RAF Mildenhall makes a stand, saves money, man-hours for Air Force

  • Published
  • By Karen Abeyasekere
  • 100th Air Refueling Wing Public Affairs
RAF MILDENHALL, England --  What started as an idea by a former maintenance group commander has saved RAF Mildenhall, and consequently, the Air Force, at least 600 man-hours and hundreds of thousands of dollars since its inception earlier this year.

The process of isochronal inspections - periodic aircraft inspections- was examined, along with smaller relative processes, such as cell design and implementation, as part of an Air Force Smart Operations for the 21st Century event.

After countless hours of research, mobile platforms were purchased which are smaller, more portable, can move in all different directions, and have several compartments and baskets for tools and equipment.

Inspections originally took 10 days from start to finish. With the new stands, that process was reduced to seven days - the original goal. Work cards for each process were previously changed, which also played a big part in reducing the time spent doing inspections.

Michael Saville, retired colonel and former 100th Maintenance Group commander, realized the mission capability rate - a key metric for both the maintenance group and wing - had serious problems, according to Larry Walker, 100th ARW AFSO 21 director.

Mr. Saville decided to analyze what was causing the falling mission-capable rate, and it was determined that isochronal inspection was the biggest factor. A target was then set to reduce the ISO inspection, positively impacting the mission-capable rate and bringing it back into standards.

The original project team met in March, and performed three week-long events, with an ISO inspection between each. The first event was brainstorming ideas with the AFSO 21 office, and for the second and third, the team went to Hangar 814 to get a visual idea of what could be done, look at current processes and to make physical changes.

"We used different (Air Force Specialty Codes) and maintainers, who were 'outside-the-box' thinkers," said Capt. Angelina Stephens, 100th Maintenance Group and project team leader.

One of those people was Staff Sgt. Christopher Klaus, 100th Maintenance Squadron ISO dock controller, who, according to Captain Stephens, masterminded the purchase and research of the mobile platforms.

Sergeant Klaus said during the initial team meetings, they started looking at different equipment that could possibly replace the current stands used by the wing, that wouldn't result in any loss of time or hinder the process.

"I remembered a piece of equipment I'd seen back home (when on leave), and suggested it to the group," said Sergeant Klaus. "It met all our needs, and solved the dilemma of having to use the wing stands.

"I coordinated a demonstration of the machine with all outside agencies (100th Air Refueling Wing leadership, 100th MXG Quality Assurance and the 100th ARW Safety Office) to get their approval."

The ISO dock controller said seven mini high-reach platforms have been purchased, replacing the wing stands which only go under the wing. For other areas on the aircraft, different stands are used, and it takes time to pull each one out and position it in-place. The old stands also have nowhere to keep tools or equipment.

"Each (of the older) stands takes an average of 20 minutes, and four people, per wing to set up," he said. "With the new mobile platforms, an individual can be in-place with their tools in less than five minutes."

Sergeant Klaus explained the new stands can be used to reach all over the aircraft - including under the wings, tail and nose. They reach up to a height of about 3 meters, and are electric, so the maintainers just hop on board, load up their tools and laptops (for viewing technical orders), and quickly move around the hangar, going up and around the aircraft as needed.

For areas higher than 3 meters, they also have a high-lift/high-reach platform which was part of the AFSO 21 project, and are waiting on the second one to arrive.

Maj. Kelly Bolen, 100th ARW AFSO 21 deputy director, said it's been projected that 1,000 man-hours will be saved per year - an equivalent of 24 extra days annually that the aircraft will be mission-ready.

"This has caused a change of attitude of the guys working in the ISO area," Major Bolen said. "They've really seen what thinking about the process can do in making their lives easier. Before the (AFSO 21) event, everyone was buying tail stands at a cost of about $1.5 million (per base). The seven mobile platforms we purchased cost less than a total of $100,000."

As part of the same AFSO 21 event, the team spearheaded new scoring and scheduling procedures for aircraft painting, which in turn also cut downtime and man-hours by 70 percent, Captain Stephens said.

Mr. Walker went on to explain how the 100th MXG was the first unit in the Air Force to come up with, and implement, the idea of using these stands for the KC-135.

"The use of the mobile platforms and other items the team has implemented, like point-of-use tools and benchstock, work fantastic ," he said. "I believe once other units see it, their use will sky rocket."

Col. Charles Westgate, 100th MXG commander, said he's impressed with how his people get the job done even better than before.

"Considering all of the manpower cuts that have happened over the last few years and the high operations tempo since 9/11, AFSO 21 and LEAN thinking have become key tools for survival in the maintenance community," he said.

"Our folks are constantly looking for ways to do things smarter and more efficiently," continued the colonel. "These mobile stands are just one of the many examples of what our innovative maintainers are coming up with to ensure success of the wing's mission."