By Renee Hatcher
NAVAIR Public Affairs

The Naval Air Systems Command Industrial Operations’ (6.0) Component Repair Program returned more usable aircraft components to the fleet during fiscal 2001 than it has in any other year during the last 10 years.

More than 121,000 aircraft components were repaired, tested and returned to fleet operational status. That figure is up by 2,000 units from fiscal 2000. The goal for fiscal 2001 was 119,000. The range of components produced includes anything that makes up an aircraft like hydraulic valves, landing gear or electronic components in the cockpit.

“This is the best we’ve done since 1992,” said John Anderson, team leader for the Component Repair Program. “This was not done by any one group. This is the result of aligning our efforts across the NAVAIR competencies as well as with the Naval Supply Systems Command (NAVSUP) and the Defense Logistics Agency.”

The process of replacing a fleet aircraft component works like this. A request is submitted to NAVSUP to replace the desired component. If the part is in stock, it is sent out to the fleet where it will replace the damaged part. That part is then routed through one of the depots to be repaired, tested and returned to the inventory.

NAVSUP’s Naval Inventory Control Point (NAVICP) in Philadelphia, Pa. calculates the fleet requirements based on demand and what is in the inventory of available components. NAVICP looks eight quarters out to plan accordingly for the fleet’s needs. Accurately forecasting the fleet’s tempo of operations is one of the challenges faced by NAVICP.

"The Components Program is very dynamic and requires a great deal of attention from many people throughout the depots, NAVICP and AIR-6.0,” said Debbie Vergos, Industrial Production department head. “It's a great team and together we are getting components out the door. FY02 will be another challenge that I believe the entire team is up for."

Anderson said the increase in production during the last fiscal year came after a 10-year effort to maximize efficiency at the NAVAIR depots while reducing downtime for fleet aircraft.

“In the early ‘90s, we right-sized our naval overhaul facilities,” Anderson said. “We closed three repair facilities and spread that workload around to the three remaining depots.”

Naval aviation depots is Alameda, Calif., Pensacola, Fla. and Norfolk, Va. were closed leaving depots in North Island, Calif., Jacksonville, Fla. and Cherry Point, N.C. NAVAIR 6.0 was given seven years to carry out this reduction but completed it in three years while at the same time, continuing to meet the needs of the fleet.

After this right-sizing effort, the 6.0 leadership took a look at the organization and recognized the need to be smarter in how they conducted business. About five years ago, 6.0 began a business process reengineering initiative and found ways to better manage material, schedule work and improve internal processes, which have all contributed to improved component reliability.

“The greatest benefit to our new way of doing business is the increase in component production because it directly affects the fleet in a most positive way,” Anderson said. “Our focus is to keep the airplanes flying without any degradation to their requirements. Considering today’s environment, it has never been more important to keep our aircraft operationally ready.”

PHOTO CAPTION

John Ruiz, an advance composite fabricator at Naval Aviation Depot North Island, Calif., works on an F/A-18 trailing edge flap. (Photo by Steve Manganelli)