Modifying the supply chain.
The Air Force is facing a significant challenge: Continue to provide expeditionary, agile combat support in an era of significant reduction in forces. In the last 10 years, the Air Force supply community has reduced the number of supply personnel by nearly 40 percent by consolidating back shop supply functions into regional supply centers. These regional supply squadrons consolidated supply functions and achieved economies of scale. Perhaps more importantly, it opened the Air Force to the myriad of opportunities of enterprise management--the management of items across a weapon system or across the entire Air Force instead of account by account. Over time, the five regional supply centers evolved into two logistics support centers (LSC)--one for the Combat Air Forces and one for the Mobility Air Forces.
Once the LSCs were formed, it soon became apparent that consolidation should not stop at just management across multiple accounts, but should also encompass the entire supply chain. Thus, the Global Logistics Support Center (GLSC) was implemented in early 2008. The GLSC will manage an item from sourcing (either from buy or repair), to determining where to stock and repair, to the final disposition and disposal. When Program Budget Decision (PBD) 720 mandated significant maintenance manpower reductions, one of the initiatives the Air Force maintenance community looked at was centralizing maintenance back shops at consolidated repair facilities (CRF) and at the depot. PBD 720 reduced over 35K active manpower authorizations over the 5-year defense period and over 20K Guard and Reserve authorizations.
Repair Network Transformation (RNT) (formerly Repair Enterprise for the 21st Century [RE21 ]) is the initiative to transfer base level repair responsibilities to CRFs or depots (direct to depot [D2D]). RNT under its former name, RE21, is described in the C-130 PPLAN draft dated 1 March 2007 as:
A lean logistics initiative and an integral part of the GLSC concept of providing global logistics support to the Air Force. RE21 leverages global visibility of all repair assets, centralized funds management, strategic sourcing, and partnerships with industry to provide the Air Force highly technical logistical support of equipment and reparable spares. RE21 accomplishes this by using the GLSC command and control network that ensures all data collected is immediately captured and available for use in a central database. The GLSC will provide oversight throughout the entire end-to-end repair processes, offer the ability to make timely and informed decisions and better plan Air Force repair priorities.
[FIGURE 1 OMITTED]
The Air Force established a process to nominate various commodities for approval by a general officer steering committee for consolidation under the RNT initiative. Figure 1 provides a summary of the nine RNT commodities currently approved for implementation.
The avionics commodities (F-16, E-3, C-130, B-1 and C-5) will transition to direct to depot (D2D) with initial operating capability in the first quarter of fiscal year 2008 (October 2007). The engines (TF33, F101, F100, F110) and pods (Pave Penny and LANTIRN) will transition to CRFs at various times.
Supply Chain Data Update
Transitioning to RNT will require adjustments to computed spares requirements and level allocations. This paper describes the process to modify the supply data. It is divided into two parts
* Changes to the worldwide requirements computation
* Changes to the readiness-based leveling (RBL) computation
The worldwide requirements computation uses the number of historical enterprise reparable generations (REPGEN), not where REPGENs occurred, to determine the enterprise need. Conversely, RBL uses the number of historical REPGENs at each base (the number and the where) in determining how best to allocate the computed worldwide requirement to the depot and applicable bases.
RNT--Modified Impact to the Worldwide Requirements Computation
D2D and CRF Changes to the Requirements Computation for Line Replaceable Units (LRU)
Transferring from base-level maintenance to a D2D or CRF maintenance concept requires changes to the number of not repaired this station (NRTS) and repaired this station (RTS) actions reported by the Standard Base Supply System (SBSS) to the Secondary Item Requirements System (D200A) for use in computing the worldwide requirement. To forecast depot repair requirements, D200A needs to see the items that will now be repaired at the depot that were previously repaired at the base. Additionally, the overall number of REPGENs in D200A needs to be increased to account for previous failures that were not reported by SBSS. Items that appear to fail on a weapon system, but whose failure cannot be duplicated (CND) on a test stand (or bench) are not recorded as failures in SBSS and are not reported to D200A. These items are recorded in SBSS as serviceable items whose failure cannot be duplicated.
Bases will no longer have resources (manpower and test stations) to repair or test LRUs; therefore, items will be removed from the weapon system and shipped as NRTS directly to the depot or to the applicable CRF. As a result, LRUs previously tested and bench checked as serviceable CND will no longer be checked at the base, but will instead get shipped as NRTS to the depot or CRF. Thus, the number of REPGENs, and therefore the requirement, should be increased by the sum of the CND actions.
Therefore the Air Force Logistics Management Agency (AFLMA) modified the (7SC) transactions that report base level REPGENs to the D200A by changing the RTS to NRTS and including eNDs as NRTS. The AFLMA provided these modified transactions 6 months prior to the actual conversion to RNT to ensure a more accurate repair and buy requirement upon implementation.
D2D and CRF--Changes to D200A for Shop Replaceable Units (SRU)
Demands for SRUs will shift from base level to the applicable depot or CRF. As a result, the number of enterprise demands for SRUs will remain the same. That is, demands for SRUs at depots and CRFs will increase by the amount of the decrease in demands for SRUs at base level. Because D200A does not consider where demands occur, there is no need to change SRU related REPGEN actions reported by SBSS (via 7SC transactions) to D200A.
Impact on the Readiness-Based Leveling Computation
D2D--Changes to SBSS, and thus RBL, for LRUs
Prior to converting to D2D, the AFLMA will generate SBSS transactions at the applicable bases to change SBSS repair cycle record data and item record demand data. These transactions will increase the number of NRTS actions by the sum of the RTS and CND actions and change the number of RTS actions to 0. Doing so will result in SBSS reporting NRTS actions to RBL, allowing RBL to allocate levels consistent with expected RNT demand and repair actions.
D2D--Changes to SBSS, and thus RBL, for SRUs
Prior to converting to D2D, the AFLMA will generate (FCL and FRR) transactions at applicable bases to delete SRU demands. This will cause SBSS to report zero REPGEN actions to RBL. As a result, D2D bases will correctly receive demand-based RBL levels of zero for SRUs. To ensure bases do not receive an RBL level greater than zero, AFLMA will provide bases adjusted stock level (ASL) load transactions (1F3L) to load a maximum ASL of zero to applicable NSNs.
CRF--Changes to SBSS, and thus RBL, for LRUs
* Bases transferring repair capability to CRFs will follow the same actions as D2D bases.
* Stock record account numbers (SRANs) gaining repair capability, that is CRF SRANs should not stock LRUs. Therefore, no adjustments to LRU repair cycle records at the CRF SRAN are required. The Centralized Intermediate Repair Facility Logistics Readiness Concept of Operations (AFLMA Report LS200316700) states the CRF should have its own SRAN. A separate SRAN for the CRF provides a method of distinguishing CRF-related repair actions from repair actions performed by personnel at the same base (location). CRF SRANs use an activity code C that prevents the CRF repair actions from being recorded in SBSS as demands (item failures). Instead, the LRU failures are recorded as demands at the forward (CRF-supported) SRAN. RBL then uses the forward SRAN demand data in determining level allocations; that is, LRU levels are allocated to CRF-supported SRANs and not to CRF SRANs.
* To protect against demand data errors created by CRF repair actions being processed incorrectly (without activity code 'C'), CRF SRANs should load maximum ASLs of zero for applicable LRU NSNs. Doing so would ensure CRF SRANs receive an RBL level of zero for LRU NSNs.
* To date, pods and engines are the only commodities transitioning to CRFs. Pods and engines are not included in D200A and RBL; therefore, computing and reporting CRF repair cycle times and CRF base repair percentages are not required. However, when additional commodities are identified for CRF maintenance that result in LRUs being repaired at the CRF, a method will be needed to compute and report these values.
CRF--Changes to SBSS, and thus RBL, for SRUs
* Bases losing capability to repair LRUs will no longer have a need for LRU component parts (the SRUs). Therefore, bases will process transactions to change the number of RTS and NRTS actions on SRUs to zero. Doing so will result in RBL levels of zero. To ensure bases do not receive an RBL level greater than 0, AFLMA will provide (1F3) transactions to load a maximum adjusted stock level (ASL) of zero to applicable SRUs.
* Bases gaining repair capability, that is CRF bases, will process transactions to populate record REPGEN data from all bases the CRF will support. The sum of all supported bases' RTS actions will be added to the existing RTS quantity at the CRF base.
The AFLMA provided (and AFMC loaded) 8 quarters of adjusted (7SC) data for the nine weapon systems (749 stock numbers and 4,588 7SC transactions) into D200A for the March and September 2007 requirements computation. The transactions increased NRTS actions by 16,718 (13,508 RTS actions were converted to NRTS and 3,210 eND actions were converted to NRTS).
The AFLMA provided [and the bases or logistics support centers (LSC) loaded] transactions for 1,045 stock numbers consisting of 5,602 stock number or base cases to the October 2007 RBL run. There were 6,095 (FRR) transactions to update base repair cycle time, 6,088 transactions to update repair actions (change eND to NRTS), 6,081 SBSS transactions to force a report to RBL, and 1,089 SBSS transactions to load maximum levels of zero to prevent a level for SRU NSNs at the bases.
There are SBSS code changes needed to accurately reflect CRF pipelines. With AFLMA's help, Headquarters 754th Electronic Systems Group personnel have identified coding changes needed to accurately compute CRF pipeline times and report those times to RBL (and eventually to D200A). The CRF pipeline times must include forward base processing times, transit time to the CRF, and CRF repair times.
AFLMA will continue to provide 2 years of historical 7SC transactions to HQ AFMC for use in D200A computations. AFLMA will provide HQ AFMC the data approximately 6 months before the base scheduled conversion date. For bases that have not yet converted, but already have had 2 years of modified 7SC data reported (those bases scheduled to convert in the near future), the AFLMA will provide the current quarter's (7SC) data, modified for RNT. For bases that have converted, modified (7SC) transactions are no longer necessary because bases will be reporting based on RNT maintenance. Thus, for bases that have already converted to RNT, AFLMA will provide quarterly (7SC) transactions without any modifications (all items should be NRTSed).
As new bases convert to RNT, the AFLMA will continue to create transactions (during the quarter that the base is scheduled to convert) to modify the SBSS data and report the accurate RNT data to RBL. The AFLMA will work with the GLSC to process the transactions whether through the LSCs to the major commands or directly to the bases. Once the bases convert to the RNT concept, no further action will be needed.
RNT will allow the Air Force to reduce base level maintenance manpower while still providing high quality repair of Air Force equipment and spares. To ensure the Air Force supply system computes accurate buy and repair requirements and provides the right levels to the right bases and depots, AFLMA has centrally managed the update to the affected Air Force supply systems. These actions should contribute to a smooth transition to RNT without any decrease in mission capability.
(1.) REPGENs are the sum of the number of failed items--both repaired or not repaired this station.
Tony Parrish, LMI
Douglas J. Blazer, PhD, LMI
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|Title Annotation:||Repair Network Transformation|
|Author:||Parrish, Tony; Blazer, Douglas J.|
|Publication:||Air Force Journal of Logistics|
|Date:||Mar 22, 2008|
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