Net-centric maintenance needed on subs: remote access to virtual repair shops could save money, gain efficiency. (Commentary).

Submarine crews often must fix broken pieces of equipment while at sea--weeks away from a shore stop. In some cases, they may not be able to figure out what is wrong. Such breakdowns can be very bad news for a submarine conducting sensitive missions in deep ocean waters.

Depending on the seriousness of the problem, a submarine may have to go back to port or technicians ashore may have to be dispatched to check out the situation.

These troubles could be avoided if submariners were linked to a virtual maintenance facility ashore that could help solve the problem, remotely.

The ship's crew would use a video camera to capture images of the broken equipment--images that would be seen in real time by an expert at the maintenance center ashore. Thanks to some well-placed sensors, the expert can start running system rests on the equipment from his desk.

Based on those rests, the expert then forwards instructions to the ship via email, describing how to fix the problem while he watches and lends advice. He can test the systems on all the hulls in the fleet electronically to see if they are at risk for a similar breakdown. Later, he can upgrade the software on navigation systems in every submarine in the fleet.

This way of doing business is known as net-centric maintenance. NCM proposes to make maximum use of the Internet and military communication networks, allowing external government agencies to securely "touch the boat" and, in the process, reduce costs and improve efficiency.

Among the benefits of NCM are avoidance of travel, increased productivity, a more responsive technical assistance process to the fleet, less equipment downtime, increased quality-of-life, distance downloading of software, elimination of security requirements for carrying classified information, and a reduction in training costs by concurrently upgrading required computer-based training. NCM, additionally, would enable "simultaneous fleet upgrades," avoiding varying software configurations

Essentially, NCM would help achieve the "paperless ship" goal.

There are five areas that need to considered in NCM:

Distance Diagnostics--The ability of a subsystem to run diagnostics at the system/subsystem level from a remote location, to assess the problem by obtaining additional data and providing an enhanced resolution, eventually eliminating the need for a physical technical assist.

Distance Grooming and Preventative Maintenance--The ability to test the subsystem from a remote location to facilitate the preventative maintenance process.

Distance Testing and Certification--The ability to test and certify the subsystem remotely, using state-of-the-art information technology.

Distance Downloading of Software and Patrol Data Extraction--The ability to provide software updates to support installation/upgrade efforts. Using the upcoming SIPRNET (Secret Internet Protocol Router Network) upgrade, SUBIS will be able to download subsystem software reducing the number of personnel currently required for this effort. SUBIS is the Submarine Imaging Subsystem, a set of analog video and digital still cameras that record the view from the periscope and provides image enhancement software for image analysis.

Distance Configuration Maintenance--The ability to maintain shipboard configuration through electronic "simultaneous" updates with the most current information, eliminating varying software configurations among class ships, and the elimination of "on-hull" ship checks will be accomplished with the video camera and current software which can determine actual dimensions using a digitized image.

The NCM concept proposes to provide a pro-active approach to maintenance and would be applicable to all classes of submarines, surface ships, aircraft and weapons.

The implementation of net-centric maintenance is anticipated to evolve in four steps.

Step 1: The "delivery system," the smart test-box.

The smart test box will be introduced first into the hull, and will provide the link to the communication media and initially permit video conferencing, IP (Internet protocol) connectivity, chat rooms, uploadings and downloadings, and information storage. The ship's crew will use this tool to provide a better initial definition of problems, enhanced by video. The ability to provide streaming video capability will allow off-site subject matter experts to participate in problem investigation and repair, enhance the current level of "on-the-job training" and be more aware of maintenance issues facing crews.

Step 2: Design new smart equipment.

The new equipment will be designed to indicate when preventive maintenance service is required, alerting NOM to this need. NCM would then relay this request to the Navy Enterprise Maintenance Automated Information System (NEMAIS), which will order the required parts and forward them to the next port of call, reducing the current level of PMS material carried on the hull.

When testing on the hull is required to support the verification of an upgrade, the smart test box is envisioned to initially be used to support the test requirements, reducing the number of individuals needed. The installation team will simply hook up the smart test box, which will then be operated remotely providing a more standardized test method, able to support multiple installations simultaneously.

Step 3: Smart test equipment.

The smart rest equipment will replace carry-on equipment and allow standardized testing of a hull to be accomplished at any time during the ship's life cycle.

Step 4: The smart facility.

The facility is envisioned to fill a role similar to that of Houston in the space program. This will be a virtual facility with assets interconnected by a network to deliver maintenance to the fleet. This facility could be battle-group based, forward-area based, or home-shore based. The facility will combine all in-service engineering agent (ISEA) functions.

Given today's tight budgets, it is not uncommon to sacrifice new equipment to support the maintenance of current equipment and the existing infrastructure.

To reduce new equipment future maintenance costs, new equipment would be designed with the ability to be remotely maintained. The increase in development costs will be recovered during the life cycle of the equipment. When this new generation of equipment is back-fitted into the fleet, smart test boxes will facilitate distance maintenance interactions.

The current method of ship introduction requires an "on-hull" ship check prior to installation. NCM will streamline this process since travel to the ship will no longer be required. Video clips of the required areas can be sent to the cognizant commands and current software will provide dimensions of the digitized images. The ship acquisition program managers will also be able to better view all pending changes with NCM, eliminating any reengineering costs.

During the past 10 years, the military services have lost many trained individuals, which has warranted a change in training philosophy. The current approach is to provide a minimal level of training until individuals sign-up for a longer enlistment. The proposed NCM concept could be used to facilitate pro-active on-the-job training. Minimally trained individuals could use the system to interface with smart facilities to obtain a better understanding of system operation, thereby reducing the responsibilities of the non-commissioned officers. The system would also allow them more direct access to the original equipment manufacturers to address repair philosophy and enhance troubleshooting abilities.

When technical problems arise, the responding technician is required to travel to a remote location, costing the Navy time and money. The network-centric maintenance concept will help define the problem upfront, so that adequate resources and properly trained technicians are assigned to the task. By allowing a remotely stationed subject-matter expert to be virtually on site with the ability to guide on-site personnel, many maintenance trips would be eliminated altogether. In addition, remote repair facilities could provide a more effective and faster repair cycle, since the subject-matter expert would be immediately available. The subject-matter expert would support multiple repairs at multiple locations.

The network-centric maintenance concept will provide a "Web-cam" approach to maintenance. Sailors will be able to interact with more experienced subject matter experts. Patrol data will be downloaded more efficiently, and decisions based on those reports will help determine corrective actions prior to the next deployment.

The Navy today has a Navy Enterprise Maintenance Automated Information System. NEMAIS is a centrally located, integrated database of the current status of applicable hulls. The NCM will enhance NEMAIS functions. Direct fleet support will be enhanced by incorporating "web-cam" maintenance facilitated by secure video, increasing initial problem definition. The system will provide simultaneous updating of the most current logistics support data, eliminating seldom-used information from hulls and eventual elimination of the preventive maintenance system.

With the implementation of NCM, it is envisioned that major changes to the current maintenance policies may occur.

* With the ability to bring the subject matter experts into the hulls, maintenance training pipelines could be shortened, and a reduction in Navy instructors could be realized.

* Interactive electronic technical manuals could be revised to eliminate seldom-used material.

* The planned maintenance system cycles could be revised to "just-in-rime" maintenance.

The key to successful implementation of this initiative will be the integration of all current resources into a functional smart facility. This facility will provide the backbone of the necessary infrastructure to expand the initiative providing fleet wide accessibility. The Naval Undersea Warfare Center would be a potential candidate for this requirement, since most hardware assets are located at its base. NUWC also is tied to other military labs.

A smart facility may be a formidable task, but the potential reduction in life cycle costs should justify the effort.

For additional information on the cost driver approach model, visit the Web site http://www.gpworldwide.com/market/government/costdriver.asp.

Carl M. Floyd is a program manager in the Submarine Electromagnetics Department at the Naval Undersea Warfare Center Division. Daniel W. Miles is a senior project control specialist at General Physics Corporation. His e-mail address is [e-mail].