NAVAL AIR SYSTEMS COMMAND, PATUXENT RIVER, Md. — Part of the mandate of the Fleet Readiness Centers is to reduce the cost and complexity of repairs to save the Navy money and return needed equipment to the fleet faster. One FRC Mid-Atlantic (FRCMA) technician took that to heart and created a new repair procedure, receiving a cash award for his suggestion.

Mark Cusic, a Work Lead from the FRCMA site at Naval Air Station Patuxent River, noticed a higher-than-normal failure rate for the brake and axle assembly for the A/S 32A-45 Shore Based Midrange tow tractor (MRTT). The tractors are used to tow most naval aircraft up to the size of the F-35 or F/A-18 as well as most ground support equipment. The repair involved replacing the rear axle at a cost of more than $2,400.

After almost five years of research, phone calls and trial and error, Cusic discovered an alternative repair method that substantially reduced parts and labor costs to about $425. This saves potentially nearly $700,000 over the lifespan of the tow tractors, and for the first year alone, about more than $28,600, naval officials said.  Under the Beneficial Suggestion award program, Capt. Michael Zarkowski, FRCMA commander, presented Cusic with a $1,900 check April 11.

“It feels great, but I’m happier that I saved maintenance time for my co-workers,” said Cusic, who has worked at FRCMA Pax River since January 1999. “We’re shorthanded here and there are very few of these tractors out in the fleet. When our customers bring these in, they need them back as soon as possible.”

The Beneficial Suggestion award program is a Department of the Navy incentive to recognize creativity in the workplace that benefits the service. Examples include recommendations on conserving manpower and budgetary resources, creative ideas regarding design, construction and repair methods, and suggestions on improving operations. Award amounts are based on the tangible and/or intangible savings.

Beyond the benefits to the Navy, “I’m also happy to save the taxpayer money,” Cusic added.

The MRTT is a modified version of a commercially available tractor and has a type of sealed brake system often found on industrial vehicles. Seals were failing and allowing brake fluid to leak into the axle assembly, which reduced the vehicle’s ability to stop.

If an operator noticed braking difficulties, repair procedures included checking the fluid level in the two-chamber master cylinder under the hood. Brake fluid would typically be found in the front chamber, meaning the front brakes were likely working properly. However there would be no fluid in the rear chamber; fluid had leaked out. With no puddles on the ground to show an external leak, technicians found that brake fluid had seeped into the axle assembly.

After the prescribed repair procedure, the repair required removal and replacement of the rear axle assembly, a labor intensive — and expensive — process.

After researching the problem and coordinating with the manufacturer, Tug Tech of Marietta, Ga., and the Aviation Equipment Support Program Office, (PMA-260), which manages the tractor program, Cusic discovered he could order a $40 brake service kit from Tug Tech. He could then replace the seals by removing access plates on the axle instead of having to replace the axle assembly and send it back to the manufacturer to be rebuilt. Technician labor was also significantly reduced as well.

The manufacturer sent a representative to Pax River to test and validate the procedure, and the new fix is now included in technical repair manuals.

Lt. Cmdr. Michael Windom, FRCMA Pax River maintenance officer, praised Cusic’s initiative.

“Mark had the confidence to ask the questions and seek out leadership on making a positive impact by saving lots of taxpayers’ money,” he said. “It’s just taking ownership, pride and professionalism in your work, and Mark did that. I’m glad he’s on our team.”

While this is Cusic’s first Beneficial Suggestion award, it may not be his last. He is already researching how to simplify another repair.