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Monterey, California
Il
EB261992
THESIS
SURFACE SHIP MAINTENANCE PLANNING PROCESS
by
Amy Murphy DeWitt
December 1991
Thesis Advisor:
Lawrence R. Jones
92-04620
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Unclassified
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t,-.J< .&7
Amy Mifrphy DeWitt
Approved by:
La$rence R. Jones, Thesis Advisor
errerrL. McCaff4,
Seon Reader
ii
ABSTRACT
An effective and efficient surface ship maintenance management
There
policy and program has long been the goal of Navy planners.
currently exist
several programs to
execution
surface
of
ship
assist
maintenance
and
modernization
fleet
is
well
planned
and
executed
during an availability.
Engineering
and
Alterations
Maintenance Project
the Type Commander.
(CSMP)
(PERA) from
the
Current
Ship's
help
plan
and
manage
work
definition
and
work
package
GrA&I
El
DTIC TAB
CD r
JU
' i . '.
. :
TABLE OF CONTENTS
I. INTRODUCTION ...........................................
A.
STATEMENT OF THE PROBLEM ..........................
B.
DEVELOPMENT OF THE RESEARCH QUESTION ..............
C.
METHODOLOGY .......................................
1
1
2
3
iv
E.
3.
F.
3.
4.
G.
1.
2.
3.
H.
CONTRACTOR ................................ 63
THE ROLE OF PLANNING FOR ENGINEERING AND
ALTERATIONS (PERA)............................. 64
I.
DEFINITION .................................... 69
1. BENEFITS ...................................... 69
2. RESPONSIBILITIES .............................. 70
3. WORK DEFINITION PROCESS ....................... 71
IV.
2.
3.
B.
C.
V.
CONCLUSION .......................................... 98
A.
B.
I.
A.
INTRODUCTION
This package is
(PERA)
This thesis
surface ships.
adequate data
Existing
2.
C.
3.
4.
METHODOLOGY
Basic data for this thesis was obtained from existing
major steps:
1-
2.
3-
4.
The
II.
A.
This
(CMPs),
strategies, CMPs, and the FMP with the Resource Sponsors and
(b) promulgates the notional durations and intervals for
depot level maintenance [Ref. 2].
(COMNAVSEASYSCOM) after
This
(1)
FLTCINCS are
(1) developing
(2)
(4) providing up
(6)
(SUPSHIPs);
(7) ensur..ng
and
(8)
B.
b.
c-
d.
e.
f.
C.
g.
h.
i.
j.
k.
a7
o
)air
c,
ty
but not
Definition
Ship maintenance is one of the two major components
tion programs are separate, they are not independent and are
closely coordinated.
The Navy ship maintenance strategy is defined as the
process of identifying and utilizing
maintenance assets in
2.
Strategy
The elements of the CNO's maintenance strategy
include:
3.
a.
b.
c.
d.
e.
f.
g.
Procedures
Class Maintenance Plans are considered by CNO to be
10
The
Equipment condition
11
(DFS) is NAVSEA-funded
It consists of support
provided to the Fleet for correcting operational and maintenance problems which are beyond the capability of ship's
12
(MOTUs).
This
(b)
(c)
The
13
nance are defined, to provide for accomplishment at increasing levels of skill and facility assets.
are explained in the next section.
A recent
14
(PERA) organization.
In the mid-
70's the Destroyer Engineered Operating Cycle (DDEOC) maintenance strategy was introduced, as was NAVSEA's Maintenance
System Development Program which instituted the concept of
reliability-centered maintenance
(RCM).
(2) time-directed
(3) longer
In
(AEC) program),
The
[Ref. 3].
LEVELS OF HAINTENANCE
As previously stated, it is Navy policy that ship
16
(Ref. 11.
Organization level
(DOPs).
Organization level
17
(3-M)
2.
level
(RSGs).
It is the
(except for
The Commanding
The functions
(1) Serve as
18
(2)
(6)
(7) act as
assistance,
conferences,
19
3.
XNDUSTRIAL AVAILABILITIES
1.
Availability Types.
The information in this section was obtained from
references 1, 5 and 8.
a. Regular Overhaul
(ROBI .
20
An
(COH).
in order to produce a
(.O8,).
21
These
Ships assigned to
22
23
Work
Availability Assignent.
COMNAVSEASYSCOM assigns and schedules overhauls,
[Ref. 9].
Availability Scheduling.
24
a.
Overhaul Schedulina
Ships generally undergo overhauls at the
The overhaul
[Ref. 2]
are to be
(WDC), it is incumbent
25
[Ref. 2]:
MAINTENANCE STRATEGIES
All Class Maintenance Plans (CMPs) are developed
26
[Ref. 11
27
A "key
An Assessment of
(2)
required.
28
2.
FFG 7 and PHM class ships that are designed for reduced
manning and limited organizational level maintenance and
specific ships homeported in forward deployed areas with
operational tempos that limit the length of intervals
available for accomplishment of maintenance.
Reduced manned
These design
From
ajor
To the
The goals
30
The essential
One
PMA in the cycle is extended by one month to included dryBoth repair and modernization are included in the
docking.
PMA.
the cycle.
b. Condition-Directed Repair.
The main determinant of repair is the actual
material condition of systems and equipment.
Only those
The
31
32
III.
[Ref. 4].
33
An effective
1.
(Ref. 3].
It should contain
34
All
(MRMS)
35
(SMAF), essentially
Manuals, also
It is Shipboard Non-
36
4.
(SARP).
The
The SARP is
As a result of TYCOM
of MAMS remains consistent with long-term Ship's Nontactical Automated Data Processing System (SNAP I,II),
Type
37
MRMS
TYCOM maintenance
b.
c.
d.
e.
f.
g.
38
h.
i.
j.
k.
1.
m.
n.
o.
p.
Type
39
module of THAIS.
(Xf.JMS-RT).
The IMMS-RT system is designed for afloat IMA's,
providing a real time, on line, interactive system in work
package screening, work package planning, and work package
management.
c. Shipboard Non-tactical ADP Program
(SNAP).
maintain CSMP files and update backup CSMP at MRMS sites via
floppy disks.
40
D.
Non-Automated Ships.
Non-automated ships maintain their CSMP on the MRMS
data base.
The work
used-
2.
Automated Ships.
SNAP and WMMSNET equipped ships maintain their own
for MRMS.
41
Inter-System Procedures.
The data base is accessible except when hardware is
Electronic mail
6.
Intra-System Procedures.
a.
XNSURV.
Following INSURV inspection, AWR's are updated,
PERA SURFACE.
(EOC) is
ZNAVSEA.
42
E.
Th
(CSMP).
(SARP).
(AWRs) are
The
It is especially
43
(CMP's).
Individual
".
44
According to
[Ref. 5],
correct definitions
are:
a. Class A.
Work requiring overhaul or repairs,
modifications, field changes, ORDALT's or SHIPALT's to
sustain or improve the operating and performance
characteristics of the system, subsystem, or component being
repaired or altered to meet the most recent design and
technical specifications for that item are defined as class
A.
All manufacturer's
45
Maintenance,
The repair
This
46
complete diagnosis.
When
Repairs, if any,
will be minor.
3.
covered.
47
a. NAVSEA
(SWI) establish a
(TRS).
48
F.
[Ref. 5 and
The
The
49
50
AVAILABILITY
PLANNING
PROCESS
NAVSEA issues
prepares
and
I
Ship's
force
and
update
CSMP
I
PERA
plans
I
PERA
issues
baseline
SARP
CSHP
updated
and
SARP
TYCOM
PERA
SUPSHIP
issues
authorized
develops
bid
SARP
specifications
SUPSHIP
awards
contract
Availability
start
Availability
complete
52
1.
Preliminary Preparations.
a. Planning Engineering Repairs and Alterations
(PERA).
PERA may be tasked to assist NAVSEA and TYCOM for
PERA may
PERA also
The role
(POA&M).
53
The plan is
Alteration Planning.
a. The Fleet Modernization Program (FXP).
FMP governs the alteration planning schedule.
It
TYCOM's control
54
(shipchecks).
Special program
55
(WPD)
a. Ship Configuration.
The work package defines authorized repairs and
alterations.
(CDM) with
In ship's
56
They
are:
1-
2.
3.
Proposed SARP.
estimates.
4.
5.
The
57
d.
Prior to phased
Work
The
It is issued by PERA
MSA guides
Work Authorization
a. Work Package Documentation.
AWR's produced by the 3-M system are used to
The ship's
59
material availability.
The repair
Additional
Precise
60
G.
This individual is
61
ADVANCE PLANNING
If the work
SUPSHIP
CONTRACT AWPD
62
Satisfying
It is,
(2)
The
The SUPSHIP
63
specifications.
AZTERATIONS (PERk)
[Ref. 6].
64
(2)
the authority to act as aaent for the NAVSEA SPM and the
TYCOM in dealing with the Planning Yard, Planning SUPSHIP,
design agents, procurement activities, Naval Supervising
Activity, and other involved commands.
As an advance planning agent, PERA integrates
modernization and repair requirements into documents
directly usable by the industrial activity and is
responsible for maintaining effective and timely
communications among the Planning Yards, Planning SUPSHIPS,
TYCOMS, NAVSEA, procurement agents, and Naval Supervising
Activities.
65
2.
following tasks:
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(SHIPALT)
(10)
Develop CMPs
forecasts to
are properly
forecasts to
(11)
(12)
66
3.
(13)
(14)
Availability Planning.
(2)
(3)
(4)
(5)
(6)
(7)
(8)
67
(9)
(a)
(b)
(c)
(10)
(11)
(12)
(13)
(a)
(b)
(c)
Technical specifications
(d)
(e)
ILS information
(f)
68
them.
I.
The port
The
1.
BENEFITS
Within the private sector port engineers have been a
engineer into the Navy did not occur until the early 1980's.
The principal benefits gained from implementation of the
port engineer concept have been the following:
(1)
(2)
(3)
69
(4)
(5)
2.
(CSMP).
RESPONSIBILITIES
Assignment of port engineers has been limited to the
The general
(2)
(3)
(4)
(5)
(6)
70
WOP
DEFINITION PROCESS
(WPD).
(RPD Plan).
sources.
71
a WPD Plan
(SSCI).
72
WDI's are
The systems
PERA
The
forms.
d. Preliminary SARP.
The preliminary SAPP is used by the port engineer
to review initial repair decisions, to obtain preliminary
estimates of availability costs from the planning
supervisor, and to ascertain which items may be affected by
known material procurement difficulties.
73
The
Often a pre-
It refines the
(b)
(c)
74
(d)
(e)
(f)
(g)
(h)
(i)
(j)
(k)
(1)
It is prepared by PERA
75
the conference.
(b)
(c)
(d)
76
(IIIAV)
Work
Fackage
(A-45
(b)
(c)
h. Fre-Arrival
Conference
77
port engineer must inform them of the schedule and any other
pertinent issues that have arisen at the Pre-Arrival
Conference.
Their
79
IV.
CSMP ACCURACY
CSMP accuracy is still the major cause of problems
80
PLANNING PROCESS
The planning process for an availability involves
examined in Chapter V.
81
3.
While
the RSGs, IMAs, automated ships, PERA, and others are now
implementing MRMS, this system is not used by other key
activities such as PMT, NAVSSES, NAVSEACENs and others,
therefore, its application is currently limited.
b. Resource Utilization
Ships and TYCOM representatives may not be taking
full advantage of the resources available in the planning
82
process.
Several of the
The
c. Maintenance Rivalries
83
It is a
A common belief
believe
84
Other
85
B.
The ship's
This
(AWRs).
The
in turn, helped to
It is the successful
In
(VRs).
In addition to an in-depth
87
(TAVs)
The
For
[Ref. 1].
For
88
Engineers may come and go, but ideally the port engineer
remains.
This
Since
(H,M&E)
equipment.
This combination of
2.
(EOC)
(POT&Is) are
Without
91
The
PROGRESSIVE MAINTENANCE
The progressive maintenance strategy is the only one
When a
If they are
Once
There
(1)
92
utilizing a cost-reimbursable activity such as PERA or nonreimbursable agents such as the port engineer and PMTs, the
non-reimbursable agent will be selected.
There is currently
The
93
C.
(2) time-based
(condition-
94
[Ref. 7].
(time-directed) and
(2) conduct
With
95
If
It
Obviously,
When the
97
V.
A.
CONCLUSION
RESEARCH FINDINGS
The answer to the first research question regarding the
(CSMP),
All
98
of bid specifications.
Most
While either
there are many experts that may come aboard and evaluate the
cause of failure-IMA, MOTU, NAVSEACEN, PMT, civilian
contractor, etc.
With the
99
(PEB)
may have
just evaluated.
If time-directed evaluations
There
All of the
If
(b)
100
PERA is an
oraanization
They
sets of requirements.
Each TYCOM
A problem
Unless
It is the type
If
the TYCOMs cannot affe-d. to fund the tasks that PERA was
established and chartered to perform, they must be performed
by someone else.
(4)
There
Such
103
P.
(1)
(2)
(3)
104
AAW
Anti-air warfare
ACC
ACF
ADF
AEL
AER
AMS
ANSUL
AF..
AFN
All-purpose nozzle
ARE
ASF
ASI
ASIR
ASROC
Anti-submarine rocket
105
ASW
Anti-submarine warfare
AT
Acceptance trial
AUTODIN
AWTT
AWR
BACD
BEDD
BOH
configuration.
CASCAN
CASCOR
CASREP
CC
Corrosion control
CCB
CCTV
CETS
CHT
CIS
CLA-VAL
cli
CMPO
COH
Complex overhaul
COLUMNS
COSAL
COTF
C02
Carbon dioxide
CRES
CRUDES
CSHE
CSRT
CTF
CTG
CTU
107
Cu-Ni
CUP
CWT
DART
DC
Damage control
DCA
DCEO
DFS
DISC
DPMA
DPMF
DFSC
DSOT
DSRA
ECP
EDTA
EGL
EIC
ETi
EOC
EOCC
EOP
EO
EOSS
ESI
ETR
FBR
Feedback report
F7
Field change
FCA
FCIG
FCT
FMCL
FMP
FMPMIS
FMS-RT
FOB
FSN
FTGECCET
GFI
Government-furnished information
GFM/GFE
GEM
GFETE
C-SE
RABALT
HALON
Liquified bromotrifluoromethane
HM&E
HP
Horsepower
HCFF
IDD
IEH
IFB
IIMPP
IIMPE
IMACC
110
IMAV
iMMS
INCHOP
INSUPV
ISIC
ITF
ITFD
JAG
JCN
(unit
LAPS
LLTA
LLTM
111
LOA
LOE
LOGSAT
LF
Low pressure
LRMS
2M
3-Pi
Maintenance and material management system system used throughout Navy for controlling
repair, preventative maintenance support which
assures maximum equipment operational readiness
3M Corp.
3-M
MAM/RSS
MCA
MDCS
Maintenance
a means for
information
maintenance
Measurement
MEASURE
METAL
MHB 400
MHR
112
MIP
MIRCS
MJC
MOT
MOTU
MOU
Memorandum of understanding
MPRP
NPIC
MSD
N2
Nitrogen
NAMSO
NAVMASSO
NARDAC
Navy Area Regional Data Automation Center Processes MDS documents submitted by ships and
activities.
NAVELEX
113
NAVSEA
NAVSEACEN
NAVSEC
NAVSEEACT
NAVSSES
NCB
(formerly
item.
NCP
No calibration required
ND
NEC
NIN
NIS
Not in stock
NOTRL
Not to all
NPMTT
NSN
NSTM
NSWSES
Naval Ship Weapon Systems Engineering Station Provides technical assistance for all combat
system and UNPEP equipment.
Conducts gun systems
operability tests (GSOT) , and ship qualification
trials (SQT) in missile ships.
114
TITPr
NWF
OAP
OBA
OCSOT
OD
Ordnance document
OFRF
OIC
Officer in charge
OLM
OSM$
OMT
Or
Ordnance publication
Operation order
OPFE
OPTAR
Operating target
OPRDALT
ORDSAT
ORDSER
PEB
PECP
PERA
PMA
PMF
P MS
POA&M
POT&I
PPH
PPM
PPP.
PQS
PRAV
PRIORITY
DESCRIPTIVE PRIORITY
MANDATORY
ESSENTIAL
HIGHLY DESIRABLE
DESIRABLE
PRL
FSA.
Post-shakedown availability
PSIG
PUBSAT
QA
Quality assurance
QPL
PRA
Restricted availability
PRAC
RAV
PAP
RCM
REFTRA
Refresher training
RFI
117
RFF
RIP,
ROH
RPM
RSG
SAIL
SARP
SCAT
SFWP
SHIPALT
118
SIMA
SITREP
Situation report
SMAF
SMMO
SNAP
SOE
SORAP
SOT
SFCC
SPETERL
SPM
SQT
SPA
SPF
SS
Stainless steel
SSCI
SSD
SSR
SSTG
SUADPS
SUPSHIP
SWAB
SWBS
SWI
WSAT
WWP
120
REFERENCES
1.
2.
3.
4.
5.
6.
7.
8.
COHAVSURFLANT
Instruction
4790.1C, COMKAVSURFLANT
9.
121
2.
Superintendent
Attn: Library, Code 52
Naval Postgraduate School
Monterey, California 93943
3.
Professor L. R. Jones
ASlJN
Naval Postgraduate School
Monterey, California 93943
4.
5.
Professor J. L. McCaffery
AS/11C
Naval Postgraduate School
Monterey, CA 93943
2
(913/915)
122