PaveHawk Programmed Depot Maintenance
The PaveHawk PDM (Programmed Depot Maintenance) is an extensive overhaul process. Because of the extensive combat usage and operating conditions, no two PaveHawks ever received the same PDM with overhaul often being as much as 25% unique per system. This required extensive inspections to be performed to ensure proper repair. Many of these inspection could not be performed until the system had been dis-assembled requiring many unique inspections located throughout the PDM flow. Due to attrition and unique combat usage, it was extremely difficult to train personnel to ensure proper inspections thus repairs were made.
The Process GuideTM (PGTM) was utilized to thoroughly document the inspections utilizing TO's (Technical Orders) and learned head knowledge to ensure proper inspections during the first pass without costly rework repairs. The standard documented discrepancies were also linked to repair packages vastly reducing re-analysis type for determining proper repairs. The PGTM implementation reduced rework 47% while reducing overall flow PDM flow days by 20.
HMMWV High Speed Maintenance
The HMMWV PDM (Programmed Depot Maintenance) line was unique because unlike traditional PDM where systems are worked one at a time, the HMMWV line was a true assembly line process churning out 26 systems a day during its peak. This required quick inspection processes with virtually zero rework to be successful.
The Process GuideTM (PGTM) was utilized to provide easily understood processes with minimal training. This enabled personnel to be easily shuffled between areas without impacting quality. Upon implementation the HMMWV was at 14 systems a day. With continued PGTM usage the final peak of 26 systems a day was reached with less than 3% QDR (Quality Deficiency Reports).
5-Ton & FMTV Programmed Depot Maintenance
The 5-ton and FMTV were lower volume, but came with many different variation of the same system. Within the 5-ton there were four primary variation including Cargo Truck, Cargo Truck W/Winch, XLWB Truck, Tractor, and Medium Wrecker. Sixty percent commonality of parts - same engines, transmissions, drivelines, power trains, tires, cabs with significant variation based on platform. Within FMTV there were 14 variations including 2.5-ton cargo and van models and 5-ton cargo, tractor, van, wrecker, tanker and dump-truck models. Eighty percent commonality of parts - same engines, transmissions, drivelines, power trains, tires, cabs but based on variation significant distinct characteristics that had to be inspected/verified. Because of the many variation it was difficult to train personnel for the unique inspections / repairs.
The Process GuideTM (PGTM) was utilized to ensure proper inspection/repair across all variations. Before implementation rework was at 42% and decreased to less than 6%. Training time was decreased almost 90%. Because maintenance was warrantee, unique serial numbers and RFID codes on critical parts were also captured for each system. Because these systems are work horses and have a long service time, the units often utilized the warranty process to obtain parts for older systems. Upon PGTM usage it was quick and easy to validate parts to a specific system virtually eliminating warranty complaints.
Fire Finder Radar Inspection and Paint
The Fire Finder radar system is an older system requiring significant upgrades to remain functional. While some upgrades were mechanical like most electronic systems, most were electronic requiring boards to be serviced, repaired, upgraded or even replaced. Much of the system still relies on older technology without the diagnostics of more advanced equipment. While technical data was available diagnosing the issue was often much difficult than the repair rendering it only partially useful.
The Process GuideTM (PGTM) was implemented within the electrical discrepancies to properly standardized issues and correct actions enabling prognostics to be utilized within repair. As much historical data as possible was standardized and deployed within the PGTM. Additional data was added as new issues were identified. Upon implementation of PGTM diagnostic time was reduced 65% and rework further reduced 41%. This reduced the overall flow days for complete repair by almost 12 days.