424th SCMS makes the connection

Published July 31, 2014
By Kimberly Woodruff
Tinker Public Affairs

TINKER AIR FORCE BASE, Okla. -- Often when something is broken, it is time to replace it, but sometimes a repair or a redesign can save more in the long run.

In the case of the B-1 rotary launcher, there was trouble with failures of the umbilical connector with acquisition cost of $3,617 each and repair costs at about $2,283 per unit.
That amount doesn't sound too bad until the Supply Management Chain needs 300 of the connectors to support 60 aircraft. It is necessary to carry so many in inventory to ensure the assets are there in times of surge operations, according to Roderick Diehl, Aerospace Engineer Section chief, 424th Supply Chain Management Squadron.

The 424th SCMS is repairing about 188 of the umbilical connectors annually. So at a repair price of $2,283 per umbilical, the costs were adding up quickly.
The small umbilical connector

doesn't look like much, but it serves an important purpose. "The umbilical connector allows for the aircraft and the weapon to communicate for a successful launch and targeting," said Mr. Diehl. "After the launch, the umbilical disengages upon release of the weapon."

Mr. Diehl said reports from the field indicated they would be fortunate to get four or five weapon ejections before the unit would break.

The legacy connector is screwed into place, like a lid on a jar. In the weapons bay, a weapons loader has to reach above their head, in between weapons to engage the umbilical, and it isn't easy to do, according to Mr. Diehl.

When the weapon is released following the launch, disconnection is difficult with a screw connector, which can account for the high usage rates after breakage occurs.
"High usage rates sparked an investigation to see if other platforms are having similar issues," said Mr. Diehl. "I discovered, after a phone call to the Joint Direct Attack Munition program office that the A-10 and F-16 platforms were experiencing similar faults."
It was later discovered that the A-10 had implemented a solution that the British employed on their Tornado Aircraft.

The manufacturer of the Field Repairable Connector System was then sought out. "The FRCS can be repaired with one small tool and with simple replacement parts," said Mr. Diehl. "And instead of having to be screwed onto the weapon, it is a simple push-on type of connector."

Now, the A-10 and British Tornado are seeing about 100 launches before the connector needs repair. Mr. Diehl says that after 100 launches, it would probably need to be replaced anyway.

"It is important to note that the Supply Chain is a team, and there is no one expert in everything," said Mr. Diehl. "We look out for one another and collectively work to solve problems. Equipment specialists, item managers, logisticians, product management specialists and the rest of the team have to work together to have a successful functioning supply chain."

In this particular case, an item manager noticed the high usage of the umbilical and brought it to everyone's attention so they could brainstorm a solution. The engineering side wouldn't have had the same visibility that the item manager would have had.

"The 424th SCMS has technical authority for about 14,000 Air Force managed items," said Mr. Diehl. "When adding Defense Logistics Agency managed items, there are over a half-million different items that 424th must manage."

Mr. Diehl said a new connector system handling approximately 100 launches means a savings of more than $400,000 per year.

"This is a project that will contribute to (Air Force Sustainment Center Commander Lt. Gen. Bruce Litchfield's) 'Road to a Billion,'" he said.

The story behind the story of the Road to Billion and Beyond is what validated cost savings and cost avoidance represent in terms of additional capacity to support the warfighter.