A feasibility study of expanding the F404 aircraft engine repair capability at the Aircraft Intermediate Maintenance Department

Abstract

This thesis provides a feasibility study and cost analysis to determine what generic engine depot level capabilities should be shifted to selected Aircraft Intermediate Maintenance Departments (AIMD) to reduce costs and improve fleet support of F404-GE-400/402 turbofan engines. The downsizing of the military in the next decade, the resulting budget constraints and the reality of base closures will force the Navy to adopt innovative cost saving measures. This thesis used simulation modeling of the F404 engine repair process at AIMDs Cecil Field and Lemoore to evaluate the feasibility of expanding repair capabilities. The simulation model outcomes provided strong indications that such expansion of the AIMDs is both feasible and cost effective. The researchers recommend shifting selected depot repair capabilities to the AIMD. Recommendations include positioning a spin-balance machine and increasing the welding repair capability at selected AIMDs to reduce BCM actions, turn-around times and repair costs for the F404 aircraft engine.