AIR FORCE LIFE CYCLE MANAGEMENT CENTER PROPULSION DIRECTORATE Ensuring Propulsion Agility 16 August 2018 Mr. Rafael Garcia, SES Director of Propulsion Air Force Life Cycle Management Center I n t e g r i t y - S e r v i c e - E x c e l l e n c e 1
Overview Propulsion Directorate Mission/Focus Areas Propulsion Strategic Emphasis Areas Propulsion Directorate Agile Initiatives Propulsion Consortium Digital Engineering Sustainment Innovation Summary 2
Propulsion Focus Areas Mission Develops, acquires, tests, fields, sustains, and modernizes leading-edge propulsion systems through life cycle management for the U.S. warfighter and international partners Vision Be the Propulsion Center of Excellence for the U.S. Air Force and International Partners Acquire and Support War-Winning Capabilities 3
Developmental Planning Concept Development = Decision Point MDD Air Force Propulsion Roles and Responsibilities Material Solution Analysis A B C Technology Maturation & Risk Reduction Engineering & Manufacturing Development Post CDR A IOC Production & Deployment LRIP/IOT&E FRP Decision Point FOC Operations & Support Pre-Systems Acquisition Systems Acquisition Sustainment System Development Production Product Support & Upgrades Fielding Disposal Senior AF Official accountable for AF Propulsion Enterprise Deputy PEO for Propulsion Propulsion Capability Development Lead Life Cycle Management responsibility Single face and voice to propulsion stakeholders Represent AF to DoD, joint services, and industry Develop engine readiness requirements Reduce engine costs improve engine reliability Ensure the highest levels of engine safety Develop/implement policy and guidance Develop and maintain propulsion workforce competencies READY AFFORDABLE SAFE EFFECTIVE 4
Propulsion Portfolio FY18 Execution USAF $2.3B FMS $246M Total $2.6B Engines USAF 13,589 FMS 8,113 TOTAL 21,702 Inventory Value USAF $36.7B FMS $19.7B TOTAL $56.4B As of FY18/Q2 USAF 38 TMS 10 Commands 133 Bases AFLCMC LP FMS 46 Nations 23 TMS FY17 REPAIR Engine 463 Major Assy 2780 FY18 REPAIR Engine 672 Major Assy 4080 5
Air Force Propulsion Portfolio Long-Term J85 (T-38) 1958/1960 T53 (UH-1H) 1961 TF33-102C (E-8C) 1963/1991 T700 (HH-60) 1978 F103 (KC-10) 1969/1971 F108-100 (KC-135R) 1980 F117-100 (C-17) 1981/1991 F101-102 (B-1B) 1983 F139 (KC-46) 1984/2018 F110-100 (F16C/D) 1986 F118-100 (B-2) 1988 F110-129 (F-16C/D) 1991 F118-101 (U-2) 1998 AE2100 (C-130J) 1998 AETP Gen 6 2016 Advanced Trainer 2020+ 1965 1975 1985 1995 2005 2015 T56 (C-130H) 1954 TF33-103 (B-52H) 1961 T102 (MQ-9) 1965/2001 T400 (UH-1N) 1971 TF34 (A-10) 1971 F107 (ALCM) 1979 TF33-100 (E-3A) 1974 F138 (C-5M) 1982/2002 F108-201 (RC-135) 1982 F100-220 (F-15, F-16) 1986 F100-229 (F-15E) 1989 F119 (F-22) 1991 T106 (T-6) 1989 AE1107 (V-22) 1998 F137 (RQ-4) 1991/1998 F135-100 (F-35) 2007 From Early Technology To Cutting Edge Propulsion Systems B-21 2025 6
Strategic Emphasis Areas Everything WE DO must contribute to the Lethality of our military -- SECDEF Mattis Build a More Lethal Force Ready safe and cost effective Modernizing key capabilities Reform the Department for Greater Performance and Affordability Achieving affordable programs Better business processes (agile, flexible and affordable) Address US technological challenges Strengthen Alliances and Attract New Partners Execution of Foreign Military Sales programs Removing barriers with commercial technology Industry Government Collaboration/Partnership Essential 7
AFLCMC/LP Agile Initiatives Propulsion Consortium Initiative Rapid propulsion prototyping capability Opportunities to increase industrial base Digital Engineering (DE) Investigate broader opportunities for partnering with industry to improve efficiencies and reduce cost Sustainment Innovation Broader collaboration opportunities for partnering with academia, research labs and industry No Formula develop innovative ideas and find a way to make them work 8
Propulsion Consortium Initiative Initiated an Other Transaction Authority (OTA) to allow for rapid propulsion prototyping capability Concept to award in 7 months - $45M agreement/5 years - already looking at increasing ceiling Consortium managed by System of Systems Security (SOSSEC) Consists of Small Business, Universities, Nontraditional & Traditional Currently 350+ members to date Obligated ~$2M in first 60 days Reduced time to award by 157 business days Speed with Discipline Average time from initial request to award: 78 Days Open for use by all DoD Partners 9
F107 (ALCM Engine) Automated Test Procedures OTA Initiatives in Work Reduced required starts by 50% and run time by 44% Prototype repair procedures for: Interstage housing, 2 nd Stage Nozzle Assembly, 3 rd Stage Turbine Rotor Seals, 2 nd Stage Rotor, 1 st Stage Compressor Rotor, & Centrifugal Compressor Forward and Aft Labyrinth Seals Prototyped Ignition Exciter Bench Test Next Generation Cruise Missile Engines Developing requirements and industry development teams for next generation Common Cruise Missile engines Currently prototyping 650lb and 200lb thrust class engines B-52 Re-engine Developing prototype engine integration concepts via virtual immersive power pods. Other projects Prototyping and validating new manufacturing methods (AFRL/RX) Prototype F100 RCVV Retract tube F107 (ALCM) 10
The Next Industrial Revolution Mechanization, Mass Production, Automation, Digitization Four Industrial Revolutions: Industry 1.0 Industry 2.0 Industry 3.0 Industry 4.0 1 2 3 4 End of 18 th Century Use of manual labor, water and steam power to run machines and facilities. Beginning of 20 th Century Electrical Power generation and use of electricity to enable longer running machines and mass production. Middle of the 20 th Century Use of electronics and basic computing to automate production. Menial, repetitive tasks began to be replaced by machines. Today and Beyond Use of IT infrastructure to connect machines and humans in a digital environment. Automated processes with active machine monitoring and analysis. Reference: Abbott, Laird, Digital Engineering for Acquisition SAF/AQRE Brief Jan 2018 11
Digital Engineering Digital Engineering - An integrated digital approach that uses authoritative sources of systems data and models as a continuum across disciplines to support lifecycle activities from concept through disposal Digital Engineering Ecosystem - The interconnected infrastructure, environment, and methodology (process, methods, and tools) used to store, access, analyze, and visualize evolving systems' data and models to address the needs of the stakeholders Digital access to the systems authoritative sources of data Transform the Culture and Workforce such that it it has sufficient Capability and Capacity to to inform decision making across the lifecycle Procure sufficient technical data to provide an enduring Authoritative Source of Truth for the Weapon System Establish supporting Infrastructure and Environments to perform activities, collaborate, and communicate across stakeholders Reference: Abbott, Laird, Digital Engineering for Acquisition SAF/AQRE Brief Jan 2018 12
The Why Why Now? Digital Engineering The Way Congress, USD(AT&L), and SAF/AQ emphasis on: Rapid, agile and innovative solutions Technical data (i.e. data rights and deliverables) Cyber-resiliency Open Systems Architecture Increased competition across the supply chain AF lagging in the Digital Industrial Revolution Logistics/IT Capabilities Initiatives The enemy gets a vote! Rapid threat evolution Digital System Model: Integrated Authoritative System Data Throughout Lifecycle Digital Thread: Enterprise Framework controlling interplay of DSM Data & Translation into Actionable Information Digital Twin: Multi-Physics, Multi-Scale Simulation Mirroring Performance of As-Built Physical Twin. Digital Engineering (DE) provides the foundation for the process required to manage and use technical data, enhancing rapid and agile acquisition Reference: Abbott, Laird, Digital Engineering for Acquisition SAF/AQRE Brief Jan 2018 13
Integrated Forecast & Health Management Hosted on Air Force Enterprise Architecture Near-real time Centralized Data Accessibility Analytics applied to live data Speed & Agility Enterprise deployment of software USAF Propulsion Directorate Condition Based Maintenance + Vision Utilize agile software development paradigm Collaboration with industry and DoD service partners Leverage guided Artificial Intelligence for insight Flexibility Not limited to in-house development Broad applicability across multiple platforms Future Propulsion Fleet Management Reliability Centered Maintenance (RCM) Machine Learned Failure Distributions for optimum engine workscope Parts Forecasting Spare Part projections for more agile procurement and usage forecasting Asset and Program Health Reporting Machine learned fault prediction Automation of Leading Health Indicators for program health monitoring Active Fleet Management 14
Sustainment Innovation Additive Manufacturing Current Efforts Main focus fixturing and tooling Used of 3D digital Computer Aided Design (CAD) models to built 3D printed mask 3D printed masks used in rapid prototyping, tooling and non-flightcritical aircraft parts PMXG - 3D printed masks used during three repair processes: Shot peen, Grit Blasting and Plasma Spray B-1 Interior Lexan Panel Replacement TF33 AGB Paint Mask Demonstration Benefits On demand tooling Short lead times Improved repeatability F100-229 Compressor Blade 3-D Printed Mask F108 Fan Shaft 3-D Printed Mask 15
Sustainment Innovation SBIR and RIF Goal SBIR Small business R&D providing innovative technologies that address DoD top needs RIF Rapid transition and implementation of innovative technology to the field Value Phase I - $150K Phase II - $750K $3M Length Technology Level (TRL) Phase I 1 Year Phase II 2 years Phase I Entry 1/2 Exit 3/4 Phase II Entry 3/4 Exit 5/6 2 years Entry 5/6 Exit 7-9 Normal BAA date December February Award Date July Following March SBIR Small Business Innovative Research RIF Rapid Innovation Fund 16
Sustainment Innovation SBIR/RIF Current Efforts SBIR Automated Airfoil Inspection Station In work - Laser inspection of engine blades - SBIR Phase II Awarded FY17 for $742K (ECD Q3FY19) - Laser dimensional scan complete, crack detection underway - Goal for lab unit (breadboard) at end of contract - Reduced HazMat, possible recovery of disposable blades RIF SmartBlend Completed - Acoustic measurement of damage/blends in IBRs - Awarded FY13 for $2.99M - Equipment and Final Report delivered July 2017 - Production in use at Depot - Results indicated 5% reduction in IBR scrap rate - F119 to save $30M annually, F135 to save $187M Additive Masking Completed - Evaluated masks for thermal spray, shot peen, blast-clean masks - Awarded FY16 for $750K - Equipment and Final Report delivered - Provides quick-turn, low-cost tooling - 90% lower cost per tool Automated, Integrated Inspection Station Completed - Improved resolution for inspection of engine blades - Awarded FY14 for $2.92M (ECD Q1FY18) - Equipment delivered and training complete - Depot production implementation underway - Reduced HazMat, possible recovery of disposable blades 17
Summary Air Force Propulsion is the Propulsion Center of Excellence for the USAF and international partners Rapid, agile and innovative solutions ensure our Air Force Propulsion is Ready, Affordable, Safe and Effective Everything WE DO must contribute to the Lethality of our military -- SECDEF Mattis 18
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