Skyplate Benefits and Impact
Almost 50% of total production time is spent fastening parts together. Fasteners are 5% of the total cost of a product, but when adding the cost of assembly about 30% of the final cost of a product is absorbed by fasteners (Kruszelnicki, 1997). For example, to understand the impact of the fastener, take a snapshot of maintenance operations at Holloman Air Force Base (49th MXS). 90% of aircraft maintenance actions captured in CAMS (core automated maintenance system) in 2006 were fastening related tasks completed by the aircraft structural maintenance shop.
Skyplate Benefits
Awareness: Know where all fasteners are at all times. Know what panel and/or component the fasteners pertains to, the condition of said fastener, and its location in the panel of component.
Detection: The Skyplate creates a pattern similar to shadow-boxes or a knife block on your kitchen countertop. It provides early detection of missing fasteners, defective fasteners, co-mingled fasteners, and inappropriate installed fasteners.
FOD: The Skyplate mitigates FOD with a proactive approach. By consolidating fasteners the Skyplate promotes good housekeeping and hardware control. The Skyplate creates a detection method by the ability to identify missing fasteners early in the MX/repair cycle and is an early warning system to prevent fastener migration. The parts tag hole identifies the specific weapon system/equipment serial number.
Identification: At the conclusion of the MX/repair evolution, technicians are always searching for the correct fasteners and replacing fasteners that were installed as an incorrect part number (NSN). The Skyplate creates a MX hedge, by early identification of these defects within the MX/repair window. This trends toward the elimination of such events and it becomes an aggregate time saver. As time is saved performing one MX/repair task; that saved time can be utilized to attend to other MX/repair task.
Inspection: Fastened joints have a direct impact on the reliability, performance, and safety of MX/repair operations. However, fasteners laying in plastic bags and paper cups cannot be properly inspected. The Skyplate configuration creates efficient visual bolt inspections that impact proper hardware stack-ups (washers, screws, and nuts) and offer cost-savings, time-savings, and performance benefits (Dropped Object Prevention).
Inventory: Hardware stored in plastic bags, mechanic pockets, and paper cups get thrown away, lost, and misplaced driving up inventory cost. In the lifetime of a weapon system, how many dollars have purchased cups and plastic bags to temporarily hold fasteners and be disposed of? The Skyplate reduces inventory cost and controls cost fluctuations by physically maintaining fasteners and eliminating the need for unreliable storage methods.
Mistake Proof: By replicating the fastener pattern on the weapon system and/or component; the Skyplate mitigates the risk of incorrect fastener installation and fastener co-mingling. The Skyplate promotes the installation of fasteners in the appropriate location.
Mitigation: Incorrectly installed fasteners will break nut-plates which increase the downtime necessary to correct defects. The Skyplate identifies the appropriate fastener and maps the proper location of said fastener.
Quality Assurance: The Skyplate increases MX/repair quality by mitigating the risk of installing incorrect fasters, defective fasteners, comingled fasteners, and improperly located fasteners. By preventing mistakes and defects that increase MX/repair turn-times scheduling volatility is reduced, the maintenance schedule become consistent, and more MX/repairs can be accomplished in the same maintenance operation window.
Repeatability: The Skyplate maps the fastener pattern of the weapon system and/or component. This allows the maintenance technician to perform MX/repair task exactly the same every single time. This methodology creates a culture of consistency and predictability.
Reproducibility: The Skyplate is a static process tool with no moving pieces. This allows the maintenance technician to perform MX/repairs exactly the same every single time regardless of the maintenance technicians’ skillset.
Safety: Unaccounted for fasteners are a FOD risk. This risk can lead to engine damage, lost item reporting, and weapon system downtime. The Skyplate profile quickly identifies missing fasteners and creates fastener accountability mitigating the loss of millions of dollars in non-scheduled repairs and thousands of man-hours in preventable maintenance.
Set: The Skyplate maps the location of each fastener corresponding with the appropriate location on the weapon system/component. This methodology saves time that can be utilized for other MX operations.
Sort: The Skyplate eliminates the need to store fasteners in plastic bags, paint cups, and technician pockets reducing NVA cost. Fasteners are consolidated, organized, and presented for visual inspections increasing readiness.
Standardize: The Skyplate creates a consistent and standardized method to maintain, house, locate, and inspect fasteners. This increased efficiency, speeds up maintenance operations returning weapon systems to service sooner and reducing weapon system down-time.
Sustain: The Skyplate affords the opportunity to re-baseline manpower requirements, control inventory variability, cut NVA cost (paper cups and plastic bags), maintain scheduling, and accomplish more MX/repairs within the same time-frame.
Training: The Skyplate allows less experienced technicians (3 level and 5 level) to perform a greater degree of MX/repair task with minimal supervision. This allows leadership to re-baseline manpower requirements and flex experienced technicians to more complex MX/repair task reducing the OFT (on the job training) burden. Less experienced technicians are afforded a pipeline for accelerated learning curves.
Transportation: Traditionally maintenance teams travel with heavy duty hardware storage (Vidmar) which weigh 1000’s lbs. and transport non-value added hardware. Every pound impacts storage space availability, fuel, and cost. The Skyplate legend identifies the appropriate hardware and promotes the transportation of the appropriate hardware.
Turn-Time: No longer waste time looking for nutplate's and fasteners part numbers, because all applicable hardware part numbers (NSN’s) are etched in a legend on each Skyplate. The Skyplate housing configuration increases efficiency; speeding up MX/repair cycle times and repair turn times which returning weapon systems to service sooner.
FMC/MC Impact
Maintenance Performance
NMCM (U/S)–not MC for maintenance, unscheduled or scheduled rate
NMCS
Abort Rate
Break Rate
Fix Rate
R/R Rate
Maintenance Scheduling Effectiveness Rate
PMC Rate
MC Rate
TNMCM
Eight- and Twelve-Hour Fix Rates
MSE Rate
DD Rate
AWM
Total Repair Cycle Time
Spare Engine Status
Logistics Departure Reliability/Worldwide Logistics Departure Reliability (AMC only metric)
References
Kruszelnicki, Karl. (1997). Nuts and bolts - part 1. University of Sydney. Retrieved from https://www.abc.net.au/science/k2/trek/4wd/nuts1.htm
Rainey, J., McGonagle, R., Scott, B., & Waller, G. (2001). Metrics handbook for maintenance leaders. Air Force Journal of Logistics. Air Force Logistics Management Agency. Retrieved from http://www.ageranger.com/pdf/Maintenance_Metrics_S.pdf
Patent Number: 10,471,586 + 11,045,942
Skyplate Benefits
Awareness: Know where all fasteners are at all times. Know what panel and/or component the fasteners pertains to, the condition of said fastener, and its location in the panel of component.
Detection: The Skyplate creates a pattern similar to shadow-boxes or a knife block on your kitchen countertop. It provides early detection of missing fasteners, defective fasteners, co-mingled fasteners, and inappropriate installed fasteners.
FOD: The Skyplate mitigates FOD with a proactive approach. By consolidating fasteners the Skyplate promotes good housekeeping and hardware control. The Skyplate creates a detection method by the ability to identify missing fasteners early in the MX/repair cycle and is an early warning system to prevent fastener migration. The parts tag hole identifies the specific weapon system/equipment serial number.
Identification: At the conclusion of the MX/repair evolution, technicians are always searching for the correct fasteners and replacing fasteners that were installed as an incorrect part number (NSN). The Skyplate creates a MX hedge, by early identification of these defects within the MX/repair window. This trends toward the elimination of such events and it becomes an aggregate time saver. As time is saved performing one MX/repair task; that saved time can be utilized to attend to other MX/repair task.
Inspection: Fastened joints have a direct impact on the reliability, performance, and safety of MX/repair operations. However, fasteners laying in plastic bags and paper cups cannot be properly inspected. The Skyplate configuration creates efficient visual bolt inspections that impact proper hardware stack-ups (washers, screws, and nuts) and offer cost-savings, time-savings, and performance benefits (Dropped Object Prevention).
Inventory: Hardware stored in plastic bags, mechanic pockets, and paper cups get thrown away, lost, and misplaced driving up inventory cost. In the lifetime of a weapon system, how many dollars have purchased cups and plastic bags to temporarily hold fasteners and be disposed of? The Skyplate reduces inventory cost and controls cost fluctuations by physically maintaining fasteners and eliminating the need for unreliable storage methods.
Mistake Proof: By replicating the fastener pattern on the weapon system and/or component; the Skyplate mitigates the risk of incorrect fastener installation and fastener co-mingling. The Skyplate promotes the installation of fasteners in the appropriate location.
Mitigation: Incorrectly installed fasteners will break nut-plates which increase the downtime necessary to correct defects. The Skyplate identifies the appropriate fastener and maps the proper location of said fastener.
Quality Assurance: The Skyplate increases MX/repair quality by mitigating the risk of installing incorrect fasters, defective fasteners, comingled fasteners, and improperly located fasteners. By preventing mistakes and defects that increase MX/repair turn-times scheduling volatility is reduced, the maintenance schedule become consistent, and more MX/repairs can be accomplished in the same maintenance operation window.
Repeatability: The Skyplate maps the fastener pattern of the weapon system and/or component. This allows the maintenance technician to perform MX/repair task exactly the same every single time. This methodology creates a culture of consistency and predictability.
Reproducibility: The Skyplate is a static process tool with no moving pieces. This allows the maintenance technician to perform MX/repairs exactly the same every single time regardless of the maintenance technicians’ skillset.
Safety: Unaccounted for fasteners are a FOD risk. This risk can lead to engine damage, lost item reporting, and weapon system downtime. The Skyplate profile quickly identifies missing fasteners and creates fastener accountability mitigating the loss of millions of dollars in non-scheduled repairs and thousands of man-hours in preventable maintenance.
Set: The Skyplate maps the location of each fastener corresponding with the appropriate location on the weapon system/component. This methodology saves time that can be utilized for other MX operations.
Sort: The Skyplate eliminates the need to store fasteners in plastic bags, paint cups, and technician pockets reducing NVA cost. Fasteners are consolidated, organized, and presented for visual inspections increasing readiness.
Standardize: The Skyplate creates a consistent and standardized method to maintain, house, locate, and inspect fasteners. This increased efficiency, speeds up maintenance operations returning weapon systems to service sooner and reducing weapon system down-time.
Sustain: The Skyplate affords the opportunity to re-baseline manpower requirements, control inventory variability, cut NVA cost (paper cups and plastic bags), maintain scheduling, and accomplish more MX/repairs within the same time-frame.
Training: The Skyplate allows less experienced technicians (3 level and 5 level) to perform a greater degree of MX/repair task with minimal supervision. This allows leadership to re-baseline manpower requirements and flex experienced technicians to more complex MX/repair task reducing the OFT (on the job training) burden. Less experienced technicians are afforded a pipeline for accelerated learning curves.
Transportation: Traditionally maintenance teams travel with heavy duty hardware storage (Vidmar) which weigh 1000’s lbs. and transport non-value added hardware. Every pound impacts storage space availability, fuel, and cost. The Skyplate legend identifies the appropriate hardware and promotes the transportation of the appropriate hardware.
Turn-Time: No longer waste time looking for nutplate's and fasteners part numbers, because all applicable hardware part numbers (NSN’s) are etched in a legend on each Skyplate. The Skyplate housing configuration increases efficiency; speeding up MX/repair cycle times and repair turn times which returning weapon systems to service sooner.
FMC/MC Impact
Maintenance Performance
- The Skyplate increases MX performance by reducing MX/repair cycle times, which accelerates MX turn-times. From an aggregate perspective the maintenance operation is able to realize the full envelope of Skyplates impact as ~50% of total production time is spent fastening parts together (Kruszelnicki, 1997).
- The Skyplate is a tool that mitigates motion, promotes repeatability, and introduces reproducibility all of which make the MX/repair process more efficient.
- The Skyplate reduces defects by mistake proofing the fastener dynamic, mitigating improper fastener installations, and standardizing the housing, locating, and inspection of fasteners.
NMCM (U/S)–not MC for maintenance, unscheduled or scheduled rate
- The Skyplate aids inexperienced maintenance technicians by mapping the location of each fastener, standardizing the housing, locating, and inspection of fasteners, promoting a repeatable process, and providing a reproducible means regardless of the maintenance technicians’ experience.
- The Skyplate addresses the lack of manpower by allowing inexperienced maintenance technicians to perform a greater degree of MX/repair task with minimal supervision. MX leadership can flex senior grade technicians to accomplish more complex MX/repair task reducing the OFT (on the job training) burden.
NMCS
- The Skyplate aids backshops that are slow turning out parts by reducing MX/repair cycle times, which accelerates MX turn-times.
- The Skyplate addresses hardware stock level problems by eliminating the need to store hardware in plastic bags, paint cups, and technician pockets which leads to unaccounted for hardware. This culture incurs hardware stock variability and volatility which drives up cost, creates lost item reports (NVA time), and presents a FOD risk.
- The Skyplate reduces inventory cost and controls cost fluctuations by physically maintaining fasteners and eliminating the need for unreliable storage methods.
Abort Rate
- The Skyplate mitigates the decrease of MX quality by providing a standardized process that promotes visual inspections of fasteners and complementary hardware, mitigating the risk of installing incorrect fasteners, defective fasteners, co-mingled fasteners, and improperly located fasteners.
- The Skyplate addresses R/R write-ups by accelerating the fastener removal and replacement process with awareness, mistake-proofing, repeatability, reproducibility, detection, decreased motion, and identification.
- The Skyplate addresses reliability problems by creating visual fastener inspections that impact proper hardware stack-ups (washers, screws, and nuts) that ensure fastened joints perform in a reliable and safe manner.
Break Rate
- The Skyplate addresses insufficient tools by eliminating the need to store hardware in plastic bags, paint cups, and technician pockets which provide insufficient process control.
Fix Rate
- The Skyplate functions as a fastener R/R process map (job guide) that allows less experienced technicians to perform a greater degree of MX/repair task reducing the support from experienced technicians. The Skyplate allows MX leadership to flex experienced technicians to more complex MX/repair task which extends the bandwidth of the maintenance operation.
- The Skyplate addresses insufficient tools by eliminating the need to store hardware in plastic bags, paint cups, and technician pockets which provide insufficient process control.
R/R Rate
- The Skyplate establishes a 21st century approach to MX practices. The Skyplate increases efficiency, speeding up maintenance operations returning weapon systems to service sooner.
- The Skyplate functions as a fastener R/R process map (job guide) that allows less experienced technicians to perform a greater degree of MX/repair task reducing the support from experienced technicians.
- The Skyplate allows MX leadership to flex experienced technicians to more complex MX/repair task which extends the bandwidth of the maintenance operation.
Maintenance Scheduling Effectiveness Rate
- The Skyplate addresses problems with particular types of MX actions being accomplished later than scheduled by implementing a standardized and repeatable process that is more efficient and provides time-savings. By mitigating NVA actions such as motion, providing hardware identification, controlling hardware, mapping the R/R of hardware, and introducing reproducibility into the maintenance operation, this platform provides the time to accomplish MX actions on schedule.
PMC Rate
- The Skyplate promotes the good maintenance practice of fixing malfunctions as soon as possible by boosting productivity through a repeatable and reproducible process that increases the efficiency of experienced and less experienced maintenance technicians.
MC Rate
- The Skyplate impacts turn-times by reducing MX/repair cycle times through a mistake proofing, repeatable, reproducible, standardized, and sustainable process.
TNMCM
- The Skyplates profile controls hardware, accelerates MX/repair turn-times (mistake proofing, repeatability, reproducibility, identification), and allows leadership to re-baseline manpower requirements and flex experienced technicians to accomplish more complex MX/repair task reducing the OFT (on the job training) burden. The Skyplate allows less experienced technicians to perform a greater degree of MX/repair task with minimal supervision increasing the bandwidth of the maintenance unit.
Eight- and Twelve-Hour Fix Rates
- The Skyplate impacts the repair process by reducing repair cycle times through a mistake proofing, repeatable, reproducible, standardized, and sustainable process.
MSE Rate
- The Skyplate impacts inspections by providing visual fastener inspections that impact proper hardware stack-ups (washers, screws, and nuts) and offer time-savings.
- The Skyplate impacts periodic maintenance by mitigating the risk of incorrectly installed fasteners, defective fasteners, co-mingled fasteners, improperly located fasteners and providing a platform for early identification of defective fasteners and/or defective complementary hardware.
DD Rate
- The Skyplates impact to MX/repair efficiency allots for less experienced technicians to accomplish minor maintenance actions more frequently which reduces the DD rate.
AWM
- The Skyplate reduction of MX/repair turn-times allows aircraft downed for a day to have a greater amount of deferred discrepancies completed.
Total Repair Cycle Time
- The Skyplate reduces total repair cycle times through a mistake proofing, repeatable, reproducible, standardized, and sustainable process.
Spare Engine Status
- Skyplates impacts the engine repair line by providing hardware management tools for hot sections and cold sections. These hardware management tools provide the benefits listed above for the engine shop and reduce the risk of spare engine non-availability.
Logistics Departure Reliability/Worldwide Logistics Departure Reliability (AMC only metric)
- The Skyplate mitigates maintenance problems by increasing efficiency, reducing quality defects, and affecting the maintenance capability of both experienced and less experienced technicians.
References
Kruszelnicki, Karl. (1997). Nuts and bolts - part 1. University of Sydney. Retrieved from https://www.abc.net.au/science/k2/trek/4wd/nuts1.htm
Rainey, J., McGonagle, R., Scott, B., & Waller, G. (2001). Metrics handbook for maintenance leaders. Air Force Journal of Logistics. Air Force Logistics Management Agency. Retrieved from http://www.ageranger.com/pdf/Maintenance_Metrics_S.pdf
Patent Number: 10,471,586 + 11,045,942