SPARE PARTS PRODUCTION AND REPROCUREMENT SUPPORT (SPARES) PROGRAM
OBJECTIVES
The GA team is developing and installing a SPARES computer-based system for the U.S. Air Force at Ogden Air Logistics Center (OO-ALC). The objective is to advance and modernize:
The technical data is brought into an intelligent, electronic format, which is readily searched and accessed by users through their existing desktop computers. The workflow performed on that data is managed, routed, and tracked through the work- place in accordance with the business rules of that organization. The SPARES system is modernizing the technical data format and the manipulation of that data by using current industry practice and commercial-off-the-shelf (COTS) software and hardware, which are integrated and implemented for the particular workplace. For data that is currently maintained electronically by an already existing "legacy" system, SPARES is improving user access to that system–enabling access through the user's existing desktop computer.
SPARES is achieving its objective of reducing the amount of work-in-process and shortening the time for processing data that supports parts reprocurement by providing an electronic data and workflow environment.
SPARES is an implementation program whose major challenge lies not in developing the technology to make the workplace electronic, but rather in integrating COTS products to fit within the business enterprise, properly training the user community, and fully assisting the user environment to migrate from a paper-based to an electronic workplace.
BENEFITS
SPARES is improving operation at the ALC by implementing state-of-the-art industry practices and using commercially available hardware and software to meet the majority of the user's requirements.
This approach has many cost-effective benefits for the government. First, it leverages commercial development of products and does not require the government to develop the software needed. Second, it enables the government to benefit from natural upgrades and new releases of the software to continuously improve the products. Third, the government is not tied to any one company to provide system support, but rather can provide system administration internally or contract with any of a growing number of support contractors. Fourth, and possibly most importantly, it enables the SPARES program to focus on implementation and not development. Implementation of a system that is intended to significantly change and improve the way individuals and a business enterprise does business requires great effort so the cultural changes can be assimilated into the business environment, while the normal workload is still performed. Merely dropping a new computer system on the using organization is not true implementation and will not be successful. SPARES is inserting its system at a deliberate pace, while training and supporting the users so that the system is truly used and the organization truly benefits.
IMPLEMENTATION
SPARES is structured to implement small portions or "modules" of the system phased over time. The module hardware and software required to meet the user's requirements is first identified and procured. The module is next integrated with the ALC's existing computer infrastructure of desktop machines, local area and wide area networks, servers, printers and existing data repositories. The module is then demonstrated to the user community for verification that the actual system does meet the user's needs and expectations. Finally, the system is implemented into the user environment, along with necessary training and support to ensure user acceptance.
This phased approach to implementation was mandated by OO-ALC to allow the users to continue with their daily workload with minimal interference. It ensures a cost-effective and complete migration of the technology and maximizes usefulness of the system for the receiving organization.
SPARES implementation modules include:
Optical Storage and Retrieval of Data
Technical data support for a weapon system includes a multitude of data management in addition to the official repository for configuration controlled contract data. This additional technical data includes:
This data is typically in paper format and filed only by the National Stock Number (NSN) of the part it supports. SPARES converts this non-EDCARS data into an electronic medium, while increasing the capability to work with that data.
The SPARES system integrated an optical disk drive with the QSTAR Mastermind read/write software. This was interfaced with Fujitsu A/B size scanners, Calcomp E-size scanners, and C-callable library scanning routines. This enables OO-ALC to migrate its paper data to an electronic format which can be accessed through the base LAN and WAN, bringing the data to any perspective user.
This SPARES module is also increasing the capability of those accessing this data by integrating it with a file management system and search engine provided by Excalibur Technologies. The scanned images are batch processed and Optical Character Recognition is performed on any text contained in the scanned image. For example, if a drawing is scanned in, any text on the drawing, such as the title block or notes with specifications, would be recognized and placed in an associated ASCII file. From the associated ASCII file, an associated binary index file is generated, which indexes the occurrence of all letter combinations. For example, the index file would locate the occurrence of "the" and its locations in the original scanned file.
The Excalibur tool has now generated an index file that is the cornerstone to the fuzzy search technology it employs. A user can then search the entire contents of the data repository containing drawings, correspondence, screening results, manufacturing processes etc. for key words without having to know the NSN. The search of this data, or "intelligence" of this data, was accomplished without the requirement for many man-hours to load key words to associate with each file. Perhaps the best way to fully appreciate the power of this technology is through an example.
Recently an RFQ for a wire insulating cover, which had been repeatedly reprocured from the same vendor, was returned. A frantic item manager sent a request to his technical engineers asking for identification of other potential manufacturers for the insulating cover. Under the current paper system, the technical engineer or screener needed to ask around and try to recall a similar part that is presently being worked. The individual would be lost among a filing system that catalogs based only on NSN. With the SPARES implemented system, the user need only enter the search words "wire insulating cover" and the fuzzy search engine would locate, not only perfect matches, but matches with words such as insulation and wiring. Because the search engines works on an associated binary index file, the search is very rapid, taking only seconds to search through the entire master folder repository. The user is presented with a simple screen of "hits" to the queried words and an easy tool with which he can peruse the documents containing the hits.
In addition, this module of SPARES is being used to scan in technical orders and specifications and then search out ozone-depleting chemicals. This enables engineers to quickly identify which tech orders need to be re-evaluated and rewritten to comply with growing DOD and federal environmental regulations. SPARES is implementing current, state-of-the-art commercial technologies into the ALC environment to help them do their job better.
Workflow Management System
Many processes on base are paper intensive and require routing across organizations around the base. These technical data management processes add a lot of time to the parts reprocurement cycle. The first workflow being implemented by SPARES is the processing of the Form 196. Air Force Form 196 is a catch-all form for answering questions that come in from vendors who will be bidding on the manufacture of spare parts. Interestingly, although the number of spare parts being reprocured is decreasing, the number of commercial vendors (and DOD-inexperienced commercial vendors) bidding on the jobs is increasing. The paper work workload of responding to bidder questions is increasing and bogging down the reprocurement process. The figure below presents a simple schematic of the Form 196 workflow. It should be noted that the workflow crosses organizations. Presently, Hill AFB is averaging between 7 and 14 days to process a Form 196. The target set by the procurement office is 5 days. Interestingly, the Form 196 averages nearly 5 days in the base mail system, leaving no time for the value- added activities of answering the bidders' questions. This is a perfect candidate for implementing commercially available technologies to electronically route and track the Form 196 work flow.
A SPARES module is implementing a workflow management tool, which provides electronic access to all data repositories necessary to process the Form 196. These data repositories include:
SPARES provides access from the user's desktop computer to all data needed to perform the work tasks assigned to the user. SPARES is not absorbing the vast legacy system in existence at Hill AFB, but rather is employing modern electronic communications protocols to ease access to these legacy systems.
The workflow management tool being employed is Xerox Corporation's Xsoft product InConcert. InConcert is configured to sit on a UNIX server and accessed from the user's desktop Macintosh, PC, or workstation client. InConcert routes and tracks the Form 196 progression through the process. It enables a manager to monitor the workflow and reconcile the routing of work with his current and projected resources and workloads.
For the user, the Form 196 and the user's required task appears in the in basket of his PC, Macintosh, or workstation desktop. The user can access all necessary data associated with that 196 question and can reroute the task if he feels the question requires a consultation with another engineer or technical equipment specialist.
DOD procurement agencies are ultimately trying to migrate toward an Electronic Data Interchange (EDI) environment with prospective commercial vendors. In an EDI environment, all requisite technical data would be sent electronically to industry for bids. SPARES implementation of electronic data and workflow management at the ALC is a natural first step towards supporting the DOD's ultimate desire for electronic data interchange with industry. This also underscores why ManTech, OO-ALC, and all technical participants on the SPARES program chose an open architecture for SPARES. SPARES must implement industry practice and standards, not develop its own unique computer solutions.
In addition to the Form 196 workflow, SPARES will be bringing other workflow processes on line. Targeted processes include the screening activity, reverse engineering projects, drafting projects, and hazardous materials reprocurement (described below).
Hazardous Material Procurement and Tracking System
The SPARES workflow management tool is being applied to the process of requesting hazardous materials. The Inspector General's office recently audited Hill AFB and found that hazardous materials are being requested without proper authorization or oversight. Furthermore, there was little in-place efforts to critically evaluate if the requested material was truly needed or if it could be replaced with a more environmentally friendly, or "greener," alternative. The SPARES workflow management system is being integrated to more rigorously request and procure hazardous materials, insure that the appropriate health and safety organizations are informed, and guide the requester through the process of selecting a greener product or justifying the continued need for the requested hazardous material.
Feature-Based Manufacturing Center
The OO-ALC repairs and overhauls all the landing gear for all U.S. Air Force aircraft. During the repair and overhaul process, there are many replacement parts that fall in the family of parts covered by bushings (single and double flanged, with and without chamfers and oil holes) and spindles. The overhaul process, which includes rehoning, replating, and rebuilding, requires new bushings and spindles to be made to specific dimensions and tolerances for a particular overhaul. This had typically caused delays in the repair line as the NC programming to fabricate these "custom" bushings was developed.
SPARES implemented a front-end driver for programming several NC lathe machines using a graphical PC-based user interface. The user specifies material and dimensions for these family of bushing/spindle parts and the system automatically generates the NC code for the manufacture of the part. In some cases this has reduced NC programming time from 10 hours down to 1 hour. The SPARES used an ARPA-developed software technology from the University of Utah and implemented this technology at Hill AFB. The SPARES FBMC has been used to manufacture over 1,000 parts to date. Its use is continuing to grow as the system is ported to include other machine tools and increased features.
Engineering Design and Analysis
This module of SPARES has been implemented in the Landing Gear Directorate where engineering personnel have responsibility for critical components of landing gears, brakes, wheels, and tires for all Air Force aircraft. These engineers respond to various kinds of problems relating to the support and safety of these aircraft components. An area of improvements they sought, which was provided by this SPARES module, is the ability to understand the mechanisms that cause parts to fail prematurely. SPARES has installed tools such as Parametric Technology Corporation's ProEngineer and Mechanica. SPARES has trained and supported the landing gear engineering staff in using these tools to support landing gear components.
For information contact:
Anthony.Gattuso@gat.com
Home | About GA | News | Visitor Information | GA Procurement | Career Center
Sciences Education Foundation | Site Map | Legal | Contact Us
©2012 General Atomics All Rights Reserved