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305 MXS 'leans' its way to AFSO21 success

  • Published
  • By Airman 1st Class Rebekah Phy
  • 305th Air Mobility Wing Public Affairs
The 305th Maintenance Squadron recently participated in the AFSO21 lean initiative efforts and held a Rapid Improvement Event here. 

During the RIE, improvements were made to more efficiently complete the KC-10 A-check process without compromising safety or quality. 

"Originally, the KC-10 A-check took about 72 hours to complete," said Senior Master Sergeant Richard McMahon, 305 MXS fabrication chief. "By adding structure to the process, along with ideas from those in the 'Inspection Section,' we have already been able to shave off 10 hours from the process during the first few tests after the RIE."
The Airmen in the Inspection Section seem to agree. 

"So far, the improvements definitely seem to be adding more structure to the process and are allowing things to go smoother," said Senior Airman Doug Loeffler, 305 MXS maintainer. 

To expedite the process, one improvement made was the "gig sheet." 

"The gig sheet is basically one reference sheet for the inspectors to use as their checklist throughout the aircraft," Sergeant McMahon said. "It allowed us to divide the aircraft into five zones, so things in common areas will all be accomplished at one time instead of traveling from the nose to tail inspecting things in different zones. Thus, less time, travel and energy is wasted." 

They also established a list of sequential, dependent tasks which make up the "critical path". 

"Supervision can now focus our resources, manpower, etc., toward completion of the critical path in a timelier manner," Sergeant McMahon said. 

As a result of the RIE, the initial test was to get it done in 68 hours, Sergeant McMahon said. Currently, they complete the KC-10 A-check inspection in 62 hours and are still making progress. Their ideal state is to get the inspections to 49 hours. 

In the end, more readily available aircraft, more often will have the most impact to McGuire and the Air Force. 

"By doing this, we look to potentially save four days non-mission capable time per KC-10 aircraft, per year which enables the aircraft to perform its mission supporting worldwide mobility commitments, increasing aircraft availability to the warfighter; all contributing to Team McGuire and Air Force efforts toward a leaner, smarter force," Sergeant McMahon said. "Overall, this adds up to 128 more days of fully mission capable KC-10 aircraft." 

They also shared their success story with Travis AFB, Calif., which can essentially double the impact of this RIE Air Force-wide. 

Although the RIE team implemented the new ideas and structure, those who work on the aircraft each day also contribute. 

"We have great troops in the Inspection Section with positive, 'Can-Do' attitudes," Sergeant McMahon said. "While the (RIE) team did an outstanding job implementing the restructure and direction of the process, the real credit goes to the men and women of Inspection Section who are making this happen on a daily basis."