INTRODUCTION:
This was the first in a series of three contractual efforts that were issued to Avion, Inc. in support of the Army Aviation and Missile Command (AMCOM) to develop, implement, field and sustain an Automated Information System (AIS) for the Army Aviation community.

Avion’s support has encompassed the complete system life cycle, including: IT System concept development, software design, coding, programming, prototyping, test and evaluation, production, integration, fielding, training and system sustainment. Under DAAB07-98-D-H502, Avion, Inc. completed the AIS - Automated Identification Technology (AIT) - Aviation Maintenance Automated Tracking System (AMATS) Demonstration Program. This work effort was performed for the PEO-AVN Army Attack Helicopter (AAH) Project Management Office (PMO) and the Aviation and Missile Research, Development and Engineering Center (AMRDEC) – Multi-Purpose Aviation Integration Laboratory (MPAIL).  The Avion Team designed, developed and implemented a product using an aviation Maintenance Management System (MMS) and Contact Memory Buttons (CMB) as an AIS solution for improving the U.S. Army aviation maintenance business processes for management of Critical Safety Items (CSI), serially-tracked high-dollar components. Avion’s software development expertise, experience and knowledge of Army Aviation logistics and Army aircraft technical expertise allowed us to provide independent, technical leadership in the development and implementation of this system.

During the system development cycle, Avion was tasked with evaluating AIT’s capability to enhance component tracking and configuration management within The Army's Maintenance Management System - Aviation (TAMMS-A). The legacy TAMMS-A system (DAPAM 738-751), includes the manual tracking of finite-life, time-sensitive rotorcraft components through a paper based system for input into the AMCOM Integrated Material Management Center (IMMC) Maintenance Consolidated Database System (MCDS). Avion developed and implemented the prototype AIT enabled tracking system based upon the existing TAMMS-A system. Since its inception, Avion has become a recognized leader in understanding the complex issues associated with integrating today’s technology into legacy military logistics systems. The development process included an in-depth investigation into the current business processes at several aviation units including the Aviation Technical Test Center (ATTC), Fort Rucker; the Aviation Training Brigade, Fort Rucker; 101st Airborne Division, Fort Campbell; 160th Special Operations Aviation Regiment (SOAR), Fort Campbell; and the Corpus Christi Army Depot (CCAD). Analysis of the unit business processes served to support the software system requirements development, allowing the Avion team to develop the AIT system to be as non-intrusive as possible to the units’ daily activities and provide tangible benefits.

Avion employed trade-off analyses as systems integration approaches were evaluated to optimize commercial off-the-shelf (COTS) hardware/software component selection and integrate today’s technology into legacy military logistics systems. The AMATS system employs COTS AIT in the form of Contact Memory Buttons (CMBs) electrically erasable programmable read-only memory (EEPROM) microcircuit bonded to components on and off the aircraft to feed historical data into the local aviation MMS via a handheld AIT device. CMBs contain the complete historical data for the associated component (including associated tracked subcomponents) and are updated when the component is removed, repaired, installed, or overhauled. The Avion Team developed a software product, the AMATS 2410 Transfer Tool that automatically transfers data from the local MMS, the Enhanced Logbook Automation System (ELAS) database, to the national maintenance level database, the IMMC MCDS.

Avion defined and designed a system concept with which to complete a meaningful AMATS Proof of Concept demonstration. The ultimate goal was to produce a demonstrable system, integrating CMB and ELAS hardware and software, which would convincingly show that CMB products could be used to automate and improve of the Army Aviation’s supply and maintenance processes, particularly as applied CSI tracking and Historical Records management. Specific objectives achieved and demonstrated as the program progressed through the System Development and Integration Phase included the following:

• A memory management plan for use of the 32KB space on the CMB.
• CMB data survivability comparing vendor information and operating temperature surveys.
• Evaluation and selection of AMATS hardware.
• The ability to read and write the appropriate DA Form 2410 information to the button.
• The ability to transfer DA Form 2410 data via ELAS into the user/AMCOM maintenance, supply and readiness system.
• A process framework for CMB initialization of component data with new procurements, with maintenance and overhaul, and field applications.
• A CMB maintenance and supply concept, including CMBs, network requirements, read/write devices, and associated equipment/materials.
• Draft CMB installation procedures and drawing modifications for Technical Data Package.
• Evaluate Depot Maintenance Work Requirements (DMWR) procedures for CMB utility and survivability.
• Operator and maintainer training materials to include operating instructions for hardware and software.

Avion developed the necessary interfaces with ELAS, the Army unit maintenance software that automates many of the forms and processes currently used by Army aviation units for maintenance management. It provides for more timely and accurate data collection, reporting, and administration. This affords the aircraft users and maintainers with the tools needed to make maintenance decisions and take actions that result in increased aircraft safety, reliability, and readiness. Access to ELAS information comes in one of two configurations, Logbook or Workstation, depending on the role of the Army user. ELAS performs three major functions in either configuration: data collection, system administration and maintenance, and report generation. AMATS interface efforts are briefly described below:

• ELAS Workstation: ELAS Workstation software was modified to support the use of CMBs. ELAS was specifically designed for use by Production Control (PC), Quality Control (QC), Maintenance, and Flight Operations (FO) personnel within the aviation maintenance organization. These personnel use ELAS to maintain aircraft and aircraft component operational, historical, readiness, and maintenance data. AMATS Phase I was limited to QC. As AMATS progressed through later phases, workstation software used by the maintenance, PC and FO personnel was modified and demonstrated, as well. The ELAS Workstation automates most of the forms and processes currently used by Army aviation units for maintenance management. ELAS Workstations are configured in a number of ways, (i.e., QC, PC, maintenance, or FO); ELAS Workstation performance is briefly summarized below:

• ELAS User Applications As mentioned above, ELAS was specifically designed for use by PC, QC, Maintenance, and FO personnel. Only the QC section of ELAS was modified to support AMATS during Phase IB. ELAS modifications to the electronic DD Forms 2408-16 and 2408-16-1 are listed below:

AMATS POPULATION TOOL:
Avion developed the CMB Population Tool to read and write CMBs. It enables receiving component data from an ELAS database, through keyboard input, or from a populated button. The program is capable of reading and writing buttons or transferring button data to a handheld PC (e.g., Symbol PPT 2740 or PDT 8146), which can then, using the companion software called Aircraft Population Tool, write buttons. This program was developed for use in the initial population, or writing, of buttons by the contract field team. It is also for use by manufacturers, repair facilities, or the various segments within a maintenance organization that might need to update or write button data but do not use the AMATS main software. The different inputs the user can select with the AMATS Button Population Tool are shown below:

 

Button reader software for the MacSema ButtonReader was developed primarily to interface with ELAS in order to input component information and update the CMB with up-to-date information from ELAS. This software also allowed the user to inventory an aircraft by reading each CMB on the aircraft. This inventory information can then be put into a file that can be imported into another application for review. This inventory feature is not equivalent to the 2408-17, but allowed the user to establish existing component configuration management on a by-aircraft basis. As the AMATS program progressed these functions migrated to and are performed using handheld PCs with AMATS embedded software.

TEST & EVALUATION:
The AMATS Demonstration Program consisted of a series of test programs, beginning with Proof of Concept laboratory and prototype demonstration and test. This was followed by an Operational Test Program in a “Low OPTEMPO environment” at ATTC and an Operational Test Program in a “high OPTEMPO environment” within the 2nd – 101st at Ft. Campbell.

• Laboratory and Prototype Demonstration and Test: The initial Test Program consisted of some relatively simple component/ELAS brass board testing in a laboratory environment and broadened to include some relatively complex prototype testing consistent with the Test Plan.
• Ground Test and Evaluation: In order to demonstrate the utility and viability of using contact memory button technology to improve the effectiveness and efficiency of Army Aviation’s supply and maintenance processes, a ground test and evaluation was performed using a mock-up of aircraft and test set of terminals representing all the elements of the maintenance process. Avion provided the necessary laboratory (facility and equipment) for initial prototype ground and operational testing of the AMATS software product. This laboratory simulated the maintenance environments associated with Army Aviation, providing a dynamic test environment. During ground testing, maintenance actions were duplicated, and the AMATS software was thoroughly tested. This simulation aided in identifying software issues so that they could be resolved before operational testing began, optimizing software product stability for operational field-testing.
• Ground testing of the mock-up was performedto ensure the memory buttons and associated hardware and software were functioning as desired prior to executing on actual aircraft which was subsequently accomplished during the Operational Demonstrations. In addition, prior to being released at ATTC, Beta testing was performed by the local users.
• Test Criteria: Successful completion of this test required correctly functioning hardware and software for the component, the unit, the depot, and the AMCOM supply and maintenance processes.
• Test Environment: All hardware, software and procedures were tested during the ground evaluation of AMATS. Modified laboratory space was used as the Avion AMATS Ground Test Facility (GTF). The GTF was equipped with all necessary hardware to model all entities required for interface with Army Aviation. This included the electronic logbook, Quality Control (QC), Production Control (PC), ELAS Server, back shops, manufacturing, and depot maintenance and re-build. Ground testing of the mock-up was performedto ensure the memory buttons and associated hardware and software were functioning as desired prior to integration and testing on actual aircraft.
• Test Execution: Ground mock testing was completed in three steps. The first phase of testing was completed to aid the development of the software products. During this step, the first editions of software in combination with the CMBs were tested daily and adjustments were made to the software as needed to improve the performance and utility. This phase was completed when the software incorporated all AIT and data transfer utility in an efficient manner. The next step was the testing of this software to identify and correct inconsistencies and errors. This step was completed when the software consistently tested without any errors. The last phase was an in depth series of tests for the finished product to ensure that the software could function without error in a unit setting and transfer errorless data to the AMCOM IMMC database.
• Software Modifications: During development, the software was tailored to meet the needs of the user. While testing, the user interface was improved and the programs were adjusted to make the maintenance actions flow more seamlessly. The CMBs performed as expected and proved to be an errorless method of storing data. The major challenges of this phase were integrating the existing ELAS software with the new AMATS specific software.
• Test Results - Proof of Concept Completion Criteria: The specific exit criteria as outlined in the AMATS Demonstration Program Plan are summarized below:

• Installation and Population: The first phase completion criterion was the error/deficiency free demonstration of button installation and population, using prescribed procedures. These procedures were used and updated in execution of Phase II. Error/deficiency free demonstration of data population was achieved by developing the AMATS Button Population Tool, a software product that works with the button link to populate buttons from an existing ELAS database, another existing database, or by manual input. This product is described in AMATS “Complete Training Manual”.
• Data Transfer and Maintenance Actions:The error/deficiency free demonstration of data transfer and procedures for component and assembly events was achieved by developing and integrating the entire system including the modifications to ELAS, the development of new software products to meet the AMATS requirements, and the integration of the CMBs into the system. ELAS was modified to readily accept data from the CMBs, perform normal maintenance actions with this functionality, and to be compatible with the other AMATS-developed software products. ELAS was also modified to have an electronically editable DA Form 2410 to ensure that the correct information would be transferred to the AMCOM IMMC database. (During this phase, the IMMC 2410 Transfer Program” software was developed that would allow transfer the DA Form 2410 data from the ELAS Server to AMCOM IMMC).
• Button Memory Management: The acceptability of button memory management was accomplished via coordination with AMCOM representatives to determine data resident on the CMB and data elements defining the fields. The product of this work is the AMATS Memory Management Plan.
• Maintenance/Supportability Concept:The fourth phase completion criteria listed above is the acceptability of maintenance/supportability concept. The maintenance and supportability concept was developed IAW DOD Implementation Plan for Logistics Automatic Identification Technology. This concept was reviewed and accepted by the AMRDEC MPAIL Office.
• Adherence to the Economic Analysis: During the ground test of AMATS no unforeseen expenses were identified.
• The AMATS software completed successful testing in a controlled environment.
• The basic functions of ELAS were tested and any foreseeable problems were addressed and corrected in order to meet the electronic transfer and automation requirements of the AMATS Demonstration Program Plan.
• Initial Testing convincingly demonstrated that COTS CMB products, coupled with ELAS, had the capacity, capability, and the reliability needed to automate of the DA Form 2410 process – from aircraft and throughout the aviation logistics system.
• AWRs were granted for the UH-60A/L and AH-64A aircraft used in Operational Testing.

 

OPERATIONAL DEMONSTRATION:
The next step was to follow the system demonstration to integration and test on actual aircraft. The AMATS Phase II “Operational Demonstration” program was defined, organized and executed in two phases.

• Phase IIA consisted of an initial AMATS demonstration on UH-60A/L (Blackhawk) and AH-64A (Apache) aircraft at the Army’s Aviation Technical Test Center (ATTC) at Ft. Rucker, AL (FTR). This work effort was successfully completed.
• Phase IIB provided for a full AMATS operational demonstration on AH-64D (Apache Longbow) aircraft of the 2nd Battalion, 101st Division (2-101) at Fort Campbell, KY (FTC). Phase IIB testing focused, both on the durability of the CMBs in fully operational scenarios and the ability of AMATS to function in an operational aviation unit. During this phase, the system was set up at an operational unit and was tested with the unit’s daily aircraft maintenance data. CMBs were installed on high dollar, DA Form 2410 tracked, time-critical components on AH-64 helicopters and populated with the most current DA Form 2410 data for the respective components. Supporting hardware and software was set up and configured, and unit personnel were trained on CMB installations and hardware and software use. ELAS Version 3.5, a product of the initial ATTC program effort, was introduced and used during the early part of this phase. Concurrent, with conduct of the test program, some software improvements where underway. These where intended to correct some existing deficiencies in and enhance the performance of ELAS Version 3.5. Thus, during the execution of this project component, ELAS 2.0 AMATS was integrated and tested. Also, while testing was underway, ELAS and AMATS software were undergoing major upgrades to allow the system to function in a web-based environment. This necessitated upgrading to the Symbol 8146 as the system read/write device and the development software for it. (It also brought about the next generations of ELAS (V6.0) and AMATS (V3.0 and V.4.0) software which where introduced and tested, primarily at Ft. Rucker, coincident with, but somewhat independent of, the Phase IIB testing at Ft. Campbell. These system changes were subsequently fielded to Ft. Rucker and within the Apache Longbow Battalions under separate contract tasks.) This work effort was also successfully completed prior to 2-101 in-theater deployment and the AMATS system remains fully functional in CY2006.

SUMMARY:
The Avion Team has developed and implemented a product using the CMB as an AIT solution for improving the DA Form 2410 business process.

• The Avion Team successfully developed a deployable capability to automate the DA Form 2410 process and significantly reduce the administrative burden associated with critical asset tracking and historical record keeping. The AMATS team has developed the end-to-end process that tracks critical Army aircraft components from the original aircraft manufacturer, through operational usage, and during the maintenance and overhaul processes and has automated the migration of component historical data from the unit to the consolidated database at AMCOM headquarters.
• In the implementation and fielding of AMATS, Avion provided the Aviation Engineering Directorate (AED) with the appropriate documentation to be granted airworthiness releases (AWRs). Avion completed the necessary tasks to obtain AWR approvals and received the AH-64 Fleet-wide AWR from the AED (AMSAM-RD-AE-I-P-A).
• Avion developed and provided documentation (IAW MIL-STD-498, Software Development and Documentation) for a fully compatible software interface application to automatically transmit data from the local MMS db to the AMCOM IMMC MCDS.
• Analysis of the unit business processes allowed the Avion team to develop the AIT system to be as non-intrusive as possible to the units’ daily activities and to provide tangible and intangible benefits to the unit.
• The Avion Team provided test plans, technical reports, fact-finding summaries, and leadership briefings on program results.
• Avion actively supported the data standards environment and has coordinated with the DoD Logistics AIT Office on the drafting of both American National Standards Institute (ANSI) Material Handling (MH) 10.8.2/International Standards Organization’s (ISO) international standard (IS) 15418 as the data semantics standard and ANSI MH10.8.3/IS 14434 as the data syntax standard.
• Avion provided comprehensive training to the users of the AMATS system. This system has performed successfully within the Apache 2--101st Battalion during OEF and OIF.
• The AMATS product is now being fielded globally to the Apache Attack Helicopter (AAH) fleet under separate contract vehicles.
• This system is being implemented within the AAH fleet to support Recapitalization requirements and coordinated during RESET operations, post deployment for OIF.
• The AMATS system is a key modular element of the Unit Level Logistics System – Aviation (ULLS-A), Software Change Package-06 (SCP06) initiative that has been approved and mandated by G-4 for global implementation across all Army Aviation rotorcraft fleets.
• The improved data quality and transmission will ease the transition to Global Combat Support System – Army (GCSS-A).