OBSOLESCENCE MGMT OVERVIEW, OBSOLESCENCE ...

NAVAL UNDERSEA WARFARE CENTER
DIVISION KEYPORT
OBSOLESCENCE MGMT OVERVIEW,
OBSOLESCENCE MANAGEMENT
INFORMATION SYSTEM (OMIS TM )
& CUSTOM ENGINEERED SOLUTIONS
CAPT STEPHEN IWANOWICZ , USN
COMMANDER
Defense Industrial Base Workshop and
Seminars
June 15-16, 2010
Robert Taylor
Customer Advocate, Logistics Agencies, Code 70CA
NUWC Division Keyport
Phone: (360) 396-1950
DSN: 744-1950
Cell: (360) 340-6381
Email: robert.o.taylor@navy.mil
Distribution Statement A: Approved for Public Release.
Distribution is unlimited
OBSOLESCENCE MANAGEMENT
INFORMATON SYSTEM TM
Mr. JAMES E. VANANTWERP
TECHNICAL OPERATIONS MANAGER
Vicky Skiff
Technical Project Manager – Obsolescence C/40V
NUWC Division Keyport
Phone: (360) 315-7503
DSN: 322-7503
Cell: (360) 620-2483
Email: victoria.skiff@navy.mil
Distribution Statement A: Approved for Public Release. Distribution is unlimited 1

Obsolescence Management
Overview & OMIS TM
Distribution Statement A: Approved for Public Release. Distribution is unlimited 2

Average Age
Years of under investment in new
acquisition / modernization…
20
15
10
Logistics
Support
Surface
Combatants
5
SSN
FixedWing Aircraft
98 00 02 04 06 08 10 12 14
Fiscal Year
Source: NAVSUP Transformation Brief, May 2003
Navy
…Has resulted
in aging Force Structure
Impact of Obsolescence
• Estimated Cost Avoidance for Navy
Proactive Electronics Obsolescence
Management is $4.9B over the life of
current systems (DoN Study, 2004)
Less than 10% of Repairable &
Consumable Electronics are tracked
at the level DASN-L wants (Bill of
Material Tracking)
Proactive Management of Mechanical
component obsolescence is even
worse!
We are here
Distribution Statement A: Approved for Public Release. Distribution is unlimited 3

Tech Doc Access &
Availability
Platform/System
Configuration Data
Commercially-
Owned
Stock Data
Government
SOM Stock Data
PBL-Supported
System Visibility
RELEX
Haystack
COTS
Vendor Surveys
NAVICP/DLA
Inventories
QStar / IHS Source Data
NUWC Keyport’s OM Process
SYSTEM
KNOWLEDGE &
EXPERIENCE
DMSMS TECHNICAL
EXPERTISE
• Legacy / COTS Out-Year Supportability
• Custom Engineered Solutions
• Service Life Extension Program
• COTS Technology Refresh
• Design Longevity (DL)
• Piece-Part Resolution
• Reverse Engineered Solution
• System Health Status
• Automated POM / Budget Reports
• Legacy Unit / Component Substitution
OMIS TM is Available for Use by ALL DoD Support Activities
Distribution Statement A: Approved for Public Release. Distribution is unlimited 4

OMISTM - Web-based Proactive Obsolescence
Management & Mitigation System.
Real-time visibility into
a Program’s
obsolescence
posture.
Kept current with Periodic
Source and Quarterly
Stock Availability
Proactive Platform
obsolescence tracking
(budget impact projections
and mitigation).
Drill down to view obsolescence
issues from Platform level to
Component level.
OMIS TM Overview
Access from any
Internet-connected
PC (Password & PKI)
Distribution Statement A: Approved for Public Release. Distribution is unlimited 5

System
Support
Inputs{
{
Source
Inputs
{ DLA
Logistic
Information
Stock
Inputs
{
Reliability
Inputs
COTS
Vendor
Inputs
{
System &
Configuration
Information
Obsolescence
Information
Component
Reliability
Information
OMIS TM System Inputs / Outputs
Relational
SQL Database
(OMIS TM WorkStation)
System Level
Health
&
Supportability
Analysis
Periodic
System
Component
ALERT Report
Interactive
“What if”
Module
Automated
Out-Year
POM / Budget
Report
Web-Accessible
Obsolescence
Management
Information System
(OMIS TM View)
OMIS Designed to Solve Obsolescence Issues As they Arise / Share Solutions Across All Platforms
Distribution Statement A: Approved for Public Release. Distribution is unlimited 6

= Labor Intensive
Capture
Technical &
System Data
Generate
Obsolescence
Cases in OCL
Build &
Load TDBD
BOM
Run
What-If
Resolution
Scenarios Senarios
Assembly
Mapping
Determine SOURCE
Data, Research &
Scrub BOM
OBSOLESCENCE ANALYSIS
OMIS TM Process Flow
Capture
STOCK
Availability
Capture
RELIABILITY
DATA
COTS Assemblies & HM&E Mechanical
Determine
Best Solution
Component Level Assemblies
DATA CAPTURE
Automated
Component
Monitoring
Obsolescence
Monitoring
Perform
Vendor
Surveys
Weekly Alert Reports, Monthly Program
Status Reports, Quarterly Health Reports,
Annual Program Reports, and
POM/Budget Reports
Auto-Plot
Out-Year
Supportability
Graphics
REPORTING & BUDGET RECOMMENDATIONS
Distribution Statement A: Approved for Public Release. Distribution is unlimited 7

OMIS TM Legacy System View
Legacy/MIL-SPEC Supportability Bar Charts
GOLD Bar - # Years
Support w/o ANY
Repairs (Do-Nothing)
BLUE Bar - # Years
Support w/Repairs, if
Each Failed CCA due to
Obsolescence Falls-Out
System, Stock, Source, & Reliability Data Used to Calculate Asset Procurability and Supportability
Distribution Statement A: Approved for Public Release. Distribution is unlimited 8

Supportability
Information
Interactive
Results
NAVICP / OEM
CCA Stock
Information {
CCA / NHA Component Source View
NON-COTS Interactive Budget Tool
“What If” Interactive Module
}
Budgeting Information
Rolls-Up into POM Feature
RELEX®
Reliability
Information
DLA and
SOM
Piece Part
Stock
Information
Component
Source
Obsolescence
Information
Distribution Statement A: Approved for Public Release. Distribution is unlimited 9

OMIS TM COTS System Level View
COTS Supportability Summary Bar Charts
GOLD Bar - # Years
of Available RFI / SOM
Assets (On-Shelf)
Green Bar – Period
of procurability
Orange Bar – Period
of RFI/SOM
Consumption
RED Bar – Period of
no assets or support
More Bars Available
for Warranty Period,
OEM Repair, 3rd Party Repair, LOT
Buy, SSB.
Distribution Statement A: Approved for Public Release. Distribution is unlimited 10

Rev. A (2005)
Power Supply
Rev “A”
Power Supply
+/- 5 volts
Obsolete COTS Example
Developed
due to
obsolescence
Rev. B (2009)
Power Supply
Rev “B”
Power Supply
(+/- 5 And +/- 10 volts)
smaller, lighter, less
expensive
Transition to Rev “B”
Low Risk in Open Architecture System Design
High Risk in Closed Architecture / Legacy Systems
COTS RESOLUTION OPTIONS
• LOT BUY
Procure enough spares to last through
System EOL
• ALTERNATE COTS ASSY
OEM has Alternate Assy, possibly
RoHS Compliant
• EXTEND OEM WARRANTY
OEM agrees to repair and/or replace
COTS Assy for extended period
• THIRD PARTY REPAIR
OEM agrees to license “3 rd Party” repair
for extended period
• TECHNICAL REFRESH / INSERTION
Insert Newer Technology (Choose Rev
“B” now or at later date)
• DESIGN LONGEVITY
Either Obtain BOM from OEM, solve
Obs. and provide obs. parts to OEM
Or Aid OEM to find 3 rd Party to Mfgr
COTS Assy for military – OEM gets
royalties.
Distribution Statement A: Approved for Public Release. Distribution is unlimited 11

Survey
Team
Vendor Survey Process
Email Survey
Phone Survey OMIS Data Entry
Distribution Statement A: Approved for Public Release. Distribution is unlimited 12

• COTS Management
Costs $
• Some items have less
Risk and require less
mitigation
• It is important to have
a strategy
Prioritizing COTS
Why Prioritize? Things to Consider
• Mission Criticality
• Open/Closed
Architecture
• Uniqueness
• Modified COTS?
• Fit
• Unusual Materials
• Safety
• Redesign Cost
Distribution Statement A: Approved for Public Release. Distribution is unlimited 13

Vendors are surveyed to determine
the production status and
supportability of their products
Surveys are conducted twice a year
(minimum)
Survey results are logged in OMIS TM
for use in platform/system
supportability analysis
COTS Vendor Surveys
Sample Survey Questions
1. When did production start for this product?
2. Is this item currently in production?
3. If not, when did it end?
4. If this product is no longer in production, can the government
still purchase it?
5. If so, how many?
6. When is the last date that the product can be purchased? (Note:
If that date has already passed, please indicate what the last
order date was).
7. If currently in production, when do you anticipate end of
production?
8. If you are not currently planning an end of production date for
this product, please provide an estimate, based on similar
products, past history, technology/component obsolescence, etc.
Keep in mind that this date is used for technology insertion
planning purposes only.
Distribution Statement A: Approved for Public Release. Distribution is unlimited 14

Initial Supportability State
COTS INTERACTIVE POM TOOL
COTS OBSOLESCENCE
RESOLUTION OPTIONS
• LOT Buy
• Alternate COTS Item
• Extend OEM Maint.
Agreement
• Purchase 3rd Party
Maint. Agreement
• Tech Insertion
• Design Longevity
Extend OEM
Maintenance
Agreement
3 rd Party
Maintenance
Agreement
Tech
Insertion
Distribution Statement A: Approved for Public Release. Distribution is unlimited 15

OBSOLESCENCE ALERT REPORTS
Periodic Monitoring Reports
Alerts Identifying All New System Component Source Obsolescence, along
with Impact to Your System and Resolution Recommendations
One Component
Obsolete, Another
OEM Component is
Still Available
Component
Obsolete,
Alternate
Component Is
Recommended
Component
Obsolete; but now
Is available as
an Aftermarket
Manufactured Part
Distribution Statement A: Approved for Public Release. Distribution is unlimited 16

SOURCE/STOCK DATA SEARCH
Double-Clicking the Obsolete Microcircuit
P/N #103065-002 On Interactive CCA View Here …
Or Entering it into the SEARCH TOOL
Here…
Opens the P/N #103065-002
Part Data Screen
OMIS Regularly Tracks Over 115,000 Components across 1200 Systems on over 50 Platforms.
Distribution Statement A: Approved for Public Release. Distribution is unlimited 17

IN SUMMARY…
• NAVSEA Division Keyport’s DMSMS Role:
Own /Maintain one of two ASN recognized DMSMS
Tools - OMIS TM
• Services include:
DMSMS Plans
DMSMS Management Teams (DMTs)
System Obsolescence Health Assessments
Technical Expertise
Analysis of Options
System/Program Metrics
Cross-System/Platform/Service Visibility
Analysis of New Designs
Custom Engineered Solutions (CES)
Over 50 Obsolescence Management Subject Matter Experts!
Distribution Statement A: Approved for Public Release. Distribution is unlimited 18

Custom Engineered
Solutions
Distribution Statement A: Approved for Public Release. Distribution is unlimited 19

NUWC Division Keyport Depot Capability
Organic Depot Repair Capability
• Electro-mechanical & Mechanical
Technologies
• Electronics Technologies
Reverse Engineering Capability
•Electronics
•Mechanical
•Electromechanical
Rapid Prototyping
Distribution Statement A: Approved for Public Release. Distribution is unlimited 20

Custom Engineered Solutions
CES Mission Impact
Reestablish Supply
Repair & Fabrication Source
Development
Organic PBL
Reliability & Supportability
Improvement
Vanquish Cannibalizations
Improve Operational Availability
Safety Net
Obsolescence Resolution
Alternatives to Redesign
Bail-Out Solutions
Trusted Agent
Not Profit Driven
In Partnership with other Depots,
but much more than a depot…
In Partnership with Industry
(CITE)
Distribution Statement A: Approved for Public Release. Distribution is unlimited 21

Advanced Machining Center for the Fleet
Voest Alpine 7 – Axis CNC Mill Haas 5 – Axis CNC Mill
Omax Waterjet Tool
Coming in
2010!
We’re making significant capital investments in
support of mechanical fabrication projects!
Hass 5 – Axis CNC Mill #2
Haas 3-Axis Vertical CNC Mill
Distribution Statement A: Approved for Public Release. Distribution is unlimited 22

Robotic Laser Cladding
Electron Beam Deposition
______ Applied _________ Technology _______ Projects _______
Advanced ____ Metal _________ Deposition _____Repair
Direct Metal Deposition (DMD) /
Friction Stir Welding (FSW)
(R4 Project)
• Deposition Materials
• Aluminum Alloys
(6000 / 7000 Series)
• Titanium
• Stainless Steels
• Carbon Steels
• Tool Steels
• Copper Alloys
• Inconel / Monel
• Stellite
• Nickel-aluminum-bronze (NAB)
• Copper Nickel (70 / 30)
Laser Engineered
Net Shaping (LENS)
Next Generation
Laser Cladding System
Distribution Statement A: Approved for Public Release. Distribution is unlimited 23

______ Applied _________ Technology _______ Projects _______
Advanced ______ Coating ______ Removal ________ Processes
Robotic Laser Stripping Workcell
(NUWC Keyport)
Laser Coating Removal
– Most Types of Paint
– Powdercoat
– Low Observable Coatings
– Organic Material
– Adhesives
– Anodize Coatings
– Corrosion / Oxidation
– Substrates: Metal or Composite
– Benefits: Significant HAZMAT Reduction / Labor Savings /
Color Selective Stripping
System Integration
by NUWC Keyport
Automated Rotor Blade Stripping
System (ARBSS)
Automated Rotor Blade Stripping
System (ARBSS)
Color Selective
Sensing
Distribution Statement A: Approved for Public Release. Distribution is unlimited 24

______ Applied _________ Technology _______ Projects _ ___ ____
In-Situ _____ Laser Repair ___________ Applications
• Navy’s First Shipboard Laser Repair Capability
• Addresses VLS Tube Corrosion
• Performs Inspection, Laser Deposition, Grinding
of VLS Missile Tubes
• Superior Corrosion Protection: Low Dilution
Laser Deposit + First Navy Use of New
Corrosion Resistant Alloy
• System is fully operational at PHNSY
Distribution Statement A: Approved for Public Release. Distribution is unlimited 25

______ Applied _________ Technology _______ Projects ____
Rapid __________ Prototyping __________ & Fabrication
AMCAST Rapid Casting System Selective Laser Sintering (SLS)
Rapid fabrication system for producing metal
castings
Produces “patternless” sands molds / cores using a
layered rapid prototyping process
Produces dramatic reductions in costs / lead times
for castings in low quantities (1-100 units)
Only AMCAST facility in the DoD
Casting Materials: aluminum, stainless steel,
bronze, copper nickel, carbon steels, nickel alloys
Advanced
Rapid
Prototyping
Advanced “direct manufacturing” capability for nonmetallic
components
Produced directly from CAD models
Part complexity has no bearing on cost
Significant cost/time savings over prototype
machining & low volume part fabrication
8000+ components produced at NUWC Keyport
Applications: brackets, fixtures, inserts, containers,
vehicle structures, prototypes, fluid control devices,
structural components, etc.
Distribution Statement A: Approved for Public Release. Distribution is unlimited 26

CES __________ Fabrication ______ Project
Keyport is manufacturing Submarine Towed Array Handling System Central
Processing Unit (CPU) Circuit Cards in support of PMS-4011 and Navy
Supply.
Depot Engineer evaluates Test Program Set built
for CCA testing with Teradyne-Spectrum
Advanced Test Equipment
• Will increase life cycle sustainment
through increased Supply Support of
spares.
• Coordinated effort between ISEA ,
Program Office and Keyport to emulate
EPROM software.
Older Version of TAHS CPU CCA
Distribution Statement A: Approved for Public Release. Distribution is unlimited 27

Problem: OEM No Bid on Repair
High Startup Costs Motivated COTS
Insertion analysis
Solid State Gyrocompass Projects
FA-18 Hornet Rate Sensor Assembly Gyro
Old Design Redesign
Keyport leveraged off FA-18
Hornet RSA
Proposal for Solid-State
“Drop-In” replacement
H-60 Seahawk Legacy Rate Gyro
Solution: Keyport Design for Solid-State
“Drop In” Replacement
New Procurement cost reduced from $20k
per unit to $5.2k
Increased hour life from 400
to 50,000 to 100,000
Expanded to H-53 and H-46
Old Design Redesign
• MTBF 500 Hrs 45,000 Hrs*
• Standard Price $10K $7K
• Repair Price $5K - $10K (70% Wear out) ~$4K (if repairable)
Distribution Statement A: Approved for Public Release. Distribution is unlimited 28

• Increase reliability over original analog
and mechanical designs.
• Reduce design costs by utilizing
"Common Core" methodologies
• Utilize "Concurrent Engineering"
practices and Rapid Prototyping
technology to reduce product
development cycle time/costs.
•EA-6B (Prowler)
• Common 3-Axis
• Rate Gyro
•C-2 (Greyhound)
•E-2C
(Hawkeye)
• Common Lateral / Normal
Accelerometers
•
Solid State Gyro Platform Support
$53M Savings
(Program Life)
•Original F-18 Rate
Sensor
•(MTBF 2,200 hrs)
AH-1W Helicopter
(Super Cobra)
H-1 3-Axis
Rate Gyro LECP
(Conceptual)
•F-18 Hornet
•Redesigned F-18 Rate
Sensor
•(MTBF 100,000 hrs)
In Production
•H-53 Helicopter
•(Sea Stallion / Sea Dragon)
•LGRP Rate Gyros – SBU-
30/A (TRU-2)
•
•Redesigned Motional
•Pressure Transducer
•AV-8B Harrier
•LGRP Rate Gyros
•LGRP Rate Gyros
•(SBU-28/A)
•
Distribution Statement A: Approved for Public Release. Distribution is unlimited 29
•SBU-29/A
•
•Original Motional
•Pressure Transducer
$100M
Combined Calc. Savings
(Program Life)
•H-53
•SBU - 32A
•Displacement
• Gyro
•
•H-60 Helicopter
•(Navy Seahawk Coast Guard Jayhawk)
•LGRP Rate Gyros – SBU-30/A
(TRU-2)
•
•P-3 Orion
•SBU - 33A
•Displacement Gyro
•SBU - 32A
•

“Take ___ Aways” ____
“Before proposing a costly redesign, talk to Keyport”
What does your “Top 25” List of Material Problems look like?
We can help proactively manage your obsolescence and system
supportability
We can usually solve your current supportability problems affected by
Material Availability and Poor Reliability
You consider our quote for overall value, and accept or decline
We assist you in developing the Statement of Work and Technical Data
Package; and collaborate with Program Offices, Technical Design
Agents (TDA) and In-Service Engineering Activities (ISEA)
It’s easy to get to us using a standard Military Procurement Requisition
Dedicated Project Office
Visit our CES cell and see for yourself!
Distribution Statement A: Approved for Public Release. Distribution is unlimited 30