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SHAUN Q MORRIS
Lt Gen, USAF, Program Executive Officer, Rapid Sustainment Office, US Air Force
Supernova Award Category:
Data to Decisions
The Organization:
The United States Air Force (USAF) Rapid Sustainment Office (RSO) was
established with a sustainment-centric focus to leverage both mature and
emerging technologies to dramatically improve USAF readiness and warfighter
capabilities. Organized with a non-traditional Air Force construct based on
agile principles and a short chain of command, the RSO pioneers innovative,
cost-effective sustainment technologies and tools that keep the Air Force fleet
flying. The RSO identifies emerging technologies, applies and validates them
through rapid prototyping, then deploys and scales the successful technologies
over time. Moving technology from one phase to another is an impressive feat
that showcases the RSO’s ability to rapidly deploy emerging technologies.
The Problem:
Sustainment is one of the biggest and most complex challenges in modern military
history. Not simply aircraft maintenance, its reach goes much further into
supply, transportation, sustaining engineering, data management, human systems,
and safety considerations. Sustainment is multi-faceted and complex with two
primary and often competing goals of increasing equipment availability while
reducing operations and sustainment costs. Since 70 percent of the cost of an
Air Force system is expended to sustain its operation, it is vital to seek and
develop novel technologies and processes that drive down costs.
To actively address these objectives, the RSO focuses on rapidly identifying
promising technologies and sustainment process improvements, prototyping and
verifying their utility and application, and deploying those that demonstrate
the ability to increase readiness across the Air Force enterprise.
Through collaborative partnerships across business, government and academia, the
RSO pushes the boundaries on scaling innovative and proven technologies that
will make Airmen safer and their jobs more efficient, reduce costs and increase
mission readiness at an accelerated speed.
The RSO has spearheaded more than 30 projects since launching in 2018, focusing
on six technology areas: artificial intelligence and machine learning, advanced
manufacturing, automation and robotics, data and digital environments, AR/VR,
and rapid and austere maintenance environments.
The Solution:
After a successful inaugural Pitch Day in 2018, the RSO awarded one of its
seventeen prototype contracts to C3 AI to target use cases such as predictive
maintenance and multi-domain command & control. RSO’s Condition-Based
Maintenance Plus (CBM+) Program Office has used C3 AI to deploy an AI-based
predictive maintenance application to improve the efficiency and effectiveness
of USAF maintenance processes. Using this solution, applications forecast
remaining life and proactively remove high-risk components before failure,
reducing the impact of unscheduled maintenance events resulting from a failure
and increasing aircraft availability. RSO will expand this technology to an
additional 20+ USAF aircraft platforms over the next several months. This
solution is now a platform of choice for the USAF to increase aircraft
availability and drive digital transformation across the enterprise through the
advanced artificial intelligence (AI) and machine learning (ML) capabilities.
The Results:
Successful implementation of artificial intelligence has reduced unscheduled
maintenance and facilitated a digital flight-line. CBM+ has streamlined
maintenance operations, optimized the supply chain, and improved asset
generation and fleet awareness.
CBM+ enables more efficient weapon system sustainment by transforming
sustainment data into valuable knowledge about the condition of components on
weapon systems. This new knowledge enables USAF maintenance organizations to
optimize maintenance plans and ensure that asset health can meet mission needs.
Metrics:
The CBM+ program to digitally transform sustainment practices by deploying
machine learning and advanced analytics to support enhanced reliability-centered
maintenance has the potential to save over $5.5B when fully implemented across
the USAF aircraft fleet. Over 14.5TBs of maintenance data and supply records
have been ingested from 6 separate systems of record. The B1-B maintenance data
alone comprised 500GBs of data. Expected results include reducing unscheduled
maintenance downtime, increasing the mission-capable rate to 80%, reducing
sustainment costs, reducing unnecessary scheduled downtime, and providing
capacity for prioritized predictive maintenance.
As of March 2021, the CBM+ program has fielded solutions for 12 aircraft
platforms and are onboarding 9 more, actively monitoring over 3000
aircraft. Over 550 maintenance units have been trained and saved a collective
5,000 hours of troubleshooting time, and handled 250 sensor based algorithm
maintenance alerts to avoid inflight failures.
The Technology:
C3 AI provides a tailored workflow for RSO using the C3 AI Suite and C3 AI
Readiness Application for Aircraft to analyze, review, and field component
remaining life thresholds, as well as offer a structured process to review and
field forecasts. USAF field users at operating bases can supplement current
tools and processes to target aircraft for scheduled maintenance and components
for predictive removal.
Disruptive Factor:
CBM+ must cover airframes that span the range of technology eras from the 1950s
to the modern day. The KC-135 was built in the mid-1950s, so there is not a lot
of technology on board. It’s necessary to look at the flight data recorder and
even manual maintenance logs and pilot notes to recreate the history of issues
and maintenance actions on the airframe, using image recognition and natural
language processing. On the other hand, the F-35 is just being fielded today,
and includes a host of sensors generating huge volumes of data on many different
operational parameters.
Building a data model and data ingestion stream for such a range of aircraft is
a huge challenge, but in the end, building a digital twin of each type of
aircraft provides a common view that can be rolled up to provide fleet-wide and
platform-wide perspectives. Logistics planners can access data at the top level
and optimize overall supply inventory and reduce excess for hundreds of millions
of dollars in savings. Meanwhile, individual maintainers can drill down to an
specific airframe, view its history, and generate predictions to guide
maintenance decisions to avoid unnecessary downtime. Solving the data
integration problem has been a huge enabler for increasing mission capability
rates and reducing sustainment costs, and the open and extensible framework
facilitated by the C3 AI model-driven architecture has delivered huge value to
the RSO and the USAF.
Shining Moment:
One highlight is analyzing seven years of data from the Integrated Maintenance
Data System to develop a Serial Number Tracking module as a big data and
AI/ML-driven solution based on C3 AI. The module monitors and tracks parts by
serial number and identifies bad actor parts, flagging them for removal from
inventory circulation. This module has increased aircraft availability
(readiness) and mission capability rates, as well as confidence in the quality
of parts in circulation.
ABOUT RAPID SUSTAINMENT OFFICE, US AIR FORCE
The US Air Force created the Rapid Sustainment Office in 2018 to transform the
operations and sustainment enterprise vital to the world’s most advanced air
force. RSO’s objective is to increase mission readiness by identifying,
applying, and scaling proven solutions at the speed of relevance to advance the
operation and sustainment of the United States Air Force.
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