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Ship Maintenance on the Horizon
RADM Clarke Orzalli
Director, Fleet Maintenance
21 October 2009
United States Fleet Forces Ready Fleet … Global Reach 1
Discussion Topics
• USFF 2010 N43 Initiatives
• Norfolk Waterfront
• MSMO way ahead
• Process Improvement
• Best Practices
• Maintenance History
• Reach Expected Service Life
United States Fleet Forces Ready Fleet … Global Reach 2
USFF 2010 N43 Initiatives
1. Partner with OPNAV, NAVSEA and other stakeholders to reduce warship
Total Ownership Costs (TOC).
Specific initiatives:
A. Incorporate recent reductions of submarine life-cycle maintenance
requirements into workload leveling efforts in public and private
shipyards.
B. Award Spiral II Multi-Ship Multi Option contracts that increase
incentives for cost control as well as continuous process improvement
efforts.
C. Co-ordinate with operational schedules to level load ports and more
efficiently utilize maintenance dollars.
D. Execute the total FY10 Ship Maintenance Requirement within the
allocated resources through implementation of continuous process
improvement initiatives.
E. Pilot cost reduction efforts in shipyard processes that have
demonstrated performance in Intermediate Level activities.
United States Fleet Forces Ready Fleet … Global Reach 3
USFF 2010 N43 Initiatives
2. Establish an integrated strategy for Navy Logistics IT
systems.
Approve Navy Logistics IT strategic plan that is resourced in POM-12.
3. Partner with OPNAV, NAVSEA and other stakeholders to
improve requirements definition for surface ships to achieve expected
service life.
Surface ship requirements reflect needed maintenance to support expected
service life and funding requirements are well understood and support the
PPBS process.
United States Fleet Forces Ready Fleet … Global Reach 4
Norfolk Waterfront
NSSA PRIVATE SECTOR WORKLOAD
7000
FY-09 FY-10 FY-11 FY-12
1,094,473 RDs 714,205 RDs
6000
Resources Per Day
5000
Preliminary projections
4000
based on ship schedules
3000
2000
1000
0
O N D J F M A M J J A S O N D J F M A M J J A S O N D J F M A M J J A S O N D J F M A M J J A S O
United States Fleet Forces Ready Fleet … Global Reach 5
MSMO Timeline
2009 2010 2011
Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar
Spiral 2 Industry Day
(Washington Navy Yard) 4/22
Norfolk DDG Docker
Spiral 2 Roll-out
Targeted Contract
Award Date
Norfolk DDG Non-Docker
Mayport CG/DDG (New)
San Diego LPD 17 (New)
Norfolk LPD 17 (New)
Norfolk LHA/LHD
PAC NW FFG/DDG
San Diego CG
…
United States Fleet Forces Ready Fleet … Global Reach 6
Spiral 2 Contract Structure Changes
(Enhanced Cost Control Mechanisms)
Spiral 1 (FY05-09) Spiral 2 (FY10-14)
• Competitive awards • Competitive awards
• CPAF • CPAF/IF
• Not exercising options • Not exercising options
• Denial of sub-ktr consent • Denial of sub-ktr consent
• TAR process • Strengthened TAR Process
• Contractor Purchasing Review System:
places ceiling on AF pool at 80%
– Corrects bad teaming behavior
Navy also drives cost outcomes:
• EVMS cert: ktr value decision only
• Port loading, AIT erosion, process
differences • Cost incentive (IF) in lieu of additional
Small Business incentive fee
• Recognized and vigorously
managed: C-RMC, MCIT, ASN • Perf-based AF progress payments
Policy (proposed) • 1-year Rate Caps (in RFP)
• Invoke “excessive fee on fee” limitation
clause in all contracts
• Pre-priced standard work-items
United States Fleet Forces Ready Fleet … Global Reach 7
Process Differences
United States Fleet Forces Ready Fleet … Global Reach 8
Continuous Process Improvement
United States Fleet Forces Ready Fleet … Global Reach 9
DDG-51 Class Depot Maintenance Programming History
DDG-51 Depot Maintenance Requirement
(MD per month) Rusting trunk and deck in
Engineered Progressive Projected Future DDG-53 Engine Room # 1
1,000
900
Intake Uptake trunk
800 (01-174-0-Q).
700
600
500
400
300
200
100
-
PR-91 POM- PR-97 PR-99 PR-03 PR-05 PR-09 POM- PR-11 Draft
94 10 POM-
12
• PR-91 through PR-97: “Engineered Operating Cycle”
Maintenance Strategy
• PR-99 thru PR-09: “Progressive” Maintenance
• POM-10 & Beyond: Return to more rigorous requirement
determination to enable ships to reach ESL
Deep Maintenance was Deferred for the Last Decade
United States Fleet Forces Ready Fleet … Global Reach 10
Life Cycle Maintenance
DDG Life Cycle Maintenance
400
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39
300
Technical Foundation Paper
Projection
K-mandays
200
100
0
DDG-51 was designed for 30 years but has an ESL of 40 years
United States Fleet Forces Ready Fleet … Global Reach 11
SSLCM Mission/Vision
• Mission: SSLCM Activity shall provide centralized surface ship lifecycle
management including; life cycle maintenance engineering, class
maintenance planning and management closely aligned to the Fleet,
Surface Warfare Enterprise (SWE), and NAVSEA’s needs and priorities.
• Vision: SSLCM Activity will significantly influence, shape, and provide
the engineering rigor for the maintenance, repairs, and modernization of the
surface Fleet to ensure ships achieve Expected Service Life (ESL).
SUSTAINED COMBAT READINESS REQUIRES SUSTAINED MATERIAL
READINESS
United States Fleet Forces Ready Fleet … Global Reach 12
SSLCM Activity - 2012
SSLCM Act
LNO (1)
NWRMC
SSLCM Act
Headquarters (~70)
Portsmouth, VA
SSLCM Act Det (~6)
Norfolk, VA
SSLCM Act
Det (~9)
San Diego, CA SSLCM Act Det (~2)
Mayport, FL
SSLCM Act
LNO (1) HRMC
SSLCM Act
Manning Build (combined MIL/Govt/KTR)
LNO (1) JRMC
June ’09 FY09 FY10 FY11
45 ~52 ~72 ~92
United States Fleet Forces Ready Fleet … Global Reach 13
Surface Ship Maintenance Continuum
MRS Alliance /
Stakeholders
OPNAVNOTE
4700
Requirement
Ship
Sheets
Modernization
Constraints
Business
9-Step
Plan
TFP
Process
Docking Frequency
BAWP
Midlife Philosophy
Philosophy (Aged
Maintenance
notionals)
CMP MMBPs
Qualified
Hot Execution Repairs
AWP
Wash
Execute CSMP
CMP Improvement Efforts Avail
- MRS Tailorings
- SSLCM Quicklooks
SSLCM ACTIVITY
- SWE Assessment Program Programming
- MSMO Recommendations FYDP (6 Year)
- ABS Hull Surveys (Pilot)
TYCOM
- N81 DDG-51 Lifecycle Study
- SSLCM/CLASSRON WGs CLASSRON/RMCs/MT
United States Fleet Forces Ready Fleet … Global Reach 14
BAWP to AWP Process
SSLCM Act “Lead” CLASSRON “Lead” SSLCM Act / CLASSRON
CLASSRON “Follow” SSLCM Act “Follow” Joint Team
BAWP to AWP BAWP to AWP Execution
C+1 C+5 A-15 A-14 A-12 A-0
Execution & EOA C+1
SEA05
SEA05
BAWP to AWP
A-12 A-8 A-4 A-0
CLASSRON
CLASSRON
BAWP
Provide Provide
Deferral Deferral
request request
letter to
SEA05
letter to
Post Avail
SSLCMA SSLCMA
AWP
MAINT TEAM
MAINT TEAM
Finds
Generates a
Closeout Growth/new
BAWP 2K marks
Previous Begin pulling in CSMP, TYCOM Execute work
Planning with a
Avail info modernization (Build AWP) Avail (lifecycle)
meeting “lifecycle
into 3-M needs to be
impact”
deferred
CLASSRON
Review
Provide BAWP for
Provide completion
Package CERTS, DFS Issue letter Deferral Provide Issue letter
Work with Ensure Deferral Ensure Reviews these to
SSLCM
SSLCM
Based on (from TYCOM,
Tech Warrant deferrals will
back to request Deferral deferrals will include in BAWP, if
Reviews to see back to
End of
3M, update approved SCD, Avail Push BAWP CLASSRON request if new push task CLASSRON
LAD in Routines, BAWP for the cycle
holder to not make
with deferral letter to request not make needed, cancel
for entire class with deferral
Cycle
approval for next avails un letter to next avails un existing 2K, write Analysis
Close-out
ICMP Deferrals,, CSMP I
deferral executable
response plus SSLCMA letter to executable BAWP 2K
is warranted response and
and D level any additions SSLCMA additions
SSLCMA
Initial Project Project
Planning Review Review
MAINT TEAM
Conference Conference
TYCOM
TYCOM
TYCOM ID
meeting
Requirment 1 2
to RMC
Issue letter
back to
CLASSRON
with deferral
response
Issue letter Issue letter
Execution Closeout
SSLCM
Issue letter
A-720
back to back to
A-540
CLASSRON CLASSRON back to
with deferral with deferral CLASSRON
response and response and with deferral
additions additions response and
additions
TYCOM
SWEAP
A-360 A-240 A-120 A-75 A-0
Process Business Rules & Continuous
Process Improvement Metrics are
Essential
Increase Process Discipline, Work Package Visibility, & Document Deferred Risk
United States Fleet Forces Ready Fleet … Global Reach 15
Technical Foundation Paper (TPF): DDG-51
SRA
SRA
SRA
1-1
3-2
1-4
Requirements by
EDSR
Maintenance
Adjudicated
SRA
SRA
Availability
2-1
2-4
A
ESRA
SRA
SRA
Each tab includes the notional
3-1
3-4
work items for:
DSRA
DSRA
•Required Maintenance Tasks
SRA
1-3
1
2
•Qualified Tasks
•Condition Based Tasks
•Tank and Voids
SRA
SRA
SRA
1-2
2-3
1-5
•Fleet Alterations
•Growth/New work
•Deferred Maintenance bow
DSRA
SRA
SRA
2-2
2-5
2
wave
ICMP Strengthening at
the task level, improving
the CMP and TFP
United States Fleet Forces Ready Fleet … Global Reach 18
United States Fleet Forces Ready Fleet … Global Reach 23
