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B-52 PDM improvement scheduled to decrease flow days

  • Published
  • By Marti D. Ribeiro
  • 76th Maintenance Wing Transformation Office
Tinker Air Force Base, Okla. --  
     The B-52 Bomber Programmed Depot Maintenance line has found a way to decrease flow days by capitalizing on aircraft in queue.
     A new transformation effort is using the queue time the B-52 aircraft has while in the Pre-Dock phase, to complete some of the tasks required in the Inspect phase. Thus, cutting down on the total number of days the aircraft is in Periodic Depot Maintenance. Basically, it's a way for this PDM line to speed up flow days and return the same quality product to the warfighter faster.
     The increased workload and reoccurring significant structural repairs for these aging aircraft are growing, so every extra minute that can be found to complete the PDM work is vital.
     "We need to take care of these major repairs without interrupting the flow," said Tony Whitmire, B-52 aircraft supervisor.
     That's where Continuous Process Improvement comes in handy.
     "We changed the process, so that mechanics can complete up to 45 tasks while the aircraft sits in queue before moving on to the next phase," said Homer Whitt, facilitation lead, 76th Aircraft Maintenance Group Transformation Office. "These tasks include inspection for defects so we can see things earlier and get parts ordered or repaired earlier."
     This new process, referred to as the prep dock phase, includes Non-Destructive Inspection work, removal of wheel doors, wing components, panels, fuel tanks and fuel bladders.
     "Right now we're scheduled to move more than a thousand man-hours out of the inspection dock, potentially saving (the Maintenance Group) about seven flow days," Mr. Whitt said.
     But, this new process wasn't just about moving hours for the B-52, it was also about finding a more efficient way to conduct significant structural repair. SSR are repairs to significant parts of the aircraft and more of these are being identified as the age of the aircraft progresses.
     "Previously, when there was SSR required, maintenance had to put the wheels back on the aircraft and move it to another area to complete the repair," Mr. Whitt said. "It meant we also had to move the maintenance crews to another location as well, taking work away from other areas."
     Moving the aircraft could cost up to four flow days, and sometimes more, depending on the severity of the SSR. Now with the extra time built in, it gives maintenance the chance to complete the repairs while the aircraft is in the same spot, cutting down on the time and the movement.
     "We also think that as crews get familiar with the new process, additional issues with this improvement will surface and we'll be able to address those," Mr. Whitt said. "Over time, we should find other tasks and other ways to streamline our phases to positively impact flow days."
     According to Mr. Whitmire, the crews dedicated to the new prep-dock phase are getting better and better.
     "We've already cut down on the time it takes for us to complete the tasks in this phase," he said. "Pretty soon it will be possible to start adding more tasks."
      He went on to explain that he's excited about the new process and sees the opportunity for this change in B-52 maintenance to have a dramatically positive impact on flow days.