Wire System Maintenance Reporting Codes

Pall B. Arnason Team Leader, Advanced Development Programs

Wiring Systems Branch Aging Aircraft IPT / AIR-4.4.4.3

• Navy Has Three Levels of Maintenance for Aircraft:

– Organizational “O” Level - on Aircraft Maintenance

– Intermediate “I” Level - off Aircraft Maintenance and Occasional on Aircraft Maintenance When Required

– Depot “D” Level - Industrial Based “Heavy” Maintenance and Refurbishment

Background: Navy Maintenance Levels

All Three Levels of Maintenance Governed by One Document:

OPNAVINST 4790.2 NAMP Establishes Central Maintenance Data System to Record

Data About- Equipment Maintainability and Reliability- Equipment Configuration, Including Alteration and TD Status- Equipment Mission Capability and Utilization- Material Usage- Material Non-Availability- Maintenance and Material Processing Times- Weapon System and Maintenance Material Costing

Background: Naval Aviation Maintenance Program

Many Combinations of Reports May Be Generated From Maintenance Data, Including:

- Maintenance Actions by Component or Aircraft Serial Number

- Repair Cycle Data

- Monthly Equipment

Mission Capability

- Man Hours Expended

and Cost Data

- Top Level Logistics

Data

Background: Maintenance Data

The Maintenance Data System Requires the Establishment of Codes for the Recording of Data on Maintenance Action Forms:

Work Unit Code ( WUC) - A one, three, five or seven character numeric or alpha/numeric code. It identifies a system, subsystem, set, major component, repairable subassembly, or part of an end item.

11XXXXX Airframe

14XXXXX Flight Controls

42XXXXX Electrical Systems

Background: Work Unit Codes

WUCs are assigned and controlled by the Naval Air Technical Engineering Services Command (NATEC) under the direction of the Commander, Naval Air Systems Command (NAVAIR). There are three categories: (1) Aircraft, Missiles, and Drones (2) Aircraft Trainers (3) Aeronautical Support Equipment.

Each aircraft type has an independent WUC manual. Each WUC identifies the system in the first two positions and sub-system elements in the third, fourth, fifth, etc...

42XXXXX Electrical Systems

428XXXX Aircraft Wiring

428W0 Warn. & Emergency Wiring (C-9)

428W1 Fire Det. Wiring (C-9)

Background: Wiring System Codes (In Theory)

There are multiple codes employed during maintenance transactions. The cumulative data set tells a story about each maintenance transaction:

• Work Unit Code

• Malfunction Description Code

• When Discovered Code

• Action Taken Code

• Type Maintenance Code

• Transaction Code

• Type Equipment Code8890

0012

344

66756 3554

1 2 3 4 5 6 7

3345

00987

545

543

777

78545

444

766

Background: Cumulative Data Set

All Codes and Data Are Entered in Specified Fields on the Visual Information System / Maintenance Action Form (VIDS/MAF)

The VIDS/MAF Contains Multiple Fields for Data Entry Before During and After Maintenance Actions

Navy Now Uses Electronic Format for VIDS/MAF Known As NALCOMIS

NALCOMIS Permits the Maintenance Activities to Track VIDS/MAF Information From Cradle to Grave and Communicate With Supply Electronically

NALCOMIS Data Is Backed up on Tape and Tapes Are Forwarded to Mechanicsburg, PA for Entry Into the Central NALDA (Logistics) Data Base

VIDS/MAF And NALCOMIS

• Multiple Reports Can Be Generated Through NALDA to Provide Analysis Information for Virtually All Aspects of Maintenance

• NALDA Data Is Used to Identify Top 10 Readiness Degraders

• The Navy Safety Center Tracks Hazardous Material Reports by Work Unit Code

• NAVAIR Developing A Metrics Program For Aircraft Wire Systems (AIR-4.4.7)

How We Use The Data

• Current Work Unit Codes Identify Subsystem Wiring and Give No Indication of Zone or Area of Failures (Hot Spots)

• Generic or Not Otherwise Covered (NOC) WUC’s Are Used Too Often

• Current Malfunction Codes Do Not Provide Adequate Information to Determine Actual Failures Occurring or Conditions That Lead To Failure (Degenerative Conditions)

• NALDA Data Is Limited In Its Utility For Reliability Centered Maintenance (RCM) Analysis For Wiring Systems

Problems With Wire System Reporting

• Work Unit Code Guide for Aeronautical Equipment Changed 8 March 2002 Directing Location Based WUC’s for Wiring and Fiber Optic Wiring (Implementation Controlled By Fleet Support Teams)

• 4790.2 Change Committee Has Approved Special Wiring Malfunction Codes

The Change

(Drum Roll Please)

42 5 1 3

Electrical System

Sub-location Wiring or Fiber Optics

Location

New Wiring WUC Structure

Old WUC Example 42830 - Electrical Power System Wiring

New WUC Example4257D - MPDB AC Power Wiring FS 347-359 RH

Old Mal Code Example615 - Shorted160 - Broken Wires, Defective Connection

New Mal Code Example W00 - Chafing against combustible/bleed air linesW01 - Chafing against structure/components/non-combustible lineW02 - Chafing against control cables/flight control componentsW03 - Chafing against other wire/WBAW46 - Arced/burned/shorted wiring – due to chafing against structure, equipment or fluid/pneumatic lines (including overheat detection elements)W47 - Arced/burned/shorted wiring – due to unknown or other causes (including overheat detection elements)W48 - Broken/open wiring (including overheat detection elements)W49 - Broken spliceW50 - Broken terminal lugs/studs

* Conditional (Non-Failure)

Delete

• Actual Failures Identified

• Conditional (Non-Failure) Flaws Identified

• Quickly Highlights Troublesome Areas of the Aircraft

• Better Metrics For RCM Analysis and Planned Maintenance

Benefits

Future Plans

NAVAIR Wire System Metrics Program:

• Verified Failures

• Mission Aborts (Before-Flight and In-Flight)

• Non-Mission Capable Hours

• Partial Mission Capable Hours

• Zonal and Component Tracking / Wiring Specific RCM Analysis

• Direct Links to Wiring Diagnostics

• Identification of Training Deficiencies

Joint Council On Aging Aircraft (JCAA):

• Investigating Joint Service Methods to Improve Wire System Reporting