.3 CBM+ES Program Plan FY16 FY17 FY18 FY19 FY20 FY21 FY22 15
Data Utilization Team Drives the future Development of CBM+ ES Applications Guidance & Roadmaps 16
Major Challenges in Achieving Service Enterprise Goals Technical risk from the constantly evolving Cyber Security posture and policies Expected shut down of NIAPS data path without solidified replacement (Testing currently underway with NAVAIR for possible replacement) Resources needed to standardize remote monitoring systems for HM&E and combat systems If required, increase in classification due to numerous compiled data sources could impact access to large portion of users 17
ConclusionsNAVSEA’s CBM+ process, when properly executed and resourced, will:Improve readiness and availability of assetsImprove equipment health to achieve Expected Service Life (ESL)Maximize efficiency and reduce life-cycle maintenance costs through data-driven maintenance decisionsCBM+ technology must be considered as a key attribute in ship design and be integrated into the acquisition, modernization, sustainment and management processes that are critical to ensuring ship material readiness throughout service life 18