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Tuesday, 16 Sep 2014

Case Studies: U.S. Military

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CASE STUDY #1

F-16 AN/APG-68 Radar System Modular Low Power Radio Frequency (MLPRF) Line Replaceable Unit (LRU)

One of the poorest performing LRUs on the F-16

Cracked ribbon cable solder joints

Massive re-soldering program implemented

Shotgun approach to maintenance

No means or equipment to detect intermittence

 

Results from Intermittent Fault Detection & Isolation System™ (IFDIS™) testing:

400 MLPRF LRU chassis IFDIS tested:

147 were considered "un-repairable" completely out of service

33 had been in the repair depot for over one year

9 had been in the repair depot for over three years

60% had one or more intermittent fault

All of these defects has been missed by conventional depot Automated Test Equipment (ATE)

Cost of a replacement MLPRF LRU chassis is $307,000.00each

Over $39 million dollars worth of flight hardware recovered and counting!

Mean Time Between Failure (MTBF) has more than TRIPLED, an additional cost saving of $11 million dollars!

$50 million dollar Reduction in Total Ownership Cost (RTOC) achieved on one LRU chassis family on one aircraft platform!

Total Government investment $2.2 million dollars, or over a 22 times ROI and growing in less than three years!

 

 

CASE STUDY #2

F/A-18 Generator Convertor Unit (GCU) Weapon Replaceable Assembly (WRA)

Second highest degrader in the NAVAIR inventory

High No Fault Found (NFF) rate

High Mission Incapable (MICAP) rate

No means or equipment to detect intermittence or reduce NFF

 

Results from IFDIS testing:

All GCUs tested were previously considered Ready for Install (RFI) after comprehensive testing by the repair depot –

80% of the GCUs tested had one or more intermittent circuit that went undetected using conventional ATE

 

 

CASE STUDY #3

EA-6B AN/AIC-45, Intercommunication System, Weapon Replaceable Assembly (WRA)

High No Fault Found (NFF) rate

High Mission Incapable (MICAP) rate

No means or equipment capable of detecting intermittent / NFF

 

Results from IFDIS testing:

71% of the AIC-45s tested had one or more intermittent circuit that went undetected using conventional ATE

 

 

CASE STUDY #4

F-16 AN/APG-68 Radar System Antenna Azimuth Elevation (AZ/EL) Shop Replaceable Unit (SRU)

Grounding F-16s

Current testing methods and equipment unable to identify defects

Non-reparable item

Purchase price $1,600.00each

IFDIS testing required for GO / NO GO testing

 

Results from IFDIS testing:

95 AZ/EL SRU ribbon cables IFDIS tested:

76% tested bad and given a NO/GO for use on F-16 aircraft

IFDIS is effectively identifying good and bad cables so that good cables are not unnecessarily discarded, and bad cables are not put into F-16 aircraft.

IFDIS testing of AZ/EL ribbon cables saved the U.S. Air Force over $35,000.00 in just six weeks!

 

CASE STUDY #5

F-16 AN/APG-68 Radar System Antenna

High MICAP rates

Conventional ATE unable to diagnose intermittent / NFF issues, improve reliability or lower MICAP rates

IFDIS testing quickly identified electronic defects and intermittent faults

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