“SNAP” decision saves squadron time

Published June 29, 2011
By Brandice J. O'Brien
Tinker PUblic Affairs

TINKER AIR FORCE BASE, Okla. -- It was a snap decision, or rather a "SNAP" decision.

Approximately a year ago, 550th Commodities Maintenance Squadron personnel realized the unit wasn't operating efficiently as it could. They studied possible causes and found the culprit -- a kitting issue. End items scheduled for repair were often put on hold because needed parts were unavailable. But, officials realized if they anticipated the repair and ordered the parts ahead of time, they could drastically cut the process time.

"Synchronization of Needed Assets and Pre-positioning," or SNAP, kitting did exactly that. Since implementing the new process, the squadron has increased its efficiency up to 44 percent.

"The group has made great strides in SNAP kitting. The 550th CMMXS is seeing huge improvements from their SNAP'ing because the kits ensure our mechanics have the parts they need when the end item drives into the shop," said Col. Herbert Phillips, 76th Commodities Maintenance Group commander. "Their wait time is virtually eliminated."

The squadron currently maintains 49 SNAP-kitted end items including ball-screw valves, actuators, drives and an assortment of air valves, which are categorized by control numbers. To manage the 49 end items, the squadron has 346 individual kits. Depending on the repair, some mechanics may need a kit for a few hours or up to four days.

The squadron is responsible for 600 control numbers -- of which, 400 are active -- and they have a plan to continue to add more SNAP kits as manpower allows.

"We're only up to 49 control numbers right now because we want to do this slow and right. We wanted to make sure we managed and learned as we went," said Rick Jack, 550th CMMXS material chief. "So many times out here a program or process fails after implementation due to sheer size and volume."

Prior to the introduction of SNAP kitting, mechanics would take apart a piece of aircraft equipment, determine what parts were needed to fix it and order them. Until the parts arrived, whether it was the next day or 10 days later, the equipment sat, untouched, off to the side.

"They were just accumulating things to overhaul until they actually got parts to repair the first item," Mr. Jack said.

Through SNAP kitting, the required pieces are already in the kit, as well as parts that might be needed. Once an item is fixed, the kit is replenished with items that were used.

"With this concept they can get the end item, build it from start to finish and they don't have to have that extra time," Mr. Jack said.

In order to know what repair pieces should be in the kit, production support technicians, or PSTs, talk with planners. Two checklists are printed and brought to the shop where, separately, two senior mechanics review the list and highlight materials they think are necessary. When finished, the PSTs compare the mechanics' lists to history.

"We don't want to rely on data from history alone," Mr. Jack said. "We want that mechanic knowledge. They're the experts."

While the squadron has made significant strides, SNAP kitting is still a process with its own learning curve.

"We see things we need to change every day," Mr. Jack said. "Even though we've been doing this for almost a year, we still feel like we're in the baby-step learning curve of the whole process. It's an ongoing improvement - all the way from how items are taken to the shop and how the kits are brought back. It'll be a learning curve for years to come."

Doug Dobbins, a PST, who manages 29 kits - of which, 13 are SNAP kits - said he loves the concept. A kit takes roughly 25 minutes to assemble and he doesn't have to guess which pieces are missing since mechanics note used items - including nuts and bolts - on a checklist.

Additionally, Mr. Dobbins' kits are color-coded. Must-have pieces are labeled "green," and when a kit is returned, he knows he definitely has to replace those items. "Ideal" pieces, which may be replaced, are labeled "yellow" or "blue."

"This is all I have to worry about," he said referring to the checklist. "I just replace what was used and wait for the next kit to come in. The mechanic doesn't need to stop and take the time to explain what he has used to me; all the information is right there. I'll just grab the kit and start the cycle again."

Snap kitting