Maintenance Innovation Challenge 2015

Summary

This booklet compiles the finalists and abstract submissions for the 2015 Department of Defense (DoD) Maintenance Innovation Challenge held at the 2015 DoD Maintenance Symposium. It highlights innovative technologies, sustainment strategies, advanced manufacturing methods, and predictive maintenance solutions submitted by military services, commercial industry, and academia to improve DoD readiness and reduce maintenance costs.

Cover Page

MAINTENANCE INNOVATION CHALLENGE Monday, December 7, 2015 Room: 129B 3:00 – 4:30 p.m.

Department of Defense Maintenance Innovation Challenge Award Winner

Memorandum for 2015 DoD Maintenance Symposium Participants

OFFICE OF THE ASSISTANT SECRETARY OF DEFENSE 3500 DEFENSE PENTAGON WASHINGTON, DC 20301-3500

LOGISTICS AND MATERIEL READINESS December 7, 2015

MEMORANDUM FOR 2015 DOD MAINTENANCE SYMPOSIUM PARTICIPANTS

Maintenance innovation is a key to DoD’s strategy to continuously improve maintenance effectiveness and efficiency. In keeping with the theme of the 2015 DoD Maintenance Symposium, Achieving Uncommon Results though Innovation, Collaboration and Leadership, we initiated the Maintenance Innovation Challenge (MIC). Based on the success of “Great Ideas Competitions” from past Symposiums, the MIC aims to elevate and expand the call for maintenance innovation beyond solely novel technology to also include unique partnerships, resourcing strategies, business practices or processes that promise to make maintenance more capable, agile, and affordable. We are pleased to announce that 69 excellent submittals were received from DoD, industry and academia.

With assistance from the DoD Joint Technology Exchange Group (JTEG), all submittals were thoroughly reviewed and six finalists were selected. Senior maintenance and sustainment leaders from the Maintenance Executive Steering Committee, the Joint Group on Depot Maintenance, and the Industrial Base Commanders group selected this year’s MIC winner.

The MIC finalists will be presenting their maintenance innovations during the Maintenance Innovation Challenge breakout on December 7, 2015 from 1500 – 1630 in the Phoenix Convention Center North, room 129 AB. We encourage your participation in this event to engage with some of the most forward-thinking individuals in our maintenance community. The MIC winner will be announced and formally recognized during the Maintenance Symposium’s plenary session on the morning of December 8, 2015. Additionally, we encourage you to please interact with these maintenance innovators throughout the Maintenance Symposium in their dedicated exhibition hall space.

Please join us in congratulating this year’s MIC winner, the six finalists and all those who contributed their efforts to share the innovative ideas showcased in the Maintenance Innovation Challenge publication. Well done!

John B Johns Deputy Assistant Secretary of Defense (Maintenance)

Table of Contents

TABLE OF CONTENTS

MEET THE JOINT TECHNOLOGY EXCHANGE GROUP - PAGE 4 COMMERCIAL TECHNOLOGIES FOR MAINTENANCE ACTIVITIES - PAGE 6

2015 MAINTENANCE INNOVATION CHALLENGE FINALISTS

• Automated Debris Analysis for At-line Maintainers (Steve Odom, GasTOPS Inc) - PAGE 9
• Using Voice Directed Technology for Transforming Maintenance & Inspection Ops (Prakash Somasundaram, Honeywell) - PAGE 10
• Phased Array Ultrasonic Testing for Increased Accuracy and Repeatability (LT Christopher G. MacLean, Pearl Harbor Naval Shipyard and IMF) - PAGE 11
• NOKOMIS Advanced Detection of Electronic Counterfeits (ADEC) (Bryan J. Neva, NAVAIR Advanced Aircraft Technologies IPT) - PAGE 12
• USCG Aviation Bonded Material Inspection System (Rusty G. Waldrop, US Coast Guard) - PAGE 13
• Assembled Replacement Integrated Circuits (ARICs) (Corey Kopp, NUWC Keyport) - PAGE 14

2015 MAINTENANCE INNOVATION CHALLENGE SUBMISSIONS

• Encourage Innovation (Brian Anderson, Anniston Army Depot) - PAGE 15
• Applying the Intermittent Fault Detection & Isolation System (IFDIS) (Ken Anderson, Les Stone, Steadman, Universal Synaptics, Total Quality Systems) - PAGE 16
• IUID Transparent Data Collection with RFID (Jon Andresen, Technology Solutions LLC) - PAGE 17
• The Benefits of Condition Based Overhaul (Jamie Bass, Red River Army Depot) - PAGE 18
• Automated Optical Scanning and Computer Modeling (Jeffrey M. Brown, AFRL/RQTI) - PAGE 19
• E-2D Rotodome Assembly Maintenance System (RAMS) (Shane Campana, NAWC Lakehurst) - PAGE 20
• External MortorQ® Super Spiral Drive System (Ken Campitelli, Phillips Screw Company) - PAGE 21
• Reliability Engineering Data Integration (Michael A DiPilla, NSWC Philadelphia) - PAGE 22
• Asset Information Management Solution (AIMS) (Matthew Edwards, Troika Solutions LLC) - PAGE 23
• Affordable Maintenance Through Partnership (Mike Evans, Aerowing) - PAGE 24
• Laser-Cladding: The Future of VLS Tube Repair (LT Mark Ewachiw, Pearl Harbor Naval Shipyard and IMF) - PAGE 25
• Resource Constrained Activity Network (RCAN) (Paul Fithian & Dr. Scott Schultz, Mercer Engineering Research Center (MERC)) - PAGE 26
• Plasma Spray of Ceramic Coatings for Component Longevity (Alex Frank, NUWC Keyport) - PAGE 27
• In-Situ Robotics for Fleet Maintenance (Joel Galles, NUWC Keyport) - PAGE 28
• Use of Add Mfg for the B-52 Stratofortress Radar Blower Motor Assembly (Scott Gray, Elevate Systems) - PAGE 29
• Membrane Dehydrator (Edgardo S. Guevara, United States Coast Guard) - PAGE 30
• Removal of Polyurea-Based Coatings (Atish Gupta, NAVAIR Lakehurst) - PAGE 31
• MRO Business Process Innovation (Michael Hamlin, Realization Technologies, Inc.) - PAGE 32
• The Superfreeze Initiative (LT Daniel Hogue, USN Pearl Harbor Naval Shipyard and IMF) - PAGE 33
• Rotorcraft Optimized Structural Health Monitoring (SHM) (Mr. Donathan Hutchings, AVNIK Defense Solutions; USA AMRDEC) - PAGE 34
• Real-time Aircraft Structural Health Monitoring Systems (Amrita Kumar, Ikegami, Bergman, Acellent Technologies Inc.) - PAGE 35
• The “Pacman” Wrench (LCDR Nick Levine, Chris Orimoto, Pearl Harbor Naval Shipyard and IMF) - PAGE 36
• Data Driven Overhaul Scheduling of Aircraft Support Equipment (Sean Loftus, Patuxent River and Lakehurst) - PAGE 37
• Assessment of impacts of commercial practices to F117 Engine (Gordon Malboeuf, Chromalloy Gas Turbine, LLC) - PAGE 38
• Ultrasonic Shot Peening Yields Significant Savings on Repairs (Kelly McClurg, Avion Solutions, Inc.) - PAGE 39
• USCG MH-65 Tail Rotor Maintenance Stand (Tom McCormick, US Coast Guard) - PAGE 40
• 3D Metal Printing for the Factory Floor (Tom McDonald, Optomec, Inc.) - PAGE 41
• Sourcing Broker (Jerome McGovern, Troika Solutions LLC) - PAGE 42
• All-Metal Thermal Control Valves (John Meyer, Senior Aerospace Metal Bellows) - PAGE 43
• Large Sensor Arrays for Navigation (Chris Moll, NUWC Keyport) - PAGE 44
• Big RUPHIS: Rotor Universal Positioning & Handling Integrated System (Trent Mulcrone, McNally Industries, LLC) - PAGE 45
• Inspection, Corrosion, and Repair Reporting (ICARR-3D) (William H. Osborne, Jr., Mercer Engineering Research Center (MERC)) - PAGE 46
• USCG MRS On-Wing Flight Control Balance Tool (Harlon Parchment, US Coast Guard) - PAGE 47
• Health monitoring of helicopter dampers using analytical modeling and sensor inputs (Ashish Purekar, InnoVital Systems, Inc.) - PAGE 48
• RFID Network System For Automatic Item Inventory Taking And Readiness (Ramos, Teran, Gomez-Macfarland, IDZ Technologies, Inc.) - PAGE 49
• Tinker Integrated Data for Maintenance (IDM) (Bradley J. Ramsey, AFLCMC/LZPTP) - PAGE 50
• GBU-X/AGM-X Logistics Analysis (Leo Rose, AFRL/RWPI) - PAGE 51
• Proposed Study of Hexavalent Chromium Conversion Secondary to Laser Ablation (Jim Russell, General Lasertronics Corporation (“Lasertronics”)) - PAGE 52
• Handling and Installation Impact on Rotary Carbon Face Seal Performance (Paul R. Ryan, Magnetic Seal Corp) - PAGE 53
• Leveraging Weapon System Data to Drive Efficient Depot Maint Induction (Robbie Sargent, Booz Allen Hamilton) - PAGE 54
• Direct Measurement of Energy in Additive Manufacturing (AM) (Federico Sciammarella, Northern Illinois University) - PAGE 55
• Easy Machining of Hard Materials (EMHM) (Federico Sciammarella, Northern Illinois University) - PAGE 56
• In situ powder flow monitoring for DED AM Systems (Federico Sciammarella, Northern Illinois University) - PAGE 56
• Interrogative Diagnostics Solutions (IDS) (Bob Silva, Lockheed Martin) - PAGE 58
• USCG MH-65 Main Gearbox Housing Repair Fixture (Thomas Simpson, US Coast Guard) - PAGE 59
• Develop Optimized Depot Flow Plan (Andrew Sloper, AFLCMC/WWUV) - PAGE 60
• Centralized On-Demand Maintenance for Tactical Training Vehicles (Lisa M. Smagala, US Army Edgewood Chemical-Biological Center) - PAGE 61
• Aircraft Cabin Pressure Leakage Testing in Hot Environments (Bradley Smith NAVAIR 4.8.6.4) - PAGE 62
• OTA Updates: Why Delta Technology is better than compression techniques (Rob Stawarz, Redbend Software) - PAGE 63
• Ergonomic Assessment Using Inertial Motion Sensors (Ed Irwin and Kristin Streilein, Mercer Engineering Research Center (MERC)) - PAGE 64
• Integrated Predictive Maintenance Solutions (Todd Stiefler, GE Digital) - PAGE 65
• Electrical Wiring Interconnect System (EWIS) On-Wing Certification Test Protocol (Thomas Sullivan, 160th SOAR(A) TAG) - PAGE 66
• Global Freeform Mapping using Laser Tracking and Active Target (Ado Umezawa, Automated Precision Inc.) - PAGE 67
• Enabling the Secure Networking of Automated Test Equipment (Mathew VanDerPol, Lockheed Martin) - PAGE 68
• U-2S Dragonlady Snap-In Inflatable Seals (Levi C. Wade, AFLCMC/HBGEA) - PAGE 69
• A Strategy to Provide Alternatives and Remove Barriers to Cr6+-Free and Cd-Free (Bob Wassmann/ Dr. Robin Nissan, Noblis/OSD SERDP and ESTCP) - PAGE 70
• Additive Manufacturing (AM) for Complex Maint Tooling and Training Systems (Bryce Weber, NUWC Keyport) - PAGE 71
• Portable Non Destructive Inspection Surface Contamination Sensor (Dr. Wayne Weimer, Agiltron, Inc.) - PAGE 72
• USCG C130J Hot Mock Up Test & Repair Benches (Stephen C. Williams, US Coast Guard - Elizabeth City) - PAGE 73
• B-2 Additive Manufacturing (Gregory Yort, AFLCMC/WWZ) - PAGE 74
• The Analysis of Resources w/ Visualization and Integrated Simulation Spt (ARVISS) (Feraidoon (Frank), Zahiri, AFSC/ENRB) - PAGE 75
• Data-Driven & Goal-Driven Condition-Based Predictive Maint (DCPM/GCPM) (Feraidoon (Frank), Zahiri, AFSC/ENRB) - PAGE 76
• Expert Troubleshooting and Repair System (ETRS) Reduces “NFF” (Feraidoon (Frank), Zahiri, AFSC/ENRB) - PAGE 77

WHERE ARE THEY NOW - PAGE 78 2016 CALL FOR SUBMISSIONS - PAGE 80 NOTES - BACK COVER

Meet the Joint Technology Exchange Group (JTEG)

JOINT TECHNOLOGY EXCHANGE GROUP (JTEG) The purpose of the Joint Technology Exchange Group (JTEG) is to improve coordination in the introduction of new or improved technology, new processes, or new equipment into Department of Defense depot maintenance activities. The JTEG will seek ways to better leverage technology improvements in depot maintenance through collaboration to support the higher DoD goals of improving effectiveness and efficiency. Composed of representatives from the military Services, the Defense Logistics Agency, the Joint Chiefs of Staff, and the Office of the Deputy Assistant Secretary of Defense for Maintenance Policy & Programs – (ODASD-MPP), the JTEG is a strong advocate for new solutions with the potential to increase efficiency or effectiveness across the Services.

The JTEG collects, analyzes and disseminates depot maintenance requirements, makes information exchange easier, and serves as an advocate for new technologies and efficiency-improving opportunities that facilitate joint service technology development.

The JTEG community includes anyone in DoD or industry interested in exchanging information associated with DoD maintenance. Overseen by a panel of representatives from each of the military Services, OSD (Maintenance), and DLA, the JTEG’s core activities include: • Compiling information on the Services’ current and future maintenance technology insertion projects, initiatives, and depot maintenance technology needs • Formatting and disseminating relevant technology information for use throughout the depot maintenance enterprise and all relevant activities • Review of maintenance requirements and capabilities to assist cross-Service coordination and knowledge sharing for efficiency improvement • Consider technologies applicable to like or similar platforms • Minimize technology duplication • Promote emerging technologies that meet current and future joint requirements • Conduct gap analysis on the Services’ technology needs and existing capabilities • Advocate for projects that improve industrial processes, increase efficiencies, and/or reduce the environmental impact of depot maintenance.

The JTEG website, http://jteg.ncms.org, provides a forum for the exchange of information on new technology, processes, and equipment developments involving depot maintenance. Industry and DoD personnel can use the site to share technology ideas and needs.

Technology forums scheduled by the JTEG: • Dec 15 - Composite Material Repair Update • Jan 26 - Maintenance Innovation Challenge Finalists • Feb 23 - Cyber Security; Overcoming Challenges to Innovation • Mar 29 – Laser De-Paint Update / Automated Painting & De-painting • Apr 26 – Environmental Impacts & Worker Safety • May – CTMA Partners’ Meeting • Jun 28 – Ergonomics; Protecting the Workforce • Jul 26 – Alternate Energy / Energy Efficiencies • Aug 30 – Welding Inspection, Operations, and Training • Sep 27 – Asset Visibility; What, Where and Condition • Oct 25 – Fiber Optic Systems Repair, Test, and Training • Nov 29 – Technology Enhanced Workforce Development • Dec 20 – Additive Repair Supporting Maintenance Operations

JTEG Principals and key representatives:

• Gregory J. Kilchenstein: Director, Enterprise Maintenance Technology, ODASD (Maintenance Policy & Programs), OSD JTEG Principal (703-614-0862, [email protected])
• Bruce A. Wilhelm: Director, Industrial Business Operations (AIR-6.7.7), Naval Air Systems Command, NAVAIR JTEG Principal (301-995-1806, [email protected])
• Eric D. Hoover: Industrial Base Lead, Edgewood Chemical Biological Center, Army JTEG Principal (309-782-1077, [email protected])
• Gerald Bates: Chief of Organic Industrial Base Sustainment / Operations Division, G-3/4, Headquarters, U.S. Army Materiel Command (AMC) (256-450-8278, [email protected])
• John R. Nestale: Workload Manager and Marine Corps MISMO, Marine Corps Logistics Command, USMC JTEG Principal (229-639-8072, [email protected])
• Gregory J. Russell: Technology Insertion Program Project Manager, Technica LLC in support of MARCORLOGCOM, USMC JTEG Alternate Principal (229-639-8072, [email protected])
• Kurt Doehnert: Senior Industrial Engineer, Naval Sea Systems Command (NAVSEA), NAVSEA JTEG Principal (202-781-3312, [email protected])
• Luke H. Burke: Technical Director, Directorate of Logistics, Civil Engineering, and Force Protection, HQ Air Force Materiel Command, USAF JTEG Co-Principal (937-257-6615, [email protected])
• Thomas Naguy: Deputy Division Chief and Technical Advisor, Air Force Materiel Center (AFMC) Life Cycle Management Division, USAF JTEG Co-Principal (937-904-0075, [email protected])
• Robert E. Kestler: Science & Technology Lead, Fleet Readiness Center - East (FRC East), Naval Air System Command (NAVAIR) (252-464-9888, [email protected])
• Steven J. Morani: Deputy Chief, Maintenance Division, Joint Staff Logistics Directorate (J-4), Joint Staff JTEG Principal (571-256-1834, [email protected])

Commercial Technologies for Maintenance Activities (CTMA)

COMMERCIAL TECHNOLOGIES FOR MAINTENANCE ACTIVITIES (CTMA) The Commercial Technologies for Maintenance Activities (CTMA) program is a joint Department of Defense/NCMS effort promoting collaborative technology development, demonstration and transition within DoD. Its objective is to ensure American troops and their equipment are ready to face any situation, with the most up-to-date and best-maintained platforms and tools available. Under CTMA, government/industry teams form collaborative partnerships between DoD, private industry and academia to enhance warfighter readiness by providing new and innovative sustainment solutions that meet their needs.

STREAMLINED TECH TRANSITION: For over 17 years, CTMA collaborative teams have been successfully pioneering innovative, award winning Mx technologies such as laser coating removal, advanced electrical wiring test systems, expeditionary fluid analysis, additive Manufacturing and big data across multiple depots, ALCs, Naval shipyards, as well as field-level maintenance activities and headquarters organizations. CTMA offers a tremendous competitive advantage for your technology deployment and offers our industry partners a venue for increasing the visibility and validation of their technologies throughout the DoD.

NEUTRAL FACILITATOR & IP PROTECTION: NCMS forms and manages the project teams, and facilitates technology development, deployment and validation for use with the DoD’s sustainment activities. IP ownership is protected through an iron-clad collaborative agreement between NCMS and each team participant. OSD serves as the advocate for the diffusion of technology solutions within the DoD maintenance operations.

Collaborative Business Model: The CTMA business model starts with a DoD entity, typically a maintenance depot with a defined need. A team is quickly formed with one or more technology providers (oftentimes small entrepreneurs) who can address the need, and a technology integrator who has the ability to combine multiple technologies into a workable system leading to a demonstrated solution.

CTMA Track Record & Key Pillars:

• Cooperative Agreement: Under the CTMA Cooperative Agreement, the DoD maintenance activities have a unique contract vehicle to demonstrate commercial developments for application to solve issues prior to full acquisition.
• Streamlined Process: CTMA program has a unique ability to cut through “red tape” and launch a new project within 45 days of receiving approval to proceed with a project or initiative.
• Cross-Industry: A robust collaborative environment with private industry participants and academia to perform research, development, and deployment that is relevant to both industry and the military.
• Agile Collaboration: CTMA “Agile” Collaboration is our experience-driven way of quickly organizing initiatives and securing the most effective technologies at best cost up front.

2015 MIC Finalists Overview

Maintenance Innovation Challenge Monday, December 7, 2015 | 3:00 - 4:30 p.m. | North 129 AB

Moderator: Greg Kilchenstein, Director, Enterprise Maintenance Technology OSD Maintenance Policy and Programs

Finalists:

1. Automated Debris Analysis for At-line Maintainers - Steve Odom, GasTOPS
2. Using Voice Directed Technology for Transforming Maintenance & Inspection Ops - Prakash Somasundaram, Honeywell
3. Phased Array Ultrasonic Testing for Increased Accuracy and Repeatability - LT Chris MacLean, Pearl Harbor NSY/IMF
4. NOKOMIS Advanced Detection of Electronic Counterfeits (ADEC) - Bryan Neva, NAVAIR AAT IPT
5. USCG Aviation Bonded Material Inspection System - Rusty Waldrop, USCG
6. Assembled Replacement Integrated Circuits (ARICs) - Corey Kopp, NUWC Keyport

Finalist: Automated Debris Analysis for At-line Maintainers

Presenter: Steve Odom (Aerowing / GasTOPS Inc) Contact: (256) 562-1120 | [email protected]

Damage of oil-wetted components within engines and gearboxes are a major safety concern and a significant cost driver for major weapon systems across all branches of the DoD.

Correct and rapid alloy identification of oil-borne debris captured on chip detectors, filters, sump screens and magnetic plugs is critical for the maintainer to identify and assess the health of an engine or gearbox and to drive maintenance decisions. Traditional methods of assessing debris based on subjective visual inspections often lead to misdiagnosis and incorrect maintenance decisions resulting in high rate of No Evidence of Failure (NEOF) Removals/Overhauls of components at significant cost. Off-site laboratory verification of debris introduces significant delays in the determination of equipment condition, resulting in extended unavailability of critical equipment while awaiting results. The ability to have rapid, accurate, quantitative analysis of debris by non-expert at-line maintenance personnel is not available today and represents a significant change to the current state of the art that will result in major reductions in O&M cost, improved safety and maximized availability of critical weapon systems.

This presentation describes a new and innovative diagnostic tool that brings the unique capability of providing at-line maintenance personnel with immediate information on the quantity, alloy type, size, and shape of debris particles allowing them to make non-subjective, conclusive fact-based decisions regarding the health of the equipment asset and take appropriate maintenance actions.

The instrument uses digital image capture in combination with an innovative spectroscopy system to automatically locate and analyse particles placed on a sample sheet inserted into the device. The analysis determines the particle quantity, as well as size, shape, composition, and alloy type of all particles on the sample sheet and applies embedded diagnostic rules to trigger GO/NO-GO maintenance decision assessment. The instrument has been designed for operation by at-line maintainers, provides full automated analysis at the touch of a button, requires no special training to operate or assess results and is rapidly deployable by the using unit for expeditionary operations.

The device has been successfully demonstrated in several field trials including at two Air Force bases under an AFRL/RTOC project (final report: AFRL-RZ-WP-TR-2010-2151). Test data from this project confirmed that the device is capable of analyzing and correctly identifying key materials commonly found within the oil systems of critical DoD weapon systems.

The device has also been fielded at GasTOPS in Dartmouth processing damage debris from the CH149 Cormorant aircraft. Results of this activity have demonstrated complete correlation of the results with traditional laboratory analyses performed via SEM-EDX. Simplicity, reliability, portability, low cost and powerful analysis capabilities combine to make this automated debris analysis device a truly innovative and practical maintenance support tool that is available today.

Finalist: Using Voice Directed Technology for Transforming Maintenance & Inspection Operations

Presenter: Prakash Somasundaram (Honeywell) Contact: (412) 349-2411 | [email protected]

Maintenance and inspections of mission critical assets - from aircraft to ground based vehicles - require the use of well-defined checklists to be followed by the maintenance technicians and detailed documentation of services performed for record keeping.

This process is beset by inefficiencies. It requires the technicians working in these hands-busy, eyes-busy environments to enter their observations and findings as a separate step from the actual visual and manual asset inspections. Honeywell’s Vocollect™ voice-directed solution enables technicians to elevate their documentation and compliance to levels never before attainable. Most importantly, it will enable the DoD to standardize and modernize maintenance processes to better support the warfighters’ mission goals.

The solution consists of a wearable mobile device and a wireless headset with microphone. Technicians listen to checklist instructions and capture their observations by simply speaking their responses. This eliminates outdated back-and-forth manual data entry and look-up time on a laptop, handheld device or paper forms. The solution also ensures that the technicians strictly adhere to the standard operating procedure for a given type of asset. The data captured is automatically transferred to any DoD EAM/back end system for record keeping.

The use of this technology for aviation maintenance at Hill Air Force Base and other commercial customers such as Lufthansa Technik has significantly improved the quality of service, asset turn-around time and error rates.

For example, the use of voice for inspection of auxiliary power units at the Honeywell Aerospace Phoenix facility resulted in a 30%+ reduction in data entry cycle time. A large truck fleet maintenance operation has reduced asset inspection time by 25% while enabling quicker training of new employees. Lufthansa Technik has eliminated significant time spent on using spreadsheets for the induction of APUs in their Hamburg, Germany facility. Other sites such as Cherry Point—USMC Air Station for induction on F16 and Osprey APUs, US Army ANAD—Anniston for A1A tank parts inspection and USMC Blount Island—MPS for inspections/repairs on Assault Amphibious Vehicles (AAVs) have recognized the value of voice and see the potential for substantial process efficiency gains.

The simplicity and intuitiveness of spoken interactions have enabled rapid adoption of this technology by the technicians. For DoD leadership, it provides detailed real-time visibility into the status of every inspection and helps to identify bottlenecks.

Finalist: Phased Array Ultrasonic Testing for Increased Accuracy and Repeatability of Structural Hull Weld Inspections

Presenter: LT Christopher G. MacLean Organization: Pearl Harbor Naval Shipyard and Intermediate Maintenance Facility (PHNSY&IMF) Contact: 808-620-5461 | [email protected]

As part of the Navy’s SUBSAFE Program, non-destructive testing and inspections are required to provide maximum reasonable assurance that submarine hulls remain structurally sound and watertight. This includes periodic testing as well as certification of critical elements affected during submarine maintenance periods. The traditional method of ultrasonic non-destructive testing is burdensome in both time and cost. The development and evolution of Phased Array Ultrasonic Testing (PAUT) technology has not only proven more accurate and reliable over traditional methods, it’s also faster and less expensive. Successful implementation of PAUT for Naval Shipyard pipe weld inspection has resulted in cost savings, to date, in excess of 2.5 million dollars.

Conventional ultrasonic systems have been used successfully for years but are lacking in various areas. They don’t have a permanent record of raw inspection data for post-inspection analysis. Data must be collected at the work site, which can be extremely cumbersome given the complex geometries and confined spaces associated with submarine maintenance. Conventional transducers are moved manually resulting in inconsistent coverage. Discontinuity length and location are measured manually and recorded on paper. The detection of weld discontinuities using the traditional system is highly dependent on the orientation of the discontinuity and the angle of the single fixed ultrasonic beam used. To precisely determine measurements of critical flaws using convention methods, follow-up testing is required using multiple inspection set-ups with several fixed inspection angles.

Utilizing Phased Array Ultrasonic Test systems, inspection data is encoded and stored digitally, providing composite images of discontinuities. This reduces dependence on operators to visually identify discontinuities on the display while simultaneously manually scanning the site. Encoded data can be analyzed off-site and provides consistent location and length measurements resulting in increased accuracy for determination of indication growth. Electronic beam steering allows multiple optimum inspection angles (e.g., 40° to 70°) to be generated simultaneously from one PAUT transducer increasing the probability of discontinuity detection. Electronic beam focusing permits optimizing the beam shape and size at the expected defect location. Additionally, this beam focusing increases the probability of detection and improves the ability to accurately size critical defects. Transducers are indexed in mechanical scanners providing consistent coverage and requiring less surface area to scan, resulting in better acoustic coupling and reduction of the influence of human factors on scanning reliability (e.g., inattention, fatigue, stress).

PAUT technology requires less time for inspection and boosts operator confidence given the additional information provided and electronically recorded for post-inspection analysis. Follow-up inspections are reduced due to increased ability to characterize and size discontinuities during initial scans, resulting in cost and schedule savings. Lastly, Time of Flight Diffraction techniques can also be utilized, for increased detection and sizing.

Side-by-side comparisons of field (shipboard) and mock-up inspections utilizing conventional UT and PAUT are ongoing at PHNSY&IMF to identify and validate the applicability and cost savings of PAUT for structural hull weld inspections.

Finalist: The Detection and Prevention of Counterfeit/Defective Electronic Integrated Circuits (ICs) Using the NOKOMIS ADEC Sensor System

Presenter: Bryan J. Neva, Sr., BSEE, MBA Organization: NAVAIR, Fleet Readiness Center South West (FRCSW) Contact: (619) 545-2967 | [email protected]

Counterfeit/defective electronic Integrated Circuits (ICs) have been infiltrating the DoD supply chain for years, wreaking havoc, and costing the DoD hundreds of millions of dollars. In fact, SAE International Director, Bruce Mahone, at the December 2013 SAE G-19A meeting, estimated the cost per counterfeit incident to be $2.8M.ThisestimateisconsistentwithLTGPatrickO’Reilly,DirectoroftheMissileDefenseAgency(MDA)from2008–2012,whostatedthatasinglecounterfeitpartfortheTHAADmissilesystemcosttheprogram$2.78M. Furthermore, the need for advanced counterfeit/defective electronic IC detection technology is well established in the requirements of the 2012 National Defense Authorization Act (NDAA), DoDI 4140.67, DoDI 5200.44, Air Force Pamphlet (AFPAM) 63-113, DFARS 252.246–7007, and SECNAVINST 4855.20.

Like many other DoD organizations, the Fleet Readiness Center Southwest (FRCSW) Avionics Manufacturing/Repair department has been victimized by counterfeit/defective ICs. These counterfeit/defective ICs have resulted in quality control issues, latent/premature failures, and increased life-cycle maintenance costs for the FRCs customers. Unfortunately, FRCSW has not been able to effectively detect and prevent counterfeit/defective ICs using standard, visual inspection methods. Legacy detection methods (which are 82% accurate) are either impractical or too expensive to implement here.

A newer, more practical, and elegant testing method to detect counterfeit electronic ICs (which is 99% accurate), called the Electromagnetic Emission Signature (EES) testing method, has been developed by NOKOMIS, Inc., topic MDA12-026 and AF09-013. The NOKOMIS Advanced Detection of Electronic Counterfeits (ADEC) Sensor System uses the characteristic electromagnetic signatures that all electronic devices give off in order to spot counterfeits and immediately alert the technician. It’s fast, easy to use, requires minimal training to perform, and is relatively inexpensive compared to other legacy detection methods. The FRCSW Advanced Aircraft Technologies (AAT) team believes the EES testing method to be the most advanced and cost effective technology for counterfeit detection available today and will eventually replace many of the legacy counterfeit detection technologies (Microscopic, X-Ray, X-RF, De-capsulation, and Parametric).

By investing in the NOKOMIS ADEC Sensor System, FRCSW could immediately see cost savings, recouping their investment in less than a year. (Preventing a single counterfeit/defective IC from being integrated into one avionics devices would pay for the entire effort.) Further, Inserting the NOKOMIS ADEC Sensor System at all FRC facilities is a cost effective way to comply with the SECNAVINST 4855.20 directive to implement counterfeit detection at Navy repair sites. The FRCSW AAT recommends considering LP-CRADA for system evaluation and SBIR Phase II.5 project funding for additional R&D.

Finalist: USCG Aviation Bonded Material Inspection System

Presenter: Rusty G. Waldrop Organization: U.S. Coast Guard Contact: (252) 333-2760 | [email protected]

Many United States Coast Guard aviation assets contain lightweight composite materials in their construction. These advanced materials realize reduced fuel consumption, increased corrosion resistance, and, in many applications, increased strength-to-weight ratio. In turn, these types of materials present unique challenges when non-destructively inspecting them to ensure serviceability.

The Coast Guard has been inspecting these components using the dated method of tap testing, literally using a solid metal object to tap the surface while the technician listens for aural indications of an anomaly. This technique is obviously subjective in nature and has many unreliable variables. An ultrasonic method of inspection was prototyped as well and found to be an acceptable replacement for some tap test applications, but was time consuming to set up and did not remove much of the subjectivity and therefore not adopted wholesale. However, recent technological advances in the field of non-destructive inspection produced Bonded Material Tester (BMT) technology. This method is actually the next generation of ultrasonic inspection and interrogates bonded materials for skin-to-core and inner ply separations layer by layer, allowing for minimally-invasive in-service inspections to evaluate on-wing component condition, typically during scheduled maintenance evolutions.

The Coast Guard has invested in BMT technology; it has trained unit-level instructors across its operational and depot maintenance facilities, developed and implemented maintenance procedures, and fielded portable BMT units. The investment in the technology has shown promising returns on labor efficiency, maintenance proficiency, and airworthiness. Set up time is minimal and inspection evolutions are more efficient, realizing significant labor savings over conventional testing methods and allowing maintenance managers to reallocate saved time to other maintenance tasks. In addition to being more efficient, these inspections are more proficient; they are based on an objective signal return from the equipment, removing human error derived from deciphering subjective signals. A high probability of accurate detection has been achieved by inspectors-in-training: 100% success rate in locating an unbonded condition on a structural component when the same inspectors-in-training achieved 0% success in locating the same unbonded condition utilizing tap test methodology. This success highlights BMT’s viable role in ensuring airworthiness through safe, effective maintenance and repair.

Finalist: Assembled Replacement Integrated Circuits (ARICs)

Presenter: Corey Kopp Organization: NUWC Keyport Contact: 360-315-3439 | [email protected]

BLUF: Naval Undersea Warfare Center (NUWC) Division Keyport has developed and been utilizing a means to fabricate drop-in replacements for obsolete integrated circuits.

Abstract: A significant and growing technical challenge for the Navy across all platforms is obsolescence of discontinued integrated circuits (ICs). When no suitable substitutes are available, expensive design changes, requalification, and documentation changes are often required. Naval Undersea Warfare Center (NUWC) Division Keyport has developed a means to fabricate drop-in replacements for these ICs, extending the maintainable life of the assembly and achieving considerable cost savings by avoiding assembly redesign, requalification, logistics and documentation changes, etc.

As an early example of this, NUWC Keyport completed an obsolescence study of the RT-1379A/ASW System. It contained a total of 217 unique electronic components, including semiconductor devices. Of these, 59 components were no longer available. As part of a RT-1379 life extension, Keyport was contracted by NAVICP Philadelphia to reverse engineer two circuit card assemblies and to stand up a depot.

The focus of the effort was twofold: (1) to minimize qualification and documentation changes and (2) to extend the reparability of the radio. To accomplish these goals, three obsolete ICs were replaced with small circuit cards made to mimic the ICs’ form, fit, and performance: IO Port, Majority Gate, and Line Driver ICs. These chips were completed, installed in circuit cards, and delivered to the fleet in RT-1379 radios repaired in the Keyport depot. For the RT-1379A system, use of these ARICs enabled an estimated cost-avoidance of $2M in qualification testing alone, not even considering other cost drivers.

The fabricated substitute ICs came to be known as Assembled Replacement Integrated Circuits (ARICs). The basic concept is to build IC-sized replacement assemblies to resolve chip obsolescence as drop-in replacements. ARIC PCBs include Complex Programmable Logic Devices (CPLDs) and/or Field-Programmable Gate Arrays (FPGAs) programmed with custom Very High Speed Integrated Circuit (VHSIC) Hardware Description Language (VHDL) to emulate the target ICs.

Using this concept, Keyport has also developed ARIC replacement for an obsolete Airborne Low Frequency Sonar system (ALFS) Analog to Digital Converter (ADC) chip, replacement AM2942 Programmable Timer/Counter DMA Address Generator ICs and resistor network ICs for B1-B Bomber CPU Assemblies, and several others.

To further enhance this capability, Keyport also designed and fabricated a custom, handheld ARIC programmer with a touchscreen user interface and “blank” ARIC boards. These ARIC blanks can be field-programmed to emulate numerous common 14-pin and 16-pin 54/74 series Logic ICs or custom 5V logic chips. These programmable ARICs can be used as troubleshooting aids or as permanent solutions to replace obsolete or failed ICs.

Submission: Encourage Innovation

Presenter: Brian Anderson Organization: Anniston Army Depot Contact: (256) 235-6268 | [email protected]

In the last several decades, Department of Defense applications of innovative manufacturing technology as applied to maintenance operations has lagged behind that of similar commercial corporations. Part of the reason is that global competition has driven competitiveness and cost cutting measures across all levels of commercial business including maintenance and repair programs. While there are innovative and enthusiastic people within the DOD, making change to legacy process and procedures proves difficult in a predominately non-technical environment.

Various methods of making change exist within Department of Defense, some of these are the suggestion program, engineering change proposal and even value engineering. Yet even with these programs, change is at a snail’s pace or not at all. Innovation, creativity or invention has come to be seen as a philosophy that only exist in the commercial world and not within the confines of government.

The suggestion program needs a suggestion for improvement and value engineering needs to be re-engineered. Rather than an extensive analysis of the existing system, a better approach might be to establish or transition to a system which is based on the architecture currently used by a commercial business. As an example, Honeywell has GRMS (Global Repair Management System), a system that routes proposed technology applications electronically though designated departments and archives inputs and evaluations.

Submission: Applying the Intermittent Fault Detection & Isolation System (IFDIS)

Presenter: Les Stone, Bryan Steadman and Ken Anderson Organization: USAF 523rd EMXS and Universal Synaptics and Total Quality Systems Contact: (801) 731-8508 ext 1 | [email protected]

No Fault Found (NFF) test results in electronic boxes, primarily driven by intermittent faults, have become a significant concern and huge maintenance and life-cycle cost driver, and an operational readiness degrader within the DoD. For many DoD weapon system components driven to the depot for repair, less than half have the actual root cause of the problem identified and repaired. The other half test NFF. Currently, NFF is a $2Bto$10B annual expense for the DoD.

The Intermittent Fault Detection & Isolation System™ (IFDIS™) was specifically designed to detect and isolate intermittent faults in electronic wiring. Its initial adaptation was to detect and isolate the intermittent faults in the F-16 AN/APG-68 Radar System Modular Low Power Radio Frequency unit (MLPRF) chassis. The operational reliability of the IFDIS tested MLPRFs has more than tripled. A cost benefit of over $114millionhasalreadybeenrealizedwithaninvestmentofonly$2.2 million. IFDIS has been expanded to interrogate the F-16 AN/APG 68 Radar Programmable Signal Processor (PSP) with over 8,000 internal connection points, providing an ROI in just six months.

Submission: IUID Transparent Data Collection with RFID

Presenter: Jon Andresen Organization: Technology Solutions LLC Contact: (510) 531-2201 | [email protected]

Establishing the UID Policy was a huge step forward for the DoD. The 2D barcodes that are required for IUID require that each part be touched and seen by a barcode reader. That same IUID data structure can now be replicated in an EPC Gen2 RFID tag that does not require line-of sight to each part. In 2009 the GS1/EPC Global organization granted a new RFID identifier called the ADI format for Aerospace & Defense Indicator. The ADI format allows the RFID tag to be encoded with CAGE Code, Serial Number, Part number, expiration date, overhaul date, etc. in ASCII characters. Handheld RFID readers can read this data at point of use without network connections. For example, commercial aviation can read 254 life vests across an aircraft cabin in 36 seconds.

Submission: The Benefits of Condition Based Overhaul

Presenter: Jamie Bass Organization: Red River Army Depot and Caterpillar Contact: (903)-334-2548 | [email protected]

Red River Army Depot (RRAD) established a public-private partnership with Caterpillar (CAT) in 2009 to reduce costs associated with the repair of CAT engines for Army supply programs. Condition Based Overhaul (CBO) repairs or replaces only components necessary to bring the engine back to a fully operational status, rather than mandatory replacement under NMWR standards. CBO saves approximately $12k per engine. Engines are dynamometer tested and covered by a joint RRAD/CAT warranty.

Submission: Automated Optical Scanning and Computer Modeling of Engine Depot Components

Presenter: Jeffrey M. Brown Organization: AFRL/RQTI Contact: (937) 255-7223 | [email protected]

Automating geometric tolerance measurements using 3D optical scanning capturing surface geometry within 0.0005 inches. AFRL developed software tools that morph available design process computer models to measurement data, enabling capability-based predictions to evaluate part safety and extend part life beyond legacy blueprint limits.

Submission: External MORTORQ® Super Spiral Drive System

Presenter: Ken Campitelli Organization: Phillips Screw Company Contact: (760) 884-6700 | [email protected]

The External MORTORQ Super bolt design provides 1.4 times drive surface contact area and 2.5 times removal surface contact area while reducing head height by 20% to 30% compared to conventional 12-point or hex flange bolts, saving 30 lbs per 1000 pieces.

Submission: E-2D Rotodome Assembly Maintenance System (RAMS)

Presenter: Shane Campana Organization: Naval Air Warfare Center Aircraft Division Lakehurst (NAWCADLKE) Contact: (732) 323-5050 | [email protected]

Air/ship/land transportable system for assembling and repairing the 24-foot diameter, 3,200 lb E-2D Rotodome in forward operating locations, utilizing scissors jacks, linear screws, and precision pneumatic positioning pads.

Submission: Reliability Engineering Data Integration (REDI)

Presenter: Michael A DiPilla Organization: NSWC Philadelphia Contact: (215) 897-1051 | [email protected]

REDI uses an Enterprise Service Bus and HTML5 tablet application to integrate disparate Navy legacy maintenance and logistics databases (ICMP, CDMD-OA, technical manuals), allowing offline work and automated data syncing at point of performance.

Submission: Asset Information Management Solution (AIMS)

Presenter: Matthew Edwards Organization: Troika Solutions LLC Contact: 812-279-8800 | [email protected]

Automated asset tracking and accountability software utilizing IUID, biometrics, and RFID. Demonstrated at USMC School of Infantry-West armory, improving check-in accuracy from 80% to 98% and saving 33 man-hours per incoming class.

Submission: Affordable Maintenance Through Partnership (Aerowing)

Presenter: Mike Evans Organization: Aerowing Contact: (702) 204-7533 | [email protected]

Rapid response fuel leak repair using reverse leak mapping, rapid sealant removal tools, accelerated automated curing, and tracer gas verification to resolve fuel leaks on-site within 24 hours.

Submission: Laser-Cladding: The Future of VLS Tube Repair

Presenter: LT Mark Ewachiw Organization: Pearl Harbor Naval Shipyard & Intermediate Maintenance Facility Contact: [email protected]

Automated laser cladding deposits Inconel-625 weld metal onto Vertical Launch System (VLS) tube sealing surfaces to repair saltwater pitting corrosion, replacing toxic brush electroplating and extending repair lifespan from 1-1.5 years to an estimated 10 years.

Submission: Resource Constrained Activity Network (RCAN)

Presenter: Paul Fithian and Dr. Scott Schultz Organization: Mercer Engineering Research Center (MERC) Contact: (478) 953-6800 | [email protected], [email protected]

Simulation modeling software in Arena/Excel for Programmed Depot Maintenance (PDM) manpower scheduling and resource allocation on C-130 and C-5 aircraft.

Submission: Plasma Spray of Ceramic Coatings for Component Longevity

Presenter: Alex Frank Organization: NUWC Keyport Contact: [email protected]

Advanced robotic plasma spray application of alumina-titania nano-ceramic coatings on submarine and fleet machinery components to provide wear, corrosion, and marine growth resistance, helping reduce the Navy’s $2.4B–$3.2B annual corrosion cost.

Submission: In-Situ Robotics for Fleet Maintenance

Presenter: Joel Galles Organization: NUWC Keyport Contact: 360-396-1983 | [email protected]

Development of micro-robotics and automation systems for in-situ laser cladding repair and CNC grinding/machining of unremovable shipboard components (valves, pumps, actuators) aboard naval vessels.

Submission: Additive Manufacturing for the B-52 Stratofortress Radar Blower Motor Assembly

Presenter: Scott Gray Organization: Elevate Systems Contact: (210) 807-9981 | [email protected]

Reverse engineering and 3D printing of B-52 blower motor impellers using Ultem 9085 thermoplastic (FDM) and aluminum (DMLS). Ultem impeller is 52% lighter, costs $350vs$3,500 for metal, and achieves a 10x cost reduction.

Submission: Membrane Dehydrator

Presenter: Edgardo S. Guevara Organization: United States Coast Guard Contact: (410) 762-6616 | [email protected]

Membrane dehydrator system for real-time removal of free, dispersed, and dissolved water from lubricating oils and Environmentally Acceptable Lubricants (EALs) without removing additives; tested on USCGC WAESCHE and USCGC ALDER.

Submission: Removal of Polyurea-Based Coatings

Presenter: Atish Gupta Organization: NAVAIR Lakehurst-4.3.4.2 Materials Engineering Contact: (732) 323-7550 | [email protected]

Magnetic induction heating tool that rapidly heats ferrous metal substrates to debond and strip durable, zero-VOC polyurea protective coatings from aircraft tow tractors in 10-15 min/sq ft.

Submission: MRO Business Process Innovation - Flow Optimization

Presenter: Michael Hamlin Organization: Realization Technologies, Inc. Contact: (503) 351-2026 | [email protected]

Focusing on flow optimization rather than resource optimization in F-18 depot maintenance, improving cycle times by 50%, throughput by 42%, and asset availability by 5%.

Submission: The Superfreeze Initiative

Presenter: LT Daniel Hogue, USN Organization: Pearl Harbor Naval Shipyard and Intermediate Maintenance Facility Contact: (808) 368-0922 | [email protected]

Stand-alone enclosed Freon freeze seal isolation system for submarine propulsion plant valve replacement on Los Angeles-class submarines, saving 5,400 man-hours ($161,000) per valve replacement.

Submission: Rotorcraft Optimized Structural Health Monitoring (SHM)

Presenter: Mr. Donathan Hutchings Organization: AVNIK Defense Solutions / US Army AMRDEC Contact: [email protected]

Machine learning-optimized piezoelectric sensor layouts providing 6-7x higher sensitivity with 50% fewer sensors, coupled with a 3D GUI interface (SHMIS) to detect cracks and corrosion as small as 0.01 inches.

Submission: Real-time Aircraft Structural Health Monitoring Systems

Presenter: Amrita Kumar, Roy Ikegami, Jeffrey Bergman Organization: Acellent Technologies Inc. Contact: (408) 745 1188 | [email protected]

SMART Layer transducer networks with integrated hardware and software for real-time detection and quantification of fatigue cracks, corrosion, and composite impact damage on rotorcraft and fixed-wing aircraft.

Submission: The ‘Pacman’ Wrench

Presenter: LCDR Nick Levine, Chris Orimoto Organization: Pearl Harbor Naval Shipyard and Intermediate Maintenance Facility Contact: (808) 306-9325 | [email protected]

Custom high-temperature steel slugging crow’s foot wrench designed to reinstall submarine shaft vibration reducer piping in tight quarters, saving 16 man-days and avoiding $15,000+ in component damage.

Submission: Data Driven Overhaul Scheduling of Aircraft Support Equipment

Presenter: Victor Rodriguez, Sean Loftus, Denise Orthner, and Atish Gupta Organization: Patuxent River and Lakehurst Materials Engineering Contact: 732-323-1892 | [email protected]

Transitioning Support Equipment from fixed 3-year overhaul cycles to condition-based scheduling using environmental corrosion sensors and predictive degradation modeling.

Submission: Assessment of Impacts of Commercial Practices to F117 Engine

Presenter: Gordon Malboeuf Organization: Chromalloy Gas Turbine, LLC Contact: (405) 733-1756 | [email protected]

Leveraging commercial PW2000 airline maintenance and repair practices for the military F117-PW-100 engine (C-17), which shares 91% part commonality, reducing life cycle sustainment costs.

Submission: Ultrasonic Shot Peening Yields Significant Savings on Repairs

Presenter: Kelly McClurg Organization: Avion Solutions, Inc. Contact: (256) 327-7185 | [email protected]

SONATS StressSonic® Ruggedized Ultrasonic Shot Peening (USP) uses an enclosed chamber eliminating tenting for FOD containment. Repaired >500 UH-60M Black Hawk wide chord blade titanium cuffs with >$60M cost avoidance.

Submission: USCG MH-65 Tail Rotor Maintenance Stand

Presenter: Tom McCormick Organization: U.S. Coast Guard Contact: (252) 335-6363 | [email protected]

Ergonomic dual-workstation maintenance stand utilizing tail gearbox spline shafts to securely hold and rotate 10-blade MH-65 Dauphin helicopter tail rotor hubs during overhaul.

Submission: 3D Metal Printing for the Factory Floor

Presenter: Tom McDonald Organization: Optomec, Inc. Contact: (401) 598-6665 | [email protected]

LENS Print Engine (LPE) modular kit that integrates laser powder deposition metal 3D printing onto standard CNC machine tools for hybrid additive/subtractive manufacturing and direct repair.

Submission: Sourcing Broker

Presenter: Jerome McGovern Organization: Troika Solutions LLC Contact: (774) 571-0811 | [email protected]

Automated intermediary request distribution platform for deployed Marine Expeditionary Units (MEU) to optimize parts requisitioning across DLA, Navy, and NATO supply systems without manual ‘swivel chair’ workflows.

Submission: All-Metal Thermal Control Valves

Presenter: John Meyer Organization: Senior Aerospace Metal Bellows Contact: 781-302-1214 | [email protected]

Replacing deteriorating rubber diaphragms in aircraft engine thermal valves with welded metal bellows, tested up to 3.1 million deflection cycles and 184,000 thermal cycles with zero failures.

Submission: Large Sensor Arrays for Navigation

Presenter: Chris Moll Organization: NUWC Keyport Contact: (360) 315-3365 | [email protected]

Integrating large arrays of inexpensive MEMS sensors (330 units) to emulate expensive Ring Laser Gyro (RLG) and Fiber Optic Gyro (FOG) accuracy in shipboard inertial navigation systems.

Submission: Big RUPHIS: Rotor Universal Positioning & Handling Integrated System

Presenter: Trent Mulcrone Organization: McNally Industries, LLC Contact: 651-346-9230 | [email protected]

Balanced fulcrum clamp tool for CH-47 Chinook 300+ lb main rotor blades allowing two soldiers to safely lift, rotate, and load blades into storage carts (reducing requirement from six soldiers).

Submission: Inspection, Corrosion, and Repair Reporting (ICARR-3D)

Presenter: William H. Osborne, Jr. Organization: Mercer Engineering Research Center (MERC) Contact: (478) 953-6800 ext. 2539 | [email protected]

Digital 3D model point-of-maintenance defect mapping and data entry tool supporting CBM+; integrated into the C-130 Automated Inspection, Repair, Corrosion, and Aircraft Tracking (AIRCAT) program.

Submission: USCG MRS On-Wing Flight Control Balance Tool

Presenter: Harlon Parchment Organization: U.S. Coast Guard Contact: (252) 335-6433 | [email protected]

Portable on-wing balancing fixture for HC-144 Ocean Sentry elevator repairs, eliminating the need to ship large flight surfaces to the depot in Elizabeth City, NC.

Submission: Health Monitoring of Helicopter Dampers Using Analytical Modeling and Sensor Inputs

Presenter: Ashish Purekar Organization: InnoVital Systems, Inc. Contact: (240) 790-0582 | [email protected]

Hydro-mechanical analytical modeling combined with non-linear Kalman filtering to monitor internal states and track slow degradation of UH-60 Black Hawk lead-lag hydraulic dampers.

Submission: RFID Network System for Automatic Item Inventory Taking and Readiness

Presenter: Rafael Ramos, Adalberto Teran and Hector Gomez-Macfarland Organization: IDZ Technologies, Inc. Contact: (210) 889-4417 | [email protected]

Passive HF RFID network placed inside toolboxes to track tools at the pocket level in real-time, coupled with an active 802.15.4 mesh network for cloud-based inventory reporting; tested at Dyess AFB.

Submission: Tinker Integrated Data for Maintenance (IDM)

Presenter: Bradley J. Ramsey Organization: AFLCMC/LZPTP Contact: (405) 736-2227 | [email protected]

COTS/GOTS content management system storing dynamic technical order components to standardize workflows and enable reuse across USAF and FMS platforms (B-1, B-52, E-3, KC-135).

Submission: GBU-X/AGM-X Logistics Analysis

Presenter: Leo Rose Organization: AFRL/RWPI Contact: (850) 883-2188 | [email protected]

Logistics footprint characterization of legacy conventional air-to-surface munitions to guide open-system architecture and modular subsystem designs for 6th-generation aircraft weapons.

Submission: Study of Hexavalent Chromium Conversion Secondary to Laser Ablation

Presenter: Jim Russell Organization: General Lasertronics Corporation (“Lasertronics”) Contact: (206) 782-6666 | [email protected]

Demonstration that pulsed laser ablation stripping of zinc chromate aircraft primer converts carcinogenic Cr6+ into benign chromium species in the vapor phase, eliminating toxic exposure.

Submission: Handling and Installation Impact on Rotary Carbon Face Seal Performance

Presenter: Paul R. Ryan Organization: Magnetic Seal Corp Contact: (401) 247-2800 ext 123 | [email protected]

Transitioning rotary seal designs to pre-assembled plug-and-play cartridges and implementing 3D PDF training animations to prevent premature failure from improper handling.

Submission: Leveraging Weapon System Data to Drive Efficient Depot Maintenance Induction

Presenter: Robbie Sargent Organization: Booz Allen Hamilton Contact: (410) 297-2549 | [email protected]

Maintenance Prioritization Model (MPM) utilizing big data analytics and decision tree regression on sensor/telemetry data to rank-order depot induction based on true condition rather than age.

Submission: Direct Measurement of Energy in Additive Manufacturing (AM)

Presenter: Federico Sciammarella Organization: Northern Illinois University Contact: (815)-753-1288 | [email protected]

Precision calorimetric system measuring net absorbed laser power (Pnet) directly during AM builds for virtual quality control and predictable metallurgical microstructure.

Submission: Easy Machining of Hard Materials (EMHM)

Presenter: Federico Sciammarella Organization: Northern Illinois University Contact: (815) 753-1288 | [email protected]

Laser-assisted machining (LAM) of structural ceramics (silicon nitride) demonstrating 4x faster processing and nearly 5x lower part manufacturing cost ($6vs$28) compared to diamond grinding.

Submission: In situ Powder Flow Monitoring for DED AM Systems

Presenter: Federico Sciammarella Organization: Northern Illinois University Contact: (815) 753-1288 | [email protected]

Acoustic emission (AE) sensors monitoring powder flow rate in real time through LENS 3D printing build head nozzles to prevent clogs and ensure consistent melt pool geometry.

Submission: Interrogative Diagnostics Solutions (IDS)

Presenter: Bob Silva Organization: Lockheed Martin Contact: (607) 727-3456 | [email protected]

Laptop-based automated diagnostics reasoning engine interfacing with IETMs, achieving >95% Fault Detection and >95% Fault Isolation on MH-60R and eliminating false removals.

Submission: USCG MH-65 Main Gearbox Housing Repair Fixture

Presenter: Thomas Simpson Organization: U.S. Coast Guard Contact: (252) 335-6414 | [email protected]

Precision alignment fixture fabricated for a Haas VF5 CNC mill to machine corroded magnesium servo lug attachment points on MH-65 gearboxes, saving $1.5M/year and reducing lead time from 1 year to 1 month.

Submission: Develop Optimized Depot Flow Plan

Presenter: Andrew Sloper Organization: AFLCMC/WWUV Contact: (801) 777-9725 | [email protected]

Applying drum-buffer-rope Theory of Constraints to F-22 depot maintenance, reducing required depot docks from 13 to 12, increasing facility utilization by >15%, and accelerating structural retrofit completion by 10 months.

Submission: Centralized On-Demand Maintenance for Tactical Training Vehicles

Presenter: Lisa M. Smagala Organization: US Army Edgewood Chemical-Biological Center ADM Contact: 410-436-5857 | [email protected]

Centrally dispatched 2-3 person contact teams replacing fixed on-site FSR contractors across 47 training sites for 171 systems, saving $8M per year.

Submission: Cabin Pressure Leakage Testing in Hot Environments

Presenter: Bradley Smith Organization: NAVAIR 4.8.6.4 Contact: 732-323-1205 | [email protected]

Water-to-air heat exchanger system cooling compressed test air from 180°F down to 112°F, enabling aircraft cabin pressure testing at ambient temperatures above 120°F and eliminating risky test flights.

Submission: OTA Updates: Why Delta Technology is Better than Compression Techniques

Presenter: Rob Stawarz Organization: Redbend Software Contact: (313) 505-4755 | [email protected]

Differential delta update software delivering only binary changes across CAN/LIN/MOST vehicle buses, minimizing download size, transport time, and storage space during automotive/defense ECU reprogramming.

Submission: Ergonomic Assessment Using Inertial Motion Sensors

Presenter: Ed Irwin and Kristin Streilein Organization: Mercer Engineering Research Center (MERC) Contact: (478) 953-6800 | [email protected], [email protected]

XSENS wireless 3D motion capture sensors measuring joint kinematics and muscular fatigue in aircraft painters performing scuff and 50/50 sanding to quantify injury risks.

Submission: Integrated Predictive Maintenance Solutions

Presenter: Todd Stiefler Organization: GE Digital Contact: (202) 680-8685 | [email protected]

Similarity-Based Modeling (SBM) creating digital twins of machinery to detect abnormal operating behavior 3-10 weeks in advance and issue actionable maintenance work orders.

Submission: Electrical Wiring Interconnect System (EWIS) On-Wing Certification Test Protocol

Presenter: Thomas Sullivan (on behalf of Steven Blasey) Organization: 160th SOAR(A) TAG Contact: (270) 412-8616 | [email protected]

Automatic Wire Test Set (AWTS) test protocol set for on-wing testing of MH-6M FADEC wiring harnesses, isolating intermittent faults and high-resistance shields during routine maintenance.

Submission: Global Freeform Mapping using Laser Tracking and Active Target

Presenter: Ado Umezawa Organization: Automated Precision Inc. Contact: (240) 268-0400 | [email protected]

Volumetric error compensation (VEC) using a dynamic laser tracking Active Target at the tool tip to calibrate 5- and 6-axis CNC machine tools and robots in hours rather than days.

Submission: Enabling the Secure Networking of Automated Test Equipment

Presenter: Mathew VanDerPol Organization: Lockheed Martin Contact: (303) 932-4800 | [email protected]

DUTCH (Defensive Unified Trusted Cyber Hardware) hardware-enforced cyber security module providing hardware whitelisting, secure networking, and runtime memory forensics for automated test stations.

Submission: U-2S Dragonlady Snap-In Inflatable Seals

Presenter: Levi C. Wade Organization: AFLCMC/HBGEA Contact: (478) 327-2599 | [email protected]

Snap-in pneumatic seals replacing room-temperature glued seals on U-2S pressurized access hatches, eliminating scraping and curing downtime and reducing associated NMC time by 75%.

Submission: A Strategy to Provide Alternatives to Cr6+-Free and Cd-Free Maintenance Technologies

Presenter: Bob Wassmann / Dr. Robin Nissan Organization: Noblis / OSD SERDP and ESTCP Contact: (703) 610-1744 | [email protected]

A 5-year strategic roadmap and depot implementation plans (LEAD, FRCSE, OC-ALC) to eliminate >90% of toxic hexavalent chromium and cadmium across DoD maintenance depots.

Submission: Additive Manufacturing (AM) for Complex Maintenance Tooling and Training Systems

Presenter: Bryce Weber Organization: NUWC Keyport Contact: (360) 396-2625 | [email protected]

3D printed full-scale and scaled training simulators (nuclear pump system, catapult water brake) and rapid tooling fixtures to accelerate maintenance training and reduce fleet rework.

Submission: Portable Non Destructive Inspection Surface Contamination Sensor

Presenter: Dr. Wayne Weimer Organization: Agiltron, Inc. Contact: (781) 465-2654 | [email protected]

Handheld 1-second optical sensor detecting amine bloom contamination on epoxy-painted submarine hulls and pre-coating steel surfaces with 100% blind-test accuracy.

Submission: USCG C130J Hot Mock Up Test & Repair Benches

Presenter: Stephen C. Williams Organization: U.S. Coast Guard - Elizabeth City Contact: (252) 335-6248 | [email protected]

In-house built Hot Mock Ups for C-130J radar ($3,600)andcommunications($78,000) suites, enabling depot repair, avoiding OEM $350K/unitcosts,andsaving$13M in avoided NFF fees.

Submission: B-2 Additive Manufacturing

Presenter: Gregory Yort Organization: AFLCMC/WWZ Contact: (405) 739-4258 | [email protected]

B-2 System Integration Lab (SIL) FDM 3D printing of >400 equipment rack panels ($200vs$10K original cost), fuel line check fixtures (saving $599K), and hydraulic drainage bottles.

Submission: ARViSS Decision Support Application

Presenter: Feraidoon (Frank) Zahiri Organization: AFSC/ENRB Contact: (478) 327-4127 | [email protected]

Analysis of Resources with Visualization and Integrated Simulation Support (ARViSS) software providing real-time ramp-level simulation, resource tracking, and predictive depot flow analysis at Warner Robins ALC.

Submission: Data-Driven & Goal-Driven Condition-Based Predictive Maintenance (DCPM/GCPM)

Presenter: Feraidoon (Frank) Zahiri Organization: AFSC/ENRB Contact: (478) 327-4127 | [email protected]

Automated abnormality pattern detection over 10K+ measurands using DFDR and AIRCAT engine data, neural networks, and Bayesian fusion for C-130 aircraft and VDATS automatic test stations.

Submission: Expert Troubleshooting and Repair System (ETRS) Reduces ‘NFF’

Presenter: Feraidoon (Frank) Zahiri Organization: AFSC/ENRB Contact: (478) 327-4127 | [email protected]

Software algorithms augmenting VDATS test program sets to isolate soft/parametric variation faults on complex circuit card assemblies (CCAs), saving an estimated $2M/yr per bad-actor CCA part number.

Where Are They Now? (Past Winners)

2008 WINNER: Eliminating Uncertainty in Oil Condition: FluidScan Q1000 Portable Fluid Condition Monitor

• Commander Dave Scalf (Retired), Joint Oil Analysis Program Technical Support Center
• Handheld infrared analyzer with built-in oil library of over 450 fluids to deliver immediate quantitative results for water, TBN, glycol, and soot.

2010 & 2011 WINNER: IFDIS (Intermittent Fault Detection & Isolation System)

• Ken Anderson, Universal Synaptics Corp
• Catalyst to DoD-wide recognition of intermittent fault testing; fielded systems testing F/A-18 GCU and F-16 radar PSP (8000 test points) and portable Ncompass-Voyager™.

2011 WINNER: No-Mask Tooling for Electroplated Parts

• George Cushnie, Advanced Tooling Corporation
• Eliminates masking during overhaul electroplating, saving millions at depots and integrated into Warner Robins AFB plating facility.

2014 WINNER: Laser Technology for Aerospace Maintenance and Sustainment Applications

• Deb Naguy, United States Air Force
• Full robotic laser depaint system replacing chemical and media blasting on aircraft.

2016 Call for Innovations & Submission Guidelines

THE CHALLENGE IS ON! 2016 DOD Maintenance Symposium December 5-8, 2016 | Albuquerque Convention Center, Albuquerque, New Mexico, USA

Deadline for Innovations: Wednesday, September 14, 2016

Abstract Criteria:

• Must be an original contribution to the state of the art
• Technically accurate
• Must include test data or valid simulation support
• Feasible and practical
• 300-500 words abstract in Word format
• PowerPoint Quad Chart covering Problem Statement, Technology, Status, and Potential Benefits
• Submission email: Kristie Saber, SAE International ([email protected])
• Website: www.sae.org/dod