Air Force Materiel Command

Air Force Materiel Command War-Winning Capabilities … On Time, On Cost

Reverse Engineering Study AFRL/MLM HQ AFMC/A4Y 2006 Integrity - Service - Excellence 1

Background • Feb 06, WR-ALC/CC concluded investigation into ability to leverage available capacity and take on additional workload (shared results with AFMC/CC) • Response led to discussion between Gen Carlson, ALC Commanders, and HQ AFMC/A4 on need for technical data, ability to obtain technical data, and use of Reverse Engineering (RE) • Based on experience developing reverse engineering technologies within the depots, AFRL/MLM (ManTech Program) accepted HQ AFMC/A4 request to initiate RE study 2

Ground Rules & Assumptions • Study Will – Focus on Reverse Engineering (RE) technologies, tools and processes – Focus on structural and mechanical part families – Identify RE capabilities at the ALCs, other DoD depots, and best practices within industry – Assess relationships between RE capabilities & technical data – Document capabilities, applications, limitations, & constraints – Identify potential pilot efforts to demonstrate expanded RE capabilities – Produce a draft report in 3-4 months

• Study Will Not – Focus on electronic parts, only mention existing activities – Evaluate policy implications associated with acquiring full technical data packages 3

Approach Use Product Lifecycle Management Model as Documentation Baseline

Step 1: Research Existing Tools, Technologies & Best Practices In Industry & Government

Step 2: Identify Existing Capabilities at AF ALCs

Step 4: Identify shortfalls and define pilot projects

Step3: Review RE applicability at part, assembly, sub-system & system levels

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Approach • Concept - Identify Capabilities & Limitations of RE as it applies to: - Levels of Product Indenture - Type of Application - Data Capture throughout the Product Life Cycle Functional Characteristics

Discrete Parts

Assemblies

Systems

Design Capture Physical Replication Functional Replication Technical Data Generation Qualification & Test Parameters Maintenance Procedures

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Status • Developed Report Outline • Established Team – Identified Government POCs – Leveraged AFRL Contract Resources

• Set-Up Communication Structure – Leveraging existing AFRL Industrial Base CoP through AF Portal to share documents – Bi-Weekly Telecons – Plan visits to ALCs as appropriate

• Assigned Responsibilities – AFRL: Research (Best Practices, Technologies, Suppliers) & Lead for writing report – HQ AFMC: Policy & Requirements – ALC POCs: Baseline Capabilities & Potential Pilots

• Developed Milestone Schedule • TBD: Define additional stakeholders, coordination & briefing reqts., report distribution

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Outline • Define Scope and Requirements – Definitions – Policy

• Characterize RE Capabilities – Best Practices – Tools and Technologies (Suppliers, Market)

• Applications – Scale – Costs & Benefits

• Limitations/Constraints – Documentation – Re-Qualification – Proprietary/Intellectual Property

• Conclusions/Recommendations 7

Definition Reverse Engineering is… • • • • •

Society of Mechanical Engineers Definition US Army Reverse Engineering Handbook (MIL-HDBK-115 ) DMSMS Case Resolution Guide The Concurrent Technologies Corporation (from OC-ALC 2003 brief) The Advanced Research and Application Corp (from OC-ALC 2003 brief)

“… the process of developing exact replicas of items through review of available technical data, testing, physical disassembly and inspection and analysis of functions performed by the item in the application.” (DMSMS Case Resolution Guide)

Reverse Engineering is the process of developing exact replicas of items through review of available technical data, testing, physical disassembly and inspection and analysis of functions performed by the item in the application. Reverse Engineering includes all aspects of engineering design, qualification, manufacturing and maintenance. (the current study)

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Pilots • Goal: Leverage a new reverse engineering capability to: – Generate necessary technical data – Produce a form, fit and function replacement – Enable sustained maintenance and repair

• Piloted capability may include: – New Tools (Off-the-shelf hardware or software) – New Technology (development and integration efforts) – New Business Processes (information management, in/out-sourcing, cost estimating) 9

Example Pilot Projects •

Candidate Reverse Engineering Pilot at WR/ALC (C-5 Crown Skins) – Crown skins experiencing cracking problem that will require a change out of up to 26 skins (per aircraft) on 62 Total Aircraft (C-5A & C) for a total of 1,612 skins (20,050 Man-Hours for Maintenance) – Tooling at AMARC used to form these skins are said to be unusable. New tools for these parts will likely consume 80% of the cost for getting these parts. Good tech data doesn’t exist to build new tools/ parts – C-5 Crown Skin Approach - Reverse engineering the parts using a re-configurable tooling machine located at WRALC/CMXG

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“Short Order Rapid Response Model” – Provides “Collaborative Infrastructure” to tie customer and suppliers – Allows for design capture, procurement, and cost modeling – Currently structuring project between ManTech program recipient that developed the tool set (Doyle Center) and DLA – Process should be transferable to an ALC – Allow AF to better leverage CII funding

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Schedule Task Description

Wk/Day • Kickoff • Heading Check I: Develop Outline • Heading Check II: Research Update • Draft Research Report • ALC Feedback • Visit ALCs • Heading Check III: Recommendation • Draft Final Report • Final Report

Mar

Month 1

6

13

Apr 20

27

3

10

17

Jun

May 24

1

8

15

22

29

1

5

12

19

26

20 March 06 31 March 06 18 Apr 06 5 May 06 22 May 06 31 May,6 Jun 06

12 Jun 06 16 Jun 06 30 Jun 06

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Summary • Study to answer question of whether Reverse Engineering can: – Resolve critical weapon system issues for those components where suppliers and data are no longer available – Generate adequate technical data required to place workload into ALC

• Study to Identify – Tools, Technologies and Processes – Best practices – Pilot Demonstrations 12