Zero-Sustainment Aircraft for the U.S. Air Force

A Workshop Summary

Gregory Eyring, Rapporteur

Committee on Zero-Sustainment Aircraft for the U.S. Air Force: A Workshop

Air Force Studies Board

Division on Engineering and Physical Sciences

NATIONAL RESEARCH COUNCIL
OF THE NATIONAL ACADEMIES

THE NATIONAL ACADEMIES PRESS

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Zero-Sustainment Aircraft for the U.S. Air Force A Workshop Summary Gregory Eyring, Rapporteur Committee on Zero-Sustainment Aircraft for the U.S. Air Force: A Workshop Air Force Studies Board Division on Engineering and Physical Sciences

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THE NATIONAL ACADEMIES PRESS 500 Fifth Street, NW Washington, DC 20001 NOTICE: The project that is the subject of this report was approved by the Governing Board of the National Research Council, whose members are drawn from the councils of the National Academy of Sciences, the National Academy of Engineering, and the Institute of Medicine. This is a report of work supported by Grant FA9550-12-1-0413 between the U.S. Air Force and the National Academy of Sciences. Any opinions, findings, or conclusions expressed in this publication are those of the author(s) and do not necessarily reflect the view of the organizations or agencies that provided support for the project. International Standard Book Number 13: 978-0-309-27261-2 International Standard Book Number 10: 0-309-27261-0 Limited copies of this report are Additional copies are available from: available from: Air Force Studies Board The National Academies Press National Research Council 500 Fifth Street, NW 500 Fifth Street, NW Keck 360 Washington, DC 20001 Washington, DC 20001 (202) 334-3111 (800) 624-6242 or (202) 334-3313 http://www.nap.edu Copyright 2013 by the National Academy of Sciences. All rights reserved. Printed in the United States of America

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COMMITTEE ON ZERO-SUSTAINMENT AIRCRAFT FOR THE U.S. AIR FORCE: A WORKSHOP CLAUDE M. BOLTON, JR., Defense Acquisition University CLAUDE V. CHRISTIANSON, National Defense University THOM J. HODGSON, North Carolina State University RONALD MUTZELBURG, Boeing Phantom Works (retired) LYLE H. SCHWARTZ, University of Maryland at College Park RAYMOND VALEIKA, Delta Airlines (retired) Staff CARTER W. FORD, Program Officer SARAH M. CAPOTE, Research Associate MARGUERITE E. SCHNEIDER, Administrative Coordinator v

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AIR FORCE STUDIES BOARD GREGORY S. MARTIN, GS Martin Consulting, Chair BRIAN A. ARNOLD, Raytheon Company CLAUDE M. BOLTON, Defense Acquisition University STEVEN R.J. BRUECK, University of New Mexico THOMAS J. BURNS, Science Applications International Corporation FRANK CAPPUCCIO, Cappuccio and Associates, LLC DONALD C. FRASER, Charles Stark Draper Laboratory (retired) MICHAEL J. GIANELLI, The Boeing Company (retired) DANIEL HASTINGS, Massachusetts Institute of Technology PAUL G. KAMINSKI, Technovation, Inc. ROBERT LATIFF, R. Latiff Associates NANCY G. LEVESON, Massachusetts Institute of Technology MARK J. LEWIS, IDA Science and Technology Policy Institute LESTER L. LYLES, The Lyles Group MATT L. MLEZIVA, Wildwood Strategic Concepts C. KUMAR N. PATEL, Pranalytica, Inc. GERALD F. PERRYMAN, JR., Independent Consultant RICHARD V. REYNOLDS, The VanFleet Group, LLC J. DANIEL STEWART, University of Tennessee REBECCA WINSTON, Winston Strategic Management Consulting Staff TERRY J. JAGGERS, Director JESSICA R. BROKENBURR, Financial Assistant SARAH M. CAPOTE, Research Associate GREGORY EYRING, Senior Program Officer CARTER W. FORD, Program Officer CHRIS JONES, Financial Manager MARGUERITE E. SCHNEIDER, Administrative Coordinator DANIEL E.J. TALMAGE, JR., Program Officer vi

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Preface The Air Force recognizes that sustainment of legacy weapon systems is a strategic issue for the United States. To assist the Air Force in addressing this issue, the Air Force Studies Board of the National Research Council drafted terms of reference (TOR) in April 2012 for a short workshop to bring together Department of Defense organizations and industry to highlight current sustainment practices that the Air Force might leverage to reduce maintenance and sustainment costs in the near term. The National Research Council approved the TOR in July 2012. The 3-day workshop was then held on December 4-6, 2012, at the National Academy of Sciences Building in Washington, D.C. 1 The committee is grateful for the support of the Air Force champion of this workshop, Lt Gen Judith Fedder, Deputy Chief of Staff for Logistics, Installations, and Mission Support, Headquarters Air Force. Lt Gen Fedder articulated a set of clear desired outcomes for the workshop prior to the workshop and in person at the workshop. In addition, the committee thanks the many expert speakers and guests who contributed to this activity. Finally, the committee’s role was limited to planning the workshop, and the workshop summary has been prepared by the workshop rapporteur as a factual summary of what occurred at the workshop. Claude M. Bolton, Jr., Chair Committee on Zero-Sustainment Aircraft for the U.S. Air Force: A Workshop 1 This is the second in a series of workshops conducted by the Air Force Studies Board at the request of the U.S. Air Force. It follows an earlier workshop titled “Energy Reduction at U.S. Air Force Facilities Using Industrial Processes,” held on November 5-7, 2012. vii

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Acknowledgment of Reviewers This report has been reviewed in draft form by individuals chosen for their diverse perspectives and technical expertise, in accordance with procedures approved by the National Research Council’s (NRC’s) Report Review Committee. The purpose of this independent review is to provide candid and critical comments that will assist the institution in making its published report as sound as possible and to ensure that the report meets institutional standards for objectivity, evidence, and responsiveness to the study charge. The review comments and draft manuscript remain confidential to protect the integrity of the deliberative process. We wish to thank the following individuals for their review of this report: Claude V. Christianson, National Defense University, Nancy G. Leveson, Massachusetts Institute of Technology, Eli Reshotko, Case Western Reserve University, and Raymond Valeika, Delta Airlines (retired). Although the reviewers listed above have provided many constructive comments and suggestions, they were not asked to endorse the views presented at the workshop, nor did they see the final draft of the workshop summary before its release. The review of this workshop summary was overseen by Wesley L. Harris, Massachusetts Institute of Technology. Appointed by the NRC, he was responsible for making certain that an independent examination of this workshop summary was carried out in accordance with institutional procedures and that all review comments were carefully considered. Responsibility for the final content of this summary rests entirely with the author and the institution. viii

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Contents OVERVIEW 1 1 INTRODUCTION 3 Workshop Terms of Reference, 4 Workshop Structure, Scope, and Approach, 4 2 PRESENTATIONS AND COMMENTS 6 Tuesday, December 4, 2012, 6 Lt Gen Judith Fedder, Deputy Chief of Staff for Logistics, Installations and Mission Support, Headquarters, U.S. Air Force, 6 Katherine Stevens, Director, Materials and Manufacturing Directorate, Air Force Research Laboratory, 8 Steven Brown, Professor, Defense Acquisition University, 10 James Yankel, Technical Director, Directorate of Logistics, Air Force Materiel Command, 12 Joann Berrett, Director, Aerospace Sustainment Directorate, Air Force Sustainment Center, 13 Mike Jennings, Deputy Director of Logistics (Acting), Air Force Life Cycle Management Center, 14 Final Thoughts—Day 1, 15 Wednesday, December 5, 2012, 16 Maj Mark Blumke, Deputy Chief, Mx Systems and Integration Branch, Directorate of Logistics, Air Mobility Command, 16 SMSgt Kevin Mead, Air Force Element Vehicle and Equipment Management Support Office, 17 Lt Col Brian Godfrey, Chief, Airborne Branch (A4CA), HQ Air Combat Command, 18 BG Edward Dorman III, Director for Logistics Operations, Readiness, Force Integration and Strategy, Office of the Deputy Chief of Staff, G-4, 19 Joe Guenther, Vice President and General Manager, Evandale Turbofan and Turbojet Engines, General Electric Aviation, 20 Raymond Valeika, Retired Senior Vice President for Technical Operations, Delta Airlines, 20 ix

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Mark Buongiorno, Director, Military Engine Aftermarket Business Development, Pratt and Whitney, 21 Final Thoughts—Day 2, 22 Thursday, December 6, 2012, 22 VADM Walter Massenburg (USN, Ret.), Senior Director, Mission Assurance Business Execution, Raytheon Company, 22 3 WRAP-UP DISCUSSION 24 Leadership and Management, 24 Mission Statement and Metrics, 26 Setting Budget Priorities and Funding, 26 Relationships with the Contractor Community, 27 Culture Issues and Training, 27 APPENDIXES A Biographical Sketches of Committee Members 29 B Workshop Agenda 33 C Workshop Participants 36 D Presentation Abstracts 38 x

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Acronyms ACAT acquisition category AFLCMC Air Force Life Cycle Management Center AFMC Air Force Materiel Command AFRL Air Force Research Laboratory AFSAC Air Force Security Assistance Center AFMC Army Force Materiel Command AFSC Air Force Sustainment Center AIM automotive information module ALC Air Logistics Complex AMC Air Mobility Command APU auxiliary power unit BCA business case analysis CFLI core function lead integrator CLS contractor logistics support DAU Defense Acquisition University DLA Defense Logistics Agency DLR depot-level repair DoD Department of Defense E2E end to end ERP enterprise resource planning FY fiscal year ISR intelligence, surveillance, and reconnaissance KPP key performance parameter KSA key system attribute LCC life cycle cost LHA Logistics Health Assessment xi

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LO low observable MAJCOM major command NAVAIR naval aviation NRC National Research Council OCO overseas contingency operations OEM original equipment manufacturer P&W Pratt and Whitney PEO Program Executive Office PM program manager PSI product support integrator PSM program support manager R&D research and development S&T science and technology TOR terms of reference VEMSO Vehicle and Equipment Management Support Office WSS weapon system sustainment xii