Readiness Sustainability through Condition Based Maintenance Plus CBM

Readiness & Sustainability through Condition Based Maintenance Plus (CBM+) OSD CBM+ Senior Leaders’ Summit CDR Jesse Black 27 November 2018 Distribution Statement A: Approved for public release; Distribution unlimited.

America’s Navy: The Next Generation Distribution Statement A: Approved for public release; Distribution unlimited. 2

NAVSEA CBM+ BLUF • CBM+ is Do. D documented policy for maintenance. NAVSEA ensures CBM+ policy is updated regularly. • NAVSEA is working to accelerate the implementation of enterprise CBM+ via the modernization of Integrated Condition Assessment System (ICAS) with enterprise Remote Monitoring (e. RM) for Hull, Mechanical and Electrical (HM&E) systems. • CBM+ has its foundation in the Reliability-Centered Maintenance (RCM) methodology that NAVSEA promulgates for all (Organizational, Intermediate & Depot level) maintenance development. Distribution Statement A: Approved for public release; Distribution unlimited. 3

CBM+ Expected Benefits Improve Readiness and Availability of Assets Improve Equipment Health to Achieve Expected Service Life (ESL) Maximize Efficiency and Reduce Life-cycle Maintenance Costs Through Data-driven Maintenance Decisions Distribution Statement A: Approved for public release; Distribution unlimited. 4

Current NAVSEA RCM & CBM+ Policy – DODI 4151. 22 Requires CBM+ as a principal consideration in the selection of maintenance plans and also be based on RCM analysis – DOD 4151. 22 -M establishes RCM as method to “ensure effective maintenance processes are implemented” – OPNAVINST 4700. 7 L (Maintenance Policy for US Navy Ships) - Requires NAVSEAs RCM process for shipboard maintenance development – OPNAVINST 4790. 16 B (CBM & CBM+ Policy) – Requires RCM integration – NAVSEAINST 4790. 27 A (RCM, CBM, & CBM+ Policy for Ships, Ship Systems and Equipment) – Describes NAVSEA requirements for use of RCM in maintenance development and sustainment – MIL-STD-3034 A RCM Process – This standard delineates the 12 phase fully detailed RCM Process and includes the associated Data Item Descriptions (DIDs) for each phase. This standard also contains the Backfit RCM process and Appendix F on NAVSEA’s RCM and CBM+ relationship. – NAVSEA Established RCM Training &Certification program in 2001 NAVSEA CBM+ is Aligned to OSD Policy Distribution Statement A: Approved for public release; Distribution unlimited. 5

RCM is the Basis for CBM+ • • • Classic RCM is the engineering analysis process used to develop organizational, intermediate and depot level maintenance requirements for new equipment and systems. Backfit RCM is the Continuous Process Improvement review of existing approved organizational, intermediate, and depot level maintenance tasks. Both Classic and Backfit RCM processes are fully described in MIL-STD-3034 A and are essential to achieving CBM+. Since 2001, NAVSEA has trained and certified 7676 in Backfit RCM and 4886 in Classic RCM NAVSEA has instituted online training for our Backfit RCM certification via e. PMS Gateway: https: //epmsgateway. pmsmis. navy. mil – CBM+ connects the maintenance tasks that RCM tells us to do with cost-effective technology to assist in evaluating system and equipment performance. – CBM+ uses RCM analysis to determine failure modes and aids in sensor placement. – CBM+ uses prognostics to schedule maintenance to REDUCE DOWNTIME Distribution Statement A: Approved for public release; Distribution unlimited. 6

NAVSEA RCM & CBM+ Relationship 1. RCM Developed Maintenance Requirements Index 2. Select Preventive Maintenance Task 3. List and Identify Specific Failure Mode(s) Resort to Non-technology CD, TD, or FF Task NO 4. Do CBM+ Technologies Exist That Can Accurately and Consistently Detect The Onset of the Failure Mode? NO KEY: CD - Condition Directed TD - Time Directed FF - Failure Finding PM - Preventive Maintenance YES 5. List Each Technology and Link to the Failure Mode(s) Identified 6. Comparing the Cost and Reliability of CBM+ Technology With Manual PM, Does Any Identified CBM+ Technology Have a Greater ROI Than Existing Low-tech Methods? YES Test CBM+ Technology in Intended Application Before Full-scale Buy or Lease NAVSEA CBM+ TECHNOLOGY DECISION LOGIC TREE Source: MIL STD 3034 A (Appx. F) Distribution Statement A: Approved for public release; Distribution unlimited. 7

Enterprise Accomplishments since Sept 2017 RCM supporting CBM+ – – – Revising NAVSEAINST 4790. 27 A – RCM, CBM &CBM+ Policy Drafting RCM Management Manual revision 21 Classic RCM courses completed 25 Backfit RCM courses completed 6 FLEET Maintenance Effectiveness Reviews completed (Part of NAVSEA maintenance CPI) • 9, 248 maintenance procedures reviewed – 12 Classic RCM workshops (Part of NAVSEA maintenance CPI) • 1, 783 maintenance procedures reviewed – Total trained in NAVSEA’s RCM methodology in FY 18 - 1370 Distribution Statement A: Approved for public release; Distribution unlimited. 8

Expectations for FY 2019 RCM Supporting CBM+ • Promulgate revised NAVSEAINST 4790. 27 B – RCM, CBM & CBM+ Policy • Issue revised NAVSEA RCM Management Manual • 29 Classic RCM courses scheduled • 37 Backfit RCM courses scheduled • 6 FLEETMERs scheduled • Plan to review approximately 9, 000 maintenance procedures • 12 Classic RCM workshops scheduled • Review online Backfit RCM Training course Distribution Statement A: Approved for public release; Distribution unlimited. 9

Expectations for FY 19 RCM Training New Jersey District of Columbia • 1/7/19 Washington (SEA 04 RM) – Classic • 1/11/19 Washington (SEA 04 RM) – Backfit • 6/10/19 Washington (SEA 04 RM) – Classic • 6/14/19 Washington (SEA 04 RM) – Backfit Maryland New Hampshire • 12/10/18 Picatinny (NSWC) – Classic • 12/14/18 Picatinny (NSWC) – Backfit • 9/13/19 Baltimore (USCG) – Classic • 9/17/19 Baltimore (USCG) – Backfit Rhode Island • 4/8/19 Newport (NUWC) – Classic • 4/12/19 Newport (NUWC) – Backfit Washington • 3/18/19 Dover (SUBMEPP)– Classic • 3/22/19 Dover (SUBMEPP)– Backfit • 9/16/19 Dover (SUBMEPP)– Classic • 9/20/19 Dover (SUBMEPP)– Backfit Pennsylvania • 10/22/18 Philadelphia (NSWC) – Classic • 10/26/18 Philadelphia (NSWC) – Backfit • 1/23/19 Philadelphia (NSWC) – Backfit • 2/4/19 Mechanicsburg (NSWC) – Classic • 2/8/19 Mechanicsburg (NSWC) – Backfit • 5/3/19 Philadelphia (NSWC)– Classic • 5/7/19 Philadelphia (NSWC)– Backfit • 7/31/19 Philadelphia (NSWC) – Backfit • 6/3/19 Keyport (NUWC) – Classic • 6/7/19 Keyport (NUWC) - Backfit Indiana • 6/17/19 Crane (NSWC) – Classic • 6/21/19 Crane (NSWC) – Backfit Virginia California • 1/14/19 San Diego (SURPAC) – Classic • 1/18/19 San Diego (SURPAC) – Backfit • 1/28/19 San Diego (FLEETMER 106) – Backfit • 5/13/19 Port Hueneme (NSWC) – Classic • 5/17/19 Port Hueneme (NSWC) – Backfit • 8/12/19 Port Hueneme (NSWC) – Classic • 8/16/19 Port Hueneme (NSWC) – Backfit • 8/26/19 San Diego (SURPAC) – Classic • 8/30/19 San Diego (SURPAC) – Backfit • 9/16/19 San Diego (FLEETMER 110) – Backfit South Carolina • 7/15/19 Charleston (SPAWAR) – Classic • 7/19/19 Charleston (SPAWAR) – Backfit Florida • 3/4/19 Panama City (NSWC) – Classic • 3/8/19 Panama City (NSWC) – Backfit • 5/13/19 Mayport (FLEETMER 108) – Backfit Hawaii • 3/18/19 Pearl Harbor (FLEETMER 107) – Backfit • 10/15/18 Chantilly (SEA 04 RM) – Classic • 10/19/18 Chantilly (SEA 04 RM) – Backfit • 11/13/18 Chesapeake (SEA 04 RM) – Classic • 11/17/18 Chesapeake (SEA 04 RM) – Backfit • 10/29/18 Chantilly (SEA 04 RM) – Classic • 11/2/18 Chantilly (SEA 04 RM) – Backfit • 11/5/18 Norfolk (FLEETMER 105) – Backfit • 12/3/18 Chantilly (SEA 04 RM) – Classic • 12/7/18 Chantilly (SEA 04 RM) – Backfit • 2/11/19 Chantilly (SEA 04 RM) – Classic • 2/15/19 Chantilly (SEA 04 RM) – Backfit • 2/25/19 Chesapeake (SEA 04 RM) – Classic • 2/29/19 Chesapeake (SEA 04 RM) – Backfit • 3/25/19 Chantilly (SEA 04 RM) – Classic • 3/29/19 Chantilly (SEA 04 RM) – Backfit • 4/29/19 Chantilly (SEA 04 RM) – Classic • 5/3/19 Chantilly (SEA 04 RM) – Backfit • 5/20/19 Chesapeake (SEA 04 RM) – Classic • 5/24/19 Chesapeake (SEA 04 RM) – Backfit • 7/26/19 Norfolk (FLEETMER 109) – Backfit • 8/5/19 Chesapeake (SEA 04 RM) – Classic • 8/9/19 Chesapeake (SEA 04 RM) – Backfit • 8/19/19 Chantilly (SEA 04 RM) – Classic • 8/23/19 Chantilly (SEA 04 RM) – Backfit Distribution Statement A: Approved for public release; Distribution unlimited. 10

NAVSEA CBM+ Program of Record Integrated Condition Assessment System (ICAS) is: • Program of Record • NAVSEA’s common tool to support Condition Based Maintenance (CBM) for the past 20 + years • Installed on over 100 ships across the Fleet • Monitoring mechanical and electrical systems including: Gas Turbine Engines Fuel Oil System Main Reduction Gears Propulsion Diesel Engines Potable Water Controllable Pitch Propeller Refrigeration Plants Gas Turbine Generators Lube Oil System Air Compressors Ships Diesel Generators Line Shaft Bearings Distilling Plants Sewage & Waste Water Air Conditioning Units Evaporators • Performing diagnostics, parametric trend analysis and providing condition alerts via Consolidated Machinery Assessment System ashore (CMAS) Distribution Statement A: Approved for public release; Distribution unlimited. 11

Enterprise Accomplishments Since 2017 Enterprise Remote Monitoring (e. RM) • NAVSEA is moving to replace ICAS with e. RM beginning FY 18 • e. RM improvements over ICAS Include: – – – – – Government owned/developed system Increased cybersecurity posture Enhanced diagnostics, fault analysis & trending Enhanced feedback to ships force Highly scalable, faster data processing Supports rapid development and revision of CBM+ algorithms Phased transition to automated predictive analytics/prognostics Digital Twin capability Linkage to existing and new Navy policy and doctrine, infrastructure, business strategy, architectural framework, RCM, and open systems and data strategy NAVSEA CBM+ is Aligned to OSD Policy Distribution Statement A: Approved for public release; Distribution unlimited. 12

Expectations for FY 2019 CMAS is in The Early Stages of Realizing Digital Twin Capability for CBM+ Distribution Statement A: Approved for public release; Distribution unlimited. 13

Expectations for FY 2019 to 2026 ICAS Sunset / e. RM Deployment 120 110 100 Total # of e. RM Installs - POM-19 (Cumulative) 102 105 102 90 88 95 Total # of ICAS Installed - POM-19 (Cumulative) 81 80 71 69 70 Planned e. RM Installs per FY - POM-19 60 ICAS Combatant Hulls Fully Sunset in FY 26 59 50 51 40 Assumptions: 44 33 LCS Hulls included into Deployment Plan 30 32 20 10 113 11 MCM not planned (decommissioning) 14 0 0 FY 18 20 9 LPD Hulls to follow Backfit schedule starting FY 26. 4 4 10 19 18 18 19 14 11 FY 19 FY 20 FY 21 FY 22 FY 23 FY 24 FY 25 FY 26 POM-19 REQUIREMENT FY 20 FY 21 FY 22 14 33 51 10 19 18 95 81 71 ICAS/e. RM CROSSOVER PLAN Total # of e. RM Installs - POM-19 (Cumulative) Planned e. RM Installs per FY - POM-19 Total # of ICAS Installed - POM-19 (Cumulative) FY 18 0 0 105 FY 19 4 4 102 FY 23 69 18 59 Distribution Statement A: Approved for public release; Distribution unlimited. FY 24 88 19 44 FY 25 102 14 32 FY 26 113 11 20 14

e. RM First in Class Roll-Out Plan CBM+ES Program Plan Q 1 FY 16 Q 2 Q 3 Q 4 Q 1 FY 17 Q 2 Q 3 Q 4 Q 1 FY 18 Q 2 Q 3 Acquisition Milestones Q 4 Q 1 FY 19 Q 2 Q 3 Q 4 FY 20 Q 2 Q 3 Q 1 MS B Q 4 Q 1 FY 21 Q 2 Q 3 MS C Q 4 IOC Q 1 FY 22 Q 3 Q 4 FRP/FD LCS 1 Var e. RM v 3. 1 CG 69 e. RM v 3. 1 First In-Class Shipboard Deployments (Key Events) DDG 87 e. RM v 3. 2 LSD 51 e. RM v 3. 2 LPD 28 e. RM v 3. 2 LHD 8 e. RM v 3. 3 e. RM v 3. 1. 0 SRR CDR TRR TER e. RM v 3. 1 DCA SRR CDR TRR TER e. RM v 3. 2 DCA SRR CDR Application Development TRR TER e. RM v 3. 3 DCA SRD CDRTRR TER CMAS v 1. 1 SRD CDR TRR TER CMAS v 1. 2 SRD CDR TRR TER CMAS v 1. 3 First in class CG-69 Q 3 FY 19 Distribution Statement A: Approved for public release; Distribution unlimited. 15

Guidance & Roadmaps Data Utilization Team Drives the future Development of CBM+ ES Applications Distribution Statement A: Approved for public release; Distribution unlimited. 16

Major Challenges in Achieving Service Enterprise Goals • Technical risk from the constantly evolving Cyber Security posture and policies • Expected shut down of NIAPS data path without solidified replacement (Testing currently underway with NAVAIR for possible replacement) • Resources needed to standardize remote monitoring systems for HM&E and combat systems • If required, increase in classification due to numerous compiled data sources could impact access to large portion of users Distribution Statement A: Approved for public release; Distribution unlimited. 17

Conclusions • NAVSEA’s CBM+ process, when properly executed and resourced, will: – Improve readiness and availability of assets – Improve equipment health to achieve Expected Service Life (ESL) – Maximize efficiency and reduce life-cycle maintenance costs through data -driven maintenance decisions • CBM+ technology must be considered as a key attribute in ship design and be integrated into the acquisition, modernization, sustainment and management processes that are critical to ensuring ship material readiness throughout service life Distribution Statement A: Approved for public release; Distribution unlimited. 18