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CH-53E works gears up at NAVAIR Depot North Island

NAVAIR Release

Press Release Number: ENI200307304

Release Date: 7/30/2003

Story by Bill Bartkus NAVAIR Depot North Island

CORONADO, Calif. - As one aircraft refurbishment was nearing its end, another is in its infancy and growing at NAVAIR Depot North Island. "No problem, we handle this," said a team of Integrated Maintenance Concept artisans who work at the Depot's Multi-Line.

Marine Corps pilots were at the Depot Test Line to pre-flight and later test fly the first Marine Corps CH-53 to go through an Integrated Maintenance Concept event at the Depot. The Industrial Logistics Support Competency made the arrangements to induct the first of five prototype CH-53Es that arrived at the Depot last December.

Though the turnaround goal on the prototype was six months, the team completed work on the first prototype in seven months. "This is excellent considering the scope of the work," said Roel Ramos, Depot Multi-Line manager.

"We feel confident that the lessons learned from this prototype will help the team to produce the next prototype in the planned manhours and turnaround time," said Ron Cobb, deputy program manager for the CH-53E and H-1.

According to Cobb, the pilots who performed the first ground turn ran all three engines through high power checks the first time the aircraft was turned after sitting idle for six months, a significant achievement. Capt. Scott Trent, the pilot, and co-pilot Capt. Tom Esposito, from the Wolfpack of Marine Heavy Helicopter Squadron 466 at Marine Corps Air Station Miramar, Calif., completed the first test flight. Each was impressed with the aircraft, and they were pleased with the first flight, which speaks volumes for the high quality of work that Depot artisans perform throughout the plant.

"The team did a fantastic job. The aircraft performed well on its first flight," said Trent, "and we didn't expect any less from the (Depot) IMC team." Trent said that two of the team members are former Marines. "One was on active duty with the Wolfpack," he noted.

After his team flew the aircraft, Trent said, "We came back for normal track and balance adjustments. This required the crew to fly the helicopter and take a picture of the rotor head while in flight. We then returned to make the adjustments, which is normal procedure."

Esposito said the artisans' work is "outstanding." He noted that the IMC team worked out a few minor kinks on the aircraft. "The aircraft looks great and everything is good. I'm pleased with the results," the co-pilot said.

The helicopter squadron is attached to Marine Aircraft Group 16 also based at Miramar, and coordinates depot maintenance of assigned squadrons. Marine Staff Sgt. David Shaw coordinated the work between MAG-16, the squadron and Depot supervisors and artisans. "Having an IMC for the CH-53 on the West Coast is an outstanding concept. The service is available to each squadron," said Shaw, the IMC coordinator for MAG-16. "Now the squadron can keep tabs on their aircraft and see the progression of work."

Shaw said that there is no longer a need for commands to fly their aircraft across the country. "Having the IMC work performed on each coast is more cost efficient and saves time," he noted. "The work that I've seen performed at the Depot is outstanding," said Shaw, who worked alongside Depot personnel every day.

Cobb said that NAVAIR Depot Cherry Point, N.C., was instrumental in training North Island artisans on evaluating and assembling the CH-53E line. "We accomplished this through on-the-job training at Cherry Point on their CH-53E. After we inducted our first prototype aircraft, Cherry Point provided over-the-shoulder confidence training for the examination and evaluation, assembly, and test line phases." He also said that the North Carolina depot had provided material usage information essential to setting up the NAVAIR Depot North Island line, and are reworking rotatable pool components to help the Depot meet its six-month turnaround time.

Third Marine Air Wing officials selected the Depot to perform the CH-53E IMC work because the plant is geographically close to CH-53E squadrons based at Miramar, and Marines can drive to the Depot when their aircraft is ready for a test flight. "In this way, the customer does not have to fly an aircrew back to Cherry Point and pay commercial airfare one way," Cobb stated.

He said that the Depot's CH-53E IMC team of artisans stepped up to the challenge of producing the first prototype aircraft. Said Cobb, "The team was scheduled to have an artisan certified to engage rotors by the end of the Depot's third prototype, but we had an artisan certified even before the first flight of our first CH-53E IMC prototype."

Cobb couldn't be more pleased at how the team functions. "The team is comprised of organic Depot employees including many retired and recently discharged Marines."

The future is bright for CH-53E IMC work at the Depot. According to Cobb, the Depot will induct three aircraft during the next fiscal year that starts Oct. 1. "We will induct eight aircraft each in fiscal years 2005 and 2006 with three to four aircraft in flow," said Cobb. Plans call for the Depot to induct 11 more aircraft each in 2007 and 2008, 10 CH-53s in 2009, and in fiscal year 2010, Cobb said that the plant will induct 13 aircraft with six to seven in process.

"By 2005, when the program goes into full production, the CH-53E IMC line will need approximately 45 to 50 direct and indirect people," Cobb stated.

As with all new programs, Cobb said that there are new challenges to overcome. "We must fine-tune our processes, documentation, and material requirements before the Depot goes into full production," Cobb elaborated. "We must establish the facilities and acquire the equipment we need to support the numbers of aircraft the IMC full production program will need after our two-year, five prototype aircraft schedule."

Ramos said that the entire team working on the first CH-53E prototype has done an outstanding job. "The contributors are many," he said, "and include people outside the Multi-Line. The folks from the Industrial Logistics Support Competency, Technical Data, the Paint Complex and Quality Assurance, as well as our sister depot at Cherry Point, all helped."

He said that the enthusiasm of the in-house CH-53E team is apparent by everyone who took the time to observe this group of professionals. The challenges of meeting quality, turnaround time and cost goal are exposed every day on the production line.

"The team is composed of unstoppable hard chargers and are dedicated to meeting the challenges associated with a prototype effort of this size," Ramos said. "I have no doubt that the team will continue to be a very successful team in the future.

NAVAIR provides advanced warfare technologies through the efforts of a seamless, integrated, worldwide network of aviation technology experts. From aircraft and weapons development to carrier launch and recovery; from sensors to real-time communications to precision targeting; from aircraft and weapons sustainment to state-of-the-art training; NAVAIR provides dominant combat effects and matchless capabilities to the American warfighter.