Maintenance Innovation for Legacy Equipment

Reliability Improvement

Problem Statement: Maintaining older, high-value military equipment is often expensive and inefficient. Specific challenges include the high cost of restoring equipment like the M149 Buffalo water tank, the hazardous and time-consuming nature of crane maintenance, and design flaws in systems like the Mobile Integrated Remains Collection System (MIRCS) that hinder field serviceability.

Description of the Innovation Solution: SIAD has implemented three key innovations:

1. High-Pressure Cold Spray (HPCS) Technology: A process that propels metal powders at supersonic speeds to repair and reinforce damaged surfaces without heat, used for restoring M149 water tanks.
2. Viper Wire Rope Cleaner and Lubrication System: An automated system for cleaning and lubricating heavy-lift crane wire ropes, improving safety and efficiency.
3. Engineering Change Proposals for MIRCS: Redesigning the hydraulic system routing and improving the roof structure to enhance durability and ease of maintenance.

Benefits: These innovations provide significant cost savings, improved safety, and enhanced equipment readiness.

1. HPCS is projected to reduce the Unit Funded Cost of restoring water tanks by 25%.
2. The Viper system reduces crane maintenance labor by 90%, resulting in over $114,000 in savings over three years, while also improving environmental compliance.
3. The MIRCS enhancements will increase system uptime and reduce long-term service costs.

Innovation Challenges: The primary challenge addressed by these innovations is overcoming the limitations of traditional repair and maintenance methods, which are often costly, slow, and present safety or environmental hazards. A specific technology shortfall identified is the lack of modern Automated Information Technology (AIT) for inventory management, which creates a considerable physical burden.

Technical Maturity/Demonstration Results: The innovations are mature and have demonstrated clear results.

1. HPCS: 54 M149 systems have been rebuilt over the past three years using this technology.
2. Viper System: The system has been fully integrated into primary heavy-lift crane maintenance operations.
3. MIRCS ECPs: The proposed redesigns are based on in-depth evaluations and have been validated by the TACOM Integrated Logistics Support Center.

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