Universal Synaptics Corp. and Total Quality Systems (TQS) just completed the F16 AN/APG-68 Radar System Modular Low Power Radio Frequency (MLPRF) joint testing project with the United States Air Force.
The F-16 MLPRF chassis’ is the box with the highest NFF cost of all F-16 avionic boxes. The boxes that have malfunctioned and/or tested bad in the field usually end up testing NFF at the depot and are subsequently returned to service as fully operational boxes.
More than $13,000,000.00 in maintenance costs is incurred annually by the U.S. Air Force for just that portion of the F-16 electronic boxes that test NFF at the depot.
Current day - 195 MLPRF chassis have been tested by the Intermittent Fault Detection and Isolation System (IFDIS).
Of the 195 MLPRF chassis tested
--- 137 were considered “un-repairable” - completely out of service
- --- 33 had been in the repair depot for over one year
- --- 9 had been in the shop for over three years
- --- 130 had one or more intermittent circuits – or 67%
- --- 40 had “opens”, 12 had “shorts”, and 7 were wired incorrectly
These defects were all missed by conventional depot Automated Test Equipment (ATE).
Cost of a replacement MLPRF LRU chassis is $307,000.00 each.
Over $36 million dollars worth of flight hardware recovered and counting!
Mean Time Between Failure (MTBF) increase from 289 hours to 729 hours, an additional cost saving of $4 million dollars annually!
$40 million dollar Reduction in Total Ownership Cost (RTOC) achieved on one LRU chassis family on one aircraft platform!
One of the largest RTOC Return On Investment (ROI) case studies in the history of the program and growing!
Total Government investment $2.2 million dollars, or over an 18 times ROI and growing!
The IFDIS diagnosed most of the problems in minutes. In addition to diagnosing existing intermittent/NFF problems, the IFDIS also caught developing problems resulting in failure avoidance opening the door for the IFDIS to function as a preventative maintenance tool, and final assessment test station before product is sent to the field or flight line.
There is a testing-void in that legacy test equipment simply cannot see intermittence. After testing with the IFDIS for these long overlooked defects, the actual repair and refurbishment of these boxes was minimal contributing to the massive ROI associated with the IFDIS. Nearly all of the “un-repairable” NFF boxes had only 2 – 3 problems keeping them from being repaired and returned to inventory, the IFDIS indentified these defects within minutes.
When it comes to reducing ownership cost, the IFDIS is supreme. Cash operating costs per unit under test are significantly lower than conventional scanning continuity test sets. And Mean Time Between Failure (MTBF) has more than doubled. One day, maybe all avionics test sets will provide figures like these. Until then, your choice is simple!
IFDIS, the right test set – right now!
For more information on IFDIS or the MLPRF project contact Universal Synaptics today 801.731.8508