As the Navy introduces new aircraft variants to bolster the fleet, Fleet Readiness Center Southwest (FRCSW) continues to adapt its maintenance methods and practices to advance the delivery of these assets to ensure mission readiness.
One such aircraft serviced by FRCSW is the E-2D Hawkeye airborne early warning system, the fourth variant manufactured by Northrop Grumman that was brought into service in 2010.
FRCSW performs two levels of periodic maintenance on the airframe: a light periodic maintenance interval one (PMI-1) and PMI-2, a heavy maintenance. The procedures are performed under a 96-month cycle: PMI-1 completed every 48 months, and PMI-2 48 months later.
FRCSW is the Navy’s sole provider of E-2D PMI-2 events, and on December 1, the command delivered its first E-2D to complete PMI-2 under the new 220-day turn-around time (TAT).
The maintenance event was completed five days early, and the aircraft was returned to Air Test and Evaluation Squadron Twenty (VX-20) based at Naval Air Station Patuxent River, Md.
“Technically, this was the first of four aircraft for Fiscal Year (FY) 2022. However, we completed eight in FY21, as well,” noted E-2/C-2 IPT Lead John Goolsby.
The E-2Ds are completely disassembled during PMI-2. Artisans evaluate, repair, and perform a complete wiring analysis of the aircraft. The aircraft’s corrosion preventive paint is also removed and an in-depth metal assessment targets cracks, corrosion, exfoliation and other surface anomalies. The aircraft are painted afterward.
“Once an aircraft is through with PMI repairs, a month-long functional check out is performed at the test line to include a functional check flight,” Goolsby said.
To ensure the best possible TAT for the E-2D, Goolsby said that the program initiated a few measures that were applied to the VX-20 aircraft.
“The E-2 program completely overhauled production flow and kitting to establish start and completion times for every part on the aircraft. We have a production tool very similar to a Buffer Management Tool that turns a part yellow if it’s within three days past due, and turns it red if it’s past three days due. Therefore, every part is tracked within three days of execution. This provided managers with a tool to manage the daily execution of the aircraft within three days of schedule,” he said.
“We also cleared out aged work-in-progress, and for the VX-20 aircraft, landing gear was provided and not repaired under the shadow of the aircraft,” he added.
To further ensure the 220-day TAT is achieved, Goolsby said that the program is currently working to have the fleet purchase landing gear for the aircraft.
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