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Beene’s big idea

  • Published
  • By Brandice J. O'Brien
  • Tinker Public Affairs
TINKER AIR FORCE BASE, Okla. --  Ricky Beene's simple, one-word question set an IDEA in motion. His answer has saved the Air Force a significant amount of money and time. Mr. Beene benefitted as well, earning a $10,000 award from the Air Force's Innovative Development through Employee Awareness program here at Tinker.

The 550th Commodities Maintenance Squadron pneudraulics mechanic asked "why." Why were level-indicator assemblies being discarded instead of repaired? Why were level-indicator assemblies on a liquid coolant reservoir being condemned instead of fixed? Why, when replacing the copper ferrules and repairing the level-indicator assemblies, a 15-minute fix, has saved the Air Force more than $200,000?

"In my mind it was, 'Why aren't we making the repairs,'" said Mr. Beene, who repairs engine valves in a drive shop. "We're mechanics, why can't we just replace the copper ferrules?"

A copper ferrule is located at the end of a cable in a coolant reservoir. It protects the stainless steel wire from corrosion and it keeps the cable from pulling out of a bolt that is connected to a piston.

The entire structure is assembled on aluminum housing. When a jet's engine becomes hot, hydraulic coolant is pumped into the bottom of the tank and the piston rises. When a computer deems the tank as full, the piston stops rising. When the coolant has cooled the engine, air is pumped from the top of the tank, which pushes the piston back to the bottom. Computer readings keep the piston from bottoming out.

Prior to Mr. Beene's idea, the entire level-indicator assembly was discarded if the copper ferrule was bad. The level-indicator assemblies cost approximately $20,000 apiece. Yet replacing one copper ferrule costs merely 18 cents.

In fiscal 2011, the shop replaced 11 level-indicator assemblies. The year before, they replaced 10 level-indicator assemblies. Liquid coolant reservoirs are one of the many items produced in the drive shop; Mr. Beene said they arrive in waves. Sometimes the shop may receive three in a month and other times, five. Prior to Mr. Beene's idea, average repair time took 45 minutes to an hour.

Mr. Beene said his shop had only acquired the liquid coolant reservoirs workload one month ago.

"How come no one else discovered this fix?" Mr. Beene asked. "We're supposed to be mechanics, not parts replacers."

David Hurley, Drive Shop supervisor, said he's not surprised Mr. Beene found the solution.

"Ricky is conscientious about his work and wants to put out a good product," Mr. Hurley said. "He's a problem solver who doesn't stop at the problem. He's not afraid to go out of the box."

Mr. Beene began researching the problem a month ago. He initiated an Air Force Technical Order 22 form to have his process included in the technical order. His work was evaluated, confirming the tangible savings and approved.

Mr. Beene said he will use the reward money to customize his vehicle, a 1984 Cadillac Hearse.