New NavSea program reduces electronic CasReps and saves time

A Naval Sea Systems Command (NavSea)-managed program for repairing shipboard circuit cards and electronic modules is reaping benefits for the Navy and keeping the fleet at peak operational readiness. The Miniature-Microminiature Module Test and Repair (2M MTR) program establishes structured work centers outfitted with repair tools, test equipment, repair and diagnostics procedures called Gold Disks, and related accessories. These work centers also carry and repair components like transistors, diodes and resistors, and can go aboard most surface ships and many shore intermediate maintenance facilities to repair circuit card assemblies and electronic modules. This portability eliminates the need to send many failed circuit cards to a depot maintenance facility.

The 2M MTR Program also supports repair of many expensive circuit cards and modules originally designated as consumables. Many failed circuit cards repaired aboard ships are not stocked in ship storerooms, and when these cards are repaired, it often means mission-critical systems are restored to 100 percent operational capability. The program set a record for completed repairs during the first quarter of fiscal year 2003. During the quarter, 2M MTR work centers repaired 2,473 circuit cards and electronic modules, averting or correcting 237 casualty reports and saving the Navy an estimated $8.5 million.

"The 2M MTR program is one of the best self-help programs in the Navy," said Tom Ingram, the program manager at NavSea. "It provides ship and shore site technicians which have 2M MTR workcenters with the capabilities to improve their operational readiness with the added benefit of saving significant operating dollars."

Many legacy and most new shipboard systems contain complex electronic circuitry. However, systems maintainers are normally trained to only troubleshoot systems down to a small group of circuit cards, or to a single failed electronic module or circuit card. "Ships only carry a limited amount of spare circuit cards aboard, so if a system goes down due to a failed circuit card and you don't have the capability to maintain it, it can take days, weeks or longer to get a replacement card through the supply system," said Ingrain. "The 2M MTR program increases readiness by eliminating the need to wait on new or depot repaired cards," he said, adding that most shipboard 2M repairs take fewer than four hours to complete.

The program includes three different training courses (Miniature Electronic Repair, Microminiature Electronic Repair and MTR Test Equipment), with each located at six homeport areas. Sailors in the program who repair shipboard circuit cards and modules normally do so as a collateral duty. They receive Gold Disk DVDs quarterly, which contain the latest diagnostic information to troubleshoot and repair faulty circuit card assemblies, and electronic modules.

"This program directly supports three of the CNO's top five priorities," said Ingram. "In addition to supporting current and future readiness, it also enhances quality of service by providing Sailors the opportunity to obtain state of the art technical skills and abilities that are critical to maintaining many mission-essential shipboard and shore systems."

Billets to attend the 2M MTR training courses have been included as part of reenlistment incentives. The 2M MTR skills and abilities frequently net technicians personal recognition and the monthly CNO Gold Disk Award, which includes $500 and a flag letter of commendation.

Since October 1997, Navy commands outfitted by NavSea's 2M MTR Program completed 48,719 repairs, avoiding 4,199 casualty reports (CasReps) and saving more than $155 million.

Ingram cited recent messages from USS Harry S. Truman (CVN 75) about how the program is paying dividends for deployed ships. While deployed in the Mediterranean Sea in January and February 2003, Truman reported 82 completed 2M MTR repairs which saved the carrier $297,000 and averted or corrected 17 casualty reports. "The initial cost to outfit Truman with its 2M MTR equipment, related tools, accessories and workbenches was about $100,000," Ingram said.

Because of the success of the program, it has been copied throughout the armed services, where it played a critical role in Operation Enduring Freedom and in other operations in the Middle East and Arabian Gulf. A Marine air control group recently deployed to Kuwait with a mobile 2M MTR workstation where, according to Ingram, they are reporting success in repairing circuit cards in the desert.

COPYRIGHT 2003 U.S. Navy Safety Center
COPYRIGHT 2003 Gale Group