552nd TOC Case Study v2.pdf

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Theory of Constraints (ToC) Implementation to Support Combat-Focused Logistics
Solicitation number
FA7014-24-R-A4TOC
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This document outlines a case study of the 552nd Air Control Wing's efforts to rebuild readiness and increase sortie generation through implementing a Theory of Constraints approach. The case study details how the Wing increased crew readiness by 131% and aircraft availability through role-focused sorties, reduced planning and execution losses, and implementing a low work-in-process combat plan based on holistic wing-level priorities.

The related federal contract opportunity is a pre-solicitation notice from the Department of the Air Force for implementation of Theory of Constraints logistics support to further combat-focused goals. The solicitation number is FA7014-24-R-A4TOC and seeks implementation services to build on efforts outlined in the case study to maximize sortie effectiveness and throughput.

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552nd Air Control Wing Rebuilding the Road to Combat

Overall Ops manning level at risk Long cycle times for PFT training Growing PFT backlog High conversion training demand

Goal: Achieve Combat Ready Manning while clearing out

PFT backlog ASAP Ops Will Maximize Sortie Effectiveness by:

Mx Will Increase Sorties Generation by:

1. Ops will reduce required # of sorties by maximizing sortie effectiveness

2. Mx will increase sorties generation

To achieve the Goal

Ops Increased Crew Readiness by 131% in Just 6 Months

Mx Increased Aircraft Availability and Unscheduled Maintenance Throughput

Enhance sortie profiles to maximize training events and throughput for specific crew positions.

Role- Focused Sorties

Use ground sorties to alleviate sortie constraint and expose capacity toward training.

Ground Sorties

Implement a low Work in Process (WIP) combat plan based on holistic wing-level priorities and remove silos.

Wing-Level Priority

Establish a scheduling process that ensures student readiness & build buffers to avoid planning and execution loss.

Student Scheduling

Position R-48 Target

Baseline (Oct’20)

Nov

Dec

Jan

Feb

Mar

Apr

AC 48 53 64 68 66 64 66 66

Co-pilot 48 61 58 57 60 65 69 69 Nav 48 44 59 54 58 58 58 59

FE 48 47 52 62 55 60 58 59

ART 48 57 60 55 59 68 71 70

ADST 48 0 0 5 22 24 26 31

ARO 48 0 0 4 23 25 24 30

ABM 192 25 69 74 120 147 159 158

SL 192 31 55 66 84 89 99 135

MSO 192 38 62 63 96 106 150 146

722 356 479 511 643 706 780 823

FY20 Goal Apr

G model sorties flown 940 1500

G model A/C per month 13.6 13.7

G model sorties per day 4.1 6.5

G A/C needed per day 5.1 7.5 7.7

FY20 Goal Apr

Break rate 40% 40%

Code 3 breaks per day 1.6 2.6

“Other” broken A/C 1.4 1.4

Throughput of A/C needed 3.0 4.0 7.0

Current Sortie Level

Goal Sortie Need

MXG

Ops

Results

Wing-Wide Theory of Constraints Effort

107% increase in sortie training throughput effectiveness by reducing planning and execution losses

552nd Air Control Wing�Rebuilding the Road to Combat

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