Propulsion Flight improves maintenance process on C-130s

Published June 27, 2012
By Senior Airman Bryan Swink
379th Air Expeditionary Wing Public Affairs

SOUTHWEST ASIA -- Members of the 379th Expeditionary Maintenance Squadron Propulsion Flight have implemented a new process that reduces the propeller maintenance repair cycle time for the C-130 Hercules.

"We are really excited about this process because the new two- and three-day flow processes we implemented have increased our (average time on wing) from 585 hours in September to more than 2,000 hours now," said Master Sgt. Shawn Davis, 379th Propeller Centralized Repair Facility flight chief. "This means much less time on the ground and more aircraft in the air, accomplishing the mission."

This is a vast improvement from when this process took between four to five days.

The flight consists of 16 men and women from six different bases, both active duty and guard.

"We produce approximately 225 C-130 propellers, which saves the Air Force more than $60 million in depot repair and transportation cost annually," said Davis, here from the 461st Air Control Wing, Robins Air Force Base, Ga.

The first step in the maintenance stage is the acceptance area. This is where the propeller is received and the crew reviews the flight hours to determine which maintenance process it will undertake.

"I'm the first person to have eyes on the propeller," said Senior Airman Joshua Smith, 379th Propulsion CRF technician.

"I make sure we have all the necessary parts to build up the prop," said Smith, here from the 19th Component Maintenance Squadron, Little Rock AFB, Ark. "I do a thorough inspection before we start the breakdown."

Once the receiving inspection is completed, the crew will begin the initial tear down process. The small parts are removed, inspected and repaired if needed.

"We individually inspect about 12 different parts here," said Senior Airman Anthony Gugino, 379th Propulsion CRF technician. "If there are any repairs needed, like the front spinner or pump control assembly, we will make all those repairs in the shop."

The prop moves on to the post-test area where either operational centered maintenance or reliability centered maintenance will be conducted.

If the propeller has less than 1,250 flight hours, OCM will be conducted to ensure everything is within limits and no blade leaks are found. This process generally takes two days to complete.

For propellers with more than 1,250 flight hours, the crew will perform RCM. During this three-day process, the crew will split the hub and remove all four blades to inspect the area.

After completion of the post test, the crew begins the buildup process and installs all serviceable parts.

The propeller is then test-cell prepared to ensure its safe. The test cell process is designed to perform multiple functional checks to ensure there are no leaks and everything is operating as it should.

"The test cell is the most rewarding part of this whole process," said Airman 1st Class Nicholas Steffen, 379th Propulsion CRF technician, originally assigned to the 355 CMS, Davis-Monthan AFB, Ariz. "We test all the parts to ensure the maintenance and repairs we did were done correctly. After a successful test, we know we are putting out a serviceable propeller to keep the C-130s in the air."

When the test cell team finishes their leak and operation check, they will perform a comprehensive final inspection. Once the propeller passes the inspection, it is wrapped for supply where it becomes a serviceable asset.

"Because of the success of this new process, we are working to incorporate this plan at all C-130 back shops to increase our mission capabilities," said Davis.