Attachment 28 COMPASS.pdf

Attachment 28 for W91CRB-21-R-0012 Instructions for Level Of Repair Analysis (LORA)

(This information is provided to assist in proposal development for W91CRB-21-R-0012)

1.0 The LORA using the Army-approved tool, Computerized Optimization Model for Predicting and Analyzing Support Structures (COMPASS). Additionally, the Contractor shall provide the COMPASS runs along with the .compass model files and the data input and output exported from COMPASS in Excel format to enable the Government to analyze maintenance and support costs of the proposed system. The source of data should be indicated. It should be noted that the following data definitions are specifically for application of the COMPASS.

a. End Item. A final combination of end products, assemblies, materials which is ready for its intended use (e.g., ship, tank, mobile machine shop, aircraft). An end item need not all be within a common enclosure (case or shelter facility). Any equipment which has LRUs in common should be grouped in the same end item, if possible. LRUs and SRUs, which are common, need to be identified.

b. LRU. Usually a subassembly, such as a receiver/transmitter unit, power supply, etc.

Removal and replacement of LRUs results in the repair of the end item. A CCA may be considered a LRU if removal and replacement results in direct end item repair.

c. SRU. An example is a CCA. Removal and replacement of a SRU results in the repair of a

LRU.

d. Piece Parts. Examples are: resistors, capacitors, transistors, integrated circuits, chips, etc.

Removal and replacement of piece parts results in the repair of a SRU.

2.0 All LRUs/SRUs shall be identified with the manufacturer part number, and if one exists, a NSN. If the same LRU/SRU is used in different equipment, the same part number shall be used.

Cabling, harnesses, miscellaneous mechanical controls, and other items which do not have a lower level of indenture shall be grouped together as units called miscellaneous LRUs or SRUs.

Removal and replacement of miscellaneous throwaway LRUs results in end item repair.

Removal and replacement of miscellaneous throwaway SRUs results in LRU repair.

3.0 It is necessary to identify LRUs, SRUs, throwaway LRUs, and throwaway SRUs. If the removal and replacement of an item results in repair of an end item, that item should be considered to be a LRU or a throwaway LRU. If the removal and replacement of an item results in repair of another item which has been labeled as a LRU, then that item is a SRU or a throwaway SRU. An item is considered to be a throwaway item (LRU or SRU) if it does not have a lower level of indenture and hence could not possibly be repaired. The lower level of indenture for a repairable LRU is a SRU. The lower level of indenture for a repairable SRU is a piece part. A tree structure diagram shall be completed for the end item. An example of a tree construct can be found in the User’s Manual under the paragraph entitled “Equipment Breakdown Overview”.

4.0 Register and download the COMPASS model and User’s Manual at the web address:

https://www.logsa.army.mil/#/lec/compass

a. Click on "COMPASS download" located on the bottom of the COMPASS homepage to get the installation file

b. Click on "LDAC Product Registration Form" and fill out and submit the requested registration information

Once LDAC (formerly called LOGSA) confirms validity of Contractor's request, LDAC will E-mail to the requesting Contractor the password necessary to install the latest COMPASS model version. Executing this download instruction will complete the actions necessary for the Contractor to obtain access and use of the COMPASS model.

Sustainment Evaluation Process & COMPASS Guidebook

Updated 20 September 2016

CECOM LCMC

G8 Cost and Systems Analysis Division

Systems Analysis Branch

Chris Skubik Branch Chief

443-861-4469

Prepared by Allyson Trapp 443-861-4446 allyson.s.trapp.civ@mail.mil

- 1 - Contact the authors, CECOM G8 Systems Analysis, for assistance and clarification.

Is there a more economical way to sustain the system?

Use COMPASS to model the current maintenance policy to determine a baseline sustainment cost for the remaining life.

Identify cost drivers and key limitations from the baseline. Determine possible alternative maintenance policies.

Use COMPASS to model the chosen alternatives.

Compare alternatives to baseline and run sensitivities based on uncertainty in data.

Document the inputs, assumptions, outputs, and recommendations of the analysis.

Use COMPASS Inputs spreadsheet provided by CECOM G8 Systems Analysis to obtain necessary system data.

Step 1 – Collect Data

Step 2 – Model Baseline

Step 3 – Identify Alternatives*

Step 4 – Model Alternatives*

Step 5 – Run Sensitivities*

Step 6 – Documentation

Make recommendations to include path forward (e.g. how to change policy, timeline, etc.). Step 7 – Execution

*Step 3, Step 4, and Step 5 are optional for Level of Repair Analyses (LORAs) but necessary for Business Case Analyses (BCAs) and Analyses of Product Support Alternatives (APSAs).

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COMPASS Inputs Spreadsheet

The COMPASS Inputs spreadsheet was developed by CECOM G8 Systems Analysis to easily organize the major inputs for COMPASS. The workbook consists of five tabs, which account for several of the tabs in COMPASS. A red triangle in the top right corner of a cell indicates a helpful comment.

Hover over the cell to read the comment.

General Data Tab – This is mostly program information which can be obtained from the program office.

System Data Tab – This is mostly component-level information which can be obtained from the program office, original equipment manufacturer, or engineers.

Support Equipment Tab – Support equipment information can be obtained from engineers, organic depot, or original equipment manufacturer.

SE Use Tab – Support equipment use data can be obtained from engineers, organic depot, or original equipment manufacturer.

Assumptions Tab – Assumptions can be confirmed by the program office.

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General Data Tab

This is mostly program information which can be obtained from the program office.

Name/Identification is the name of the End Item.

Life, Density, OpTempo, and Ao Target can typically be obtained from the PM.

At which level(s) is each component allowed to be repaired? If more than one is selected, COMPASS will determine the optimal level.

How many shops are fielded at each level? Depot and Contractor default to one.

How long does it take for an item to be repaired at each level, from the time it arrives at the facility until the time it is placed back on the shelf, repaired? This includes repair and administrative times, but EXCLUDES transportation times.

This TAT assumes any required spares are in stock.

The loaded hourly labor rate includes benefits, vacation, profit, and all other costs associated with hiring personnel.

Org (organizational unit), DSU (direct support unit), GSU (general support unit), Depot, and Contractor are arbitrary labels and can be changed to reflect different situations, or omitted completely. These simply represent the maintenance levels allowed by COMPASS. End item repair is usually conducted at the Org level, stock is usually stored at the DSU level, and sub-components are typically repaired at the Depot or Contractor level. Forward repair activities (FRA) and regional support centers (RSCs) are typically modeled at the GSU level.

The End Item is repaired by removing and replacing a line replaceable unit (LRU), and an LRU is repaired by removing and replacing a shop replaceable unit (SRU). For example, if LRUs are removed and replaced at the Org level, select YES for End Item repair at Org.

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How long does it take from the time a spare is requested until the time it arrives at the destination?

What is the cost per pound for transportation between two echelons?

From which echelon does a failed item ship to the contractor? Items often pass through the organic depot before shipment to the contractor.

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System Data Tab

These component-level inputs can normally be obtained from the program office, engineer, or original equipment manufacturer.

Line replaceable units (LRUs) and shop replaceable units (SRUs) are subcomponents which are modeled individually. LRUs are higher level components and SRUs are the subcomponents within LRUs.

Removing/replacing a faulty SRU accomplishes repair of its LRU, and removing/replacing a faulty LRU accomplishes repair of the end item.

SRUs should be placed directly under their parent LRUs. Enter “dummy” SRUs for LRUs that have no set of SRUs to account for MTBF. The MTBF for “dummy” SRUs should represent the entire LRU, and the price should be the average price of materials to repair the LRU.

Be sure to include non-reparable LRUs and SRUs, however exclude piece parts such as screws and bolts. Piece parts are accounted for separately.

The sum of the prices of lower level parts should be reasonably match the next higher assembly. For example, the LRU price should be close to the sum of the prices of its SRUs.

The sum of the weights of lower level parts should reasonably match the next higher assembly. For example, the LRU weight should be close to the sum of the weights of its SRUs.

The mean time between failures (MTBF) of lower level parts should mathematically roll up to the MTBF of its next higher assembly. For example, the Pistons and Cam Shaft within the Engine each have a MTBF of 20,000 hours, meaning that the Engine will fail when either one of these fails, or on average every 10,000 hours.

To do this, take the inverse of the SRU MTBFs and add them together (for example, 1/20,000 + 1/20,000). Then, take the inverse again to arrive at the LRU MTBF.

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System Data Tab, continued

This information can typically be obtained from engineers, original equipment manufacturer, or organic depot.

MTTR is the hands-on time to repair a component, including diagnostic time. Only repairable components use this entry.

Diagnostic Time is the time required to verify a failure and determine the cause. It is a subset of the MTTR. Only repairable components use this.

How much would it cost annually to maintain any test software or connectors necessary to diagnose the cause of failure for a component? This input can also be used to reflect technical data which must be purchased annually.

How much would it cost to develop or acquire any test software or connectors necessary to diagnose the cause of failure for a component? This input can also be used to reflect technical data purchased on a one-time basis.

How many parts within the subcomponent may need NSNs? See cell comment for clarification.

Does the subcomponent need an NSN established?

The price of piece parts represents the average cost of parts per repair. This input only applies to repairable SRUs.

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System Data Tab, continued

These inputs can be obtained from the contractor. While the contractor may give a total cost per repair and a total response time, it is helpful if these inputs can be broken down to ensure accuracy. However, only the Total Contractor Diagnostic Cost, Total Contractor Repair Cost, and Total Contractor Response Time are entered into COMPASS.

Contractor repair can be enabled on a part-by-part basis for repairable components.

The loaded hourly labor rate includes labor, benefits, administrative, profit, and all other costs associated with hiring personnel.

What is the total cost (round-trip) to ship the component to and from the contractor?

The total contractor repair cost per failure can be calculated as the product of labor rate and MTTR, plus price of parts and shipping costs.

However, contractors may give the single total cost per repair instead of the price breakdown. COMPASS only accepts the total cost per repair.

Contractor set-up costs are costs charged to the government to initially establish repair capability.

How long does it take to ship an item each way from organic to contractor and vice versa?

TAT is the time from when a component arrives at the contractor facility until a repaired item or replacement is shipped out.

The total contractor response time is the sum of shipping each way plus TAT.

COMPASS only accepts the total response time as an input.

The total contractor diagnostic cost is the total cost charged to the government for the contractor to run diagnostics.

This is a subset of contractor repair cost and would only be charged separately in cases of false removals.

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Support Equipment Tab

This information can be obtained from engineers, original equipment manufacturer, or organic depot.

SE Use Tab

This information can be obtained from engineers, original equipment manufacturer, or organic depot.

This is the name of the piece of support equipment.

What is the life of the SE?

What is the price of the SE?

How much does it cost to develop and install the SE?

What does it cost annually to maintain the

SE?

How many hours is the SE available annually?

lowest level that the support equipment may be used?

Common SE means that equipment may be shared with other systems. If this applies, what is the lowest echelon where it is common?

Which SE will be used for which parts?

How long will the SE be used for each component failure?

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Assumptions Tab

The below assumptions are COMPASS defaults and will be used unless otherwise specified. The assumptions came from a study done by LOGSA to estimate the average values for each of these inputs.

Assumptions can be confirmed by the program office.

False Removal Rate is the percentage increase in removals beyond the failure rate caused by false removals. For example, if there are 100 true failures per year and 2 false removals (102 removals total), the false removal rate would 2/100 = 2%. Each component can have a unique false removal rate.

Washout Rate is the percentage of time that an item is damaged beyond economical repair and must be replaced.

Each component can have a unique washout rate.

Procurement Lead Time is the average time between identification of a demand until the item is introduced into the supply system, to include all delay times such as administrative and shipping.

Initial Bin Cost is the initial cost of entering an item into the retail supply system, to include all administrative costs.

Recurring Bin Cost is the annual recurring administrative cost of maintaining a bin for an item in the retail system.

Holding Cost Fraction is the percentage of inventory value to account for storage, loss, obsolescence, and interest incurred as a result of maintaining inventory.

Cost Per Requisition is the administrative cost to prepare and submit a requisition for the replenishment of a spare/repair part.

Initial Cataloging Cost is the initial cost of entering a new item into the wholesale supply system. This is generally the cost of screening the item and assigning a NSN.

Recurring Cataloging Cost is the annual recurring administrative cost of maintaining an item in the wholesale supply system.

Wholesale Fill Rate is the percentage of time that stock is available upon the first request.

If the answer is YES to any of these items, more information will be required. It is recommended to contact the authors for guidance.

Consider End Item floats if the end item can be spared as a whole when a specific LRU fails.

Redundant LRUs means there are multiple identical LRUs to back up an LRU failure, thus the failure of one of these LRUs does not result in a failure of the End Item.

Screening allows COMPASS to consider testing a failed to ensure it truly failed (avoiding false removal) before the item is evacuated for repair. This is no longer supported in COMPASS 7.

Multiple Repair allows COMPASS to consider up to three repair methods. This is no longer supported in

COMPASS 7.

Peculiar repairmen are used when a specialized repairman is required to repair a certain component(s).

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Document the inputs, assumptions, outputs, and recommendations of the analysis.

Use COMPASS Inputs spreadsheet provided by CECOM G8 Systems Analysis to obtain necessary system data.

Step 1 – Collect Data

Step 2 – Model Baseline

Step 3 – Identify Alternatives*

Step 4 – Model Alternatives*

Step 5 – Run Sensitivities*

Step 6 – Documentation

Make recommendations to include path forward (e.g. how to change policy, timeline, etc.). Step 7 – Execution

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Using COMPASS

New users can visit https://www.logsa.army.mil/lec/compass/index.cfm to download the COMPASS 7 installation file. New users must also request the registration form and installation password by e-mailing LOGSA Technical Support at usarmy.redstone.logsa.mbx.tsb-smartdesk@mail.mil.

LOGSA requires registration to track its active users in order to distribute patches and updates, so it is critical to register and obtain the password via LOGSA Technical Support. Ensure that COMPASS 7 is installed in the C:\Program Files folder. No administrative privileges are required for COMPASS 7.

Unlike COMPASS 6.2, COMPASS 7 does not limit file or folder names, nor does it require files to be saved in a specific folder. COMPASS 7 introduces a new file format, *.compass, but also has the ability to open the legacy format, *.mdb. To open a *.mdb, click File > Import > COMPASS 6.2 (.mdb).

Using the data in the COMPASS Inputs spreadsheet, populate COMPASS in the appropriate fields. This guide will walk through each input and output option.

System structure automatically populates as parts are added.

The input tab selection changes depending on the item selected.

The end item has nine potential input tabs which include global settings.

LRUs and SRUs have four potential input tabs specific to each part.

https://www.logsa.army.mil/lec/compass/index.cfm mailto:usarmy.redstone.logsa.mbx.tsb-smartdesk@mail.mil

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End Item Information

Enter the name of the End Item.

The LCN, Part Number, NIIN, Cage Code, and SMR Code are not required but may be entered as applicable.

Many of the End Item inputs can be obtained from the PM.

DS Delay occurs when DSU personnel are sent to the ORG for remove/replace/repair of an item. This is a rare case.

How long does it take for the End Item to be repaired at each level, from the time it arrives until the time it is placed back on the shelf?

This includes repair and administrative times, but excludes transportation times. This TAT assumes any required spares are in stock.

Note: TAT entered here overrides TAT entered in System Information.

Check these boxes as applicable if the End Item is an assembly or if contractor repair of the End Item will be considered.

See below for End Item Float Information.

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End Item Information, continued

Order and Ship Time (OST) for floats is the time to move a good end item from the issuing echelon to the ORG level. If the issuing echelon is the ORG level, then the value for this input should be 0.

Mean Time to Install is the time it takes to install the End Item, if applicable.

What is the lowest echelon which is allowed to issue a float?

What is the lowest echelon which is authorized to repair the failed item?

Check the box if the End Item has floats available.

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Echelons

Enter the number of shops at the Organizational/Unit level, Direct Support Unit (DSU) level, and General Support Unit (GSU) level.

If there are no shops at a certain level, enter 0.

The names of these levels are arbitrary, and the intermediate echelons can be used to represent forward repair activities (FRAs) or sparing points.

At which level(s) is each component allowed to be repaired? These names are arbitrary and simply reflect potential levels of maintenance. If more than one is selected, COMPASS will determine the optimal level.

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Supply Data

Procurement Lead Time is the average time between identification of a demand until the item is introduced into the supply system, to include all delay times such as administrative and shipping.

Initial Bin Cost is the initial cost of entering an item into the retail supply system, to include all administrative costs.

Recurring Bin Cost is the annual recurring administrative cost of maintaining a bin for an item in the retail system.

Holding Cost Fraction is the percentage of inventory value to account for storage, loss, obsolescence, and interest incurred as a result of maintaining inventory.

Cost Per Requisition is the administrative cost to prepare and submit a requisition for the replenishment of a spare/repair part.

Initial Cataloging Cost is the initial cost of entering a new item into the wholesale supply system. This is generally the cost of screening the item and assigning a NSN.

Recurring Cataloging Cost is the annual recurring administrative cost of maintaining an item in the wholesale supply system.

Documentation Cost Per Page is the average cost to develop one page of technical documentation.

Discount Rate is the interest rate used to account for the time-value of money to arrive at present value. Office of Management and Budget (OMB) Circular A-94 Appendix C updates this rate annually. The “real” discount rate from this circular should be used as it adjusts for inflation.

Wholesale Fill Rate is the percentage of time that stock is available upon the first request.

Note: These inputs are defaults within COMPASS but can be changed.

https://www.whitehouse.gov/omb/circulars_a094/a94_appx-c https://www.whitehouse.gov/omb/circulars_a094/a94_appx-c

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Resources

Specialized support equipment (SE) may be used for diagnostics and/or repair of certain parts.

Give each piece of support equipment a name.

Enter the one-time development cost, if applicable (common support equipment may already be established).

Enter the life of the support equipment.

Leave unchecked if the support equipment is also used for diagnostics.

What is the lowest level that the support equipment may be used?

Enter the unit price of the support equipment, one-time installation cost, annual costs to maintain the support equipment, and annual hours which the support equipment can be used. Each of these items can vary by repair level.

COMPASS will then calculate the SE costs both initially and annually.

lowest level that the support equipment may be shared with other systems?

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Resources, continued

Specialized personnel are used if certain parts must be diagnosed and/or repaired under special conditions which are different from Common Labor or are not covered under contractor cost per repair.

Leave unchecked if the repairman also conducts diagnostics.

Enter the annual productive hours, loading factor, unloaded annual salary, initial training cost, and annual turnover rate for each repairman. Each of these items can vary by repair level. COMPASS will then calculate the repairmen costs both initially and annually.

What is the lowest level that the repairman may be placed?

What is the lowest level that the repairman may be shared with other systems?

Give each repairman a name.

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Common Labor Data

Common labor refers to organic labor at the respective levels.

Given the unloaded labor rate, productivity factor (to account for nonproductive time), and loading factor (to account for overhead, benefits, etc), COMPASS will calculate a loaded labor rate using the following formula:

Unloaded Base Hourly Rate * (1 + Loading Factor) / Productivity Factor

The numbers shown here are COMPASS defaults, however the defaults are a low estimate it is not recommended to use these.

If entered, the Effective Hourly Labor Rate will override the Unloaded Labor Data calculations. This rate should be loaded to account for productivity and administrative factors.

If the military occupational specialty (MOS) and grade are known, the loaded annual salary can be found on the Army Military-Civilian Cost System (AMCOS) Lite application at https://www.osmisweb.army.mil/Amcos/app/lite/default.aspx.

https://www.osmisweb.army.mil/Amcos/app/lite/default.aspx

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Contractor Data (End Item)

If the Contractor Repair Considered box is checked on the End Item Information screen, the Contractor Data tab unlocks to store contractor repair data. Although the image below is specific to contractor repair of the End Item, the Contractor Data tabs for LRUs and SRUs are identical and accept the same information.

One Time Installation Costs are costs charged to the government for the contractor to initially

What does the contractor charge per failure to repair the item? This includes labor, parts, diagnostics, transportation, and other administrative costs.

What does the contractor charge per false removal for resources spent to diagnose the item?

Contractor Turn Around Time is how many days it takes from the time an item leaves the previous echelon (defined above) until the time it arrives back in stock at that echelon, to include both contractor TAT and round-trip shipping.

From which echelon does a failed item ship to/from the contractor? Items often pass through the organic depot before shipment to the contractor.

Washout Rate is the fraction of the time that an item is damaged beyond economical repair and must be replaced. This entry is specific to

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Shipping

Order Ship Time is the number of days from the time a spare is requested until the time it arrives at the destination.

COMPASS will calculate the dollars per pound per mile multiplied by the distance, or the user can enter an overall cost per pound to ship materiel. If entered, the cost per pound will override the cost * distance.

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Repair Method (End Item)

Although the image below is specific to repair of the End Item, the Repair Method entries for LRUs and SRUs are identical and accept the same information.

What are the initial and annual costs of the Test Program Set for repair? This entry is often used to reflect the cost of technical data.

If resources (personnel and support equipment) are necessary for repair, check the applicable box(es) and enter the time required from each.

Enter the number of pages of technical documentation which will be multiplied by the Documentation Cost Per Page in the Supply Data tab.

MTTR is the hands-on time to repair a component, including diagnostic time.

Diagnostic Time is the time required to verify a failure and determine the cause. It is a subset of the MTTR.

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Global Settings

Check these boxes as applicable if contractor repair of depot-level repairables is an option, or if this item has redundant LRUs. Redundant LRUs mean there are multiple identical LRUs to back up an LRU failure, thus the failure of one of these LRUs does not result in a failure of the End Item.

How long does it take for an item to be repaired at each level, from the time it arrives until the time it is placed back on the shelf? This includes repair and administrative times, but excludes transportation times. This TAT assumes any required spares are in stock. TAT entered in individual part screens override this global input.

Since the echelon and item labels are arbitrary in nature, users can change the labels to reflect specific locations or items.

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Adding and Editing Parts

For the purposes of COMPASS modeling, LRUs/NLRUs are defined as parts which can be directly removed/replaced from the End Item in order to repair the End Item, while SRUs/NSRUs are defined as parts which are removed/replaced from an LRU in order to repair the LRU.

To edit a lower level component, select it in the drop-down list under the End Item tab.

Alternately, click on the LRUS or SRUS tab to edit a lower level component.

To add a new LRU or SRU, click New in the appropriate tab. Users can also Delete or Duplicate a part here.

If an item is defined as non-repairable, this box will automatically be checked.

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General Information (LRU)

Enter the name of the LRU. The NSN/NIIN, LCN, CAGE Code, Part

Number, and SMR Code are not required but may be entered if applicable.

Many of the LRU inputs can be obtained from the PM.

How long does it take for the LRU to be repaired at each level, from the time it arrives until the time it is placed back on the shelf? This includes repair and administrative times, but excludes transportation times. This TAT assumes any required spares are in stock.

Note: TAT entered here overrides TAT entered in Global Settings.

To define a LRU as non-repairable, check the Non-Repairable box.

Note: Some inputs are enabled/disabled based on selected/deselected options. For example, the MTBF input for LRUs only applies if the LRU is non-repairable. Otherwise, LRU MTBF will be calculated using the MTBFs of its children SRUs.

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Non-Repairable (LRU)

For Non-Repairable parts, many inputs are disabled. Only False Removal Rate and MTBF should be entered in the General Information tab.

Additional data is entered in the Non-Repairable tab. Enter the Average Price of Parts for Repair and Average Weight of Parts for Repair here rather than the Unit Price and Shipping Weight in the General Information tab.

Additionally enter the Total Number of Parts the NLRU represents and the Number of Parts Needing NSN, if applicable.

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Repair Method (LRU)

Entering repair information for LRUs and SRUs is similar to the End Item.

for repair? This entry is often used to reflect the cost of technical data.

If resources (personnel and support equipment) are necessary for repair, check the applicable box(es) and enter the time required from each.

Enter the number of pages of technical documentation which will be multiplied by the diagnostic time.

Diagnostic Time is the time required to verify a failure and determine the cause. It is a subset of the MTTR.

Select Peculiar Repair and enter the information if failure of this item requires repair of the End Item which is different from general End Item repair.

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Contractor Data (LRU)

Entering contractor data for LRUs and SRUs is similar to the End Item.

previous echelon (defined above) until the time it beyond economical repair and must

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General Information (SRU)

Enter the name of the SRU. The NSN/NIIN, LCN, CAGE Code, Part

Number, and SMR Code are not required but may be entered if applicable.

Many of the SRU inputs can be obtained from the PM.

How long does it take for the SRU to be repaired at each level, from the time it arrives until the time it is placed back on the shelf? This includes repair and administrative times, but excludes transportation times.

This TAT assumes any required spares are in stock.

Note: TAT entered here overrides TAT entered in Global Settings.

To define a SRU as non-repairable, check the Non-Repairable box.

Note: Some inputs are enabled/disabled based on selected/deselected options. For example, washout rate only applies to repairable SRUs.

To assign MTBFs, click Add and select the appropriate LRU.

Enter the MTBF (hours) and hit Enter on the keyboard. The same SRU can be assigned to several LRUs as applicable.

Average price of Piece Parts represents the average price of materials required to repair the SRU.

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Non-Repairable (SRU)

For Non-Repairable parts, many inputs are disabled. Only False Removal Rate and MTBFs should be entered in the General Information tab.

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Non-Repairable (SRU), continued

Non-reparable SRUs (NSRUs) are inherently non-reparable sub-components, and could also be used to represent a collection parts (e.g. several cables). “Dummy” NSRUs are a special case often used when the sub-components of an LRU are not explicitly modeled. In this case, a “dummy” NSRU is a placeholder for the group of parts within the LRU and can account for the LRU MTBF. If modeling an NSRU as a “dummy” part, the total price of parts for average replacement should reflect the average cost of parts to repair its parent LRU. It should be noted that if a repairable LRU does not have any SRUs or NSRUs modeled under it, COMPASS assumes that the LRU can be repaired with labor only (no parts required).

Additional data is entered in the Non- Repairable tab. Enter the Average Price of Parts for Replacement and Average Weight of Parts for Repair here rather than the Unit Price and Shipping Weight in the General Information tab.

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Repair Method (SRU)

Entering repair information for LRUs and SRUs is similar to the End Item.

for repair? This entry is often used to reflect the cost of technical data.

If resources (personnel and support equipment) are necessary for repair, check the applicable box(es) and enter the time required from each.

Enter the number of pages of technical documentation which will be multiplied by the diagnostic time.

Diagnostic Time is the time required to verify a failure and determine the cause. It is a subset of the MTTR.

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Contractor Data (SRU)

Entering contractor data for LRUs and SRUs is similar to the End Item.

previous echelon (defined above) until the time it beyond economical repair and must

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Importing Items

It should be noted that the COMPASS Inputs Spreadsheet developed by CECOM G8 cannot be directly imported into COMPASS. However, there are importing options in COMPASS 7 to include importing a legacy COMPASS 6.2 file (*.mdb) and importing another COMPASS 7 front end analysis export (*.xls), as well as *.xml and *.csv formats.

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Front End Analysis (FEA)

The Front End Analyzer can be accessed in the Analysis drop-down menu on the toolbar. The FEA Results and Costs tabs display a number of user inputs as well as some calculated values such as Derived MTBF, Present Value Factor, and Inherent Availability. The Failure Modes tab shows a list of parts with their MTBFs. Users can export the FEA to HTML or Excel by clicking the Export button. Exporting the FEA centralizes all inputs (both user-input and default) in one place.

Note that Derived MTBF should reasonably match with the MTBF that was entered for the End Item. If these do not match, check the MTBFs for each of the SRUs to ensure accuracy. There are two reasons for which the derived and input MTBFs should match:

1. If the MTBFs do not match and no typographical errors were made, the given failure rates may be embellished or wrong.

2. COMPASS uses Derived MTBF to calculate failures/repairs, but it uses the Input MTBF to calculate Ao. Therefore, if these do not agree, the results will be skewed. However, there are times when the user may adjust LRU MTBFs to account for redundancy or intentionally leave out low cost, low failure rate parts, both of which could skew the Derived MTBF.

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Optimizer

The Optimizer provides the optimal maintenance policy results as calculated by COMPASS. It can be accessed in the Analysis drop-down menu on the toolbar. The report displays the total costs in each category for the determined optimal maintenance policy. These costs represent the total present value over the given system life.

Other tabs in the output report include the maintenance policy and the sparing levels required to achieve the target Ao. The maintenance policy output reads as follows: When a specific SRU is the cause of failure, the End Item is repaired at the End Item Repair Echelon, the LRU is repaired at the LRU Repair Echelon, and the SRU is repaired at the SRU Repair Echelon. For example, the first line indicates that when the Torque Converter is the cause of failure, the Automobile end item is repaired at the ORG level, the Transmission is repaired at the DSU, and the Torque Converter is thrown away.

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Additionally, users can export the results to HTML or Excel by clicking the Export button. Exporting the Optimizer allows users to view the detailed costs broken out by part and cost category. The explanations of each cost category are below:

• Initial Spares costs are the costs for any spares required to initially fill the sustainment pipeline. These spares include LRUs, SRUs, and piece parts required to repair the SRUs. TAT and MTBF are major factors when determining the quantity of initial spares required.

Therefore, alternatives with lower TATs and higher MTBFs require less initial spares.

• Consumption Spares are those components that are used to replace failed components that are not repaired. This includes the piece parts to repair higher level assemblies, assemblies determined to be beyond economic repair (washouts), and assemblies designated as throw-away items. Systems with higher MTBFs have fewer failures and therefore lower requirements for consumption spares than those with lower MTBFs. Since the cost for consumption spares is included in the contractor cost to repair, the only cost for consumption spares in an all-contractor alternative is for washouts and tosses.

• Inventory Holding Costs are those costs associated with holding inventory. These costs include items such as physical storage space, loss of parts due to damage during storage, or loss of parts due to obsolescence and are estimated within COMPASS at the default value of 6% of the inventory value per year. Therefore, differences in holding costs will be proportional to the difference in initial spares costs.

• Transportation Costs account for the shipping of items.

• Requisition Costs account for the ordering parts from a more rearward echelon, such as the depot.

• Cataloging Costs are the costs to set up and maintain NSNs.

• Bin Costs are the administrative cost of establishing and maintaining a bin for an item in the retail system.

• Common Labor Costs represent all organic repair labor costs not associated with a specialized repairman. Highly reliable systems have fewer failures and therefore lower labor requirements than systems with low MTBFs. Since common labor is the only repair labor utilized at the organic depot, this number is much higher for organic alternatives than for contractor alternatives. Common labor also applies to labor conducted at the field level which includes on-system remove and replacement of parts.

• Documentation Costs are the costs to develop and provide technical manuals.

• Test Program Set Costs represent the cost for the government to purchase the software or data necessary to diagnose the cause of a failure to the next lower level assembly. It also includes the specialized fixtures to allow the system/component to interface with common support equipment. If the contractor already owns this data/fixtures, the all-contractor alternative has no test program set costs.

• Contractor Costs include the fixed contractor costs and contractor repair costs. Fixed contractor costs represent any initial costs the contractor may incur and pass on to the government. Contractor repair cost is an all-inclusive cost that represents the average cost per part for the contractor to perform a repair. It includes the loaded labor costs (to include

- 37 -labor, administrative costs, overhead, and profit), consumption parts costs, and transportation costs. All-organic alternatives will have no contractor costs.

• Contact Team Costs are costs to have a team come to the location of the end item from a more rearward location.

• Support Equipment is the equipment necessary to test and repair the components of the system. Since some support equipment is common equipment, the costs reflect only the time the equipment is used for the specific system. Since all contractor costs are rolled up into one contractor repair cost, there is no separate cost for support equipment in all-contractor alternatives.

• Repairmen are specialized repairmen with a specific skill set required for repair. Since some specialized repairmen are common, the costs reflect only the time the repairman is used for the specific system.

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Evaluator

In addition to the Optimizer, COMPASS also has an Evaluator option. The Evaluator allows users to specify a maintenance policy and view the COMPASS-determined costs and resources associated with that policy to meet the target Ao. The Evaluator can also be accessed in the Analysis drop-down menu on the toolbar. To specify a maintenance policy for the Evaluator, click on the part for which the specified maintenance policy applies. A list of repair options appear along with fraction of time that this policy applies. In the example below, a failure of the Torque Converter is associated with a maintenance policy of ORG/DSU/TOSS 100% of the time.

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Evaluator, continued

To change the policy of the selected item, first change the Percentage Chosen from 100 to 0 and hit Enter on the keyboard. Then select the desired policy from the list and enter 100 (or the desired fraction) in the Percentage Chosen for that line. Be sure to hit enter on the keyboard to save the input.

The percentages must add to 100%.

Note the result comparison on the right side of the screen. This indicates that the Total maintenance Policy Cost has changed by 1% from $2,891,290.45 to $2,929,577.77. Clicking the Totals shows the comparison between the original costs and the modified costs, broken out by category. Similarly, the Spares tabs show the modified results and any deviations from the original numbers. The modified results can also be exported to HTML and Excel to view the parts breakouts.

Enter 0 for the original policy and enter 100 (or desired fraction) for the desired policy. Be sure to hit Enter on the keyboard after each input.

The percentages must add to 100%.

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STAT

COMPASS Sensitivity Trend Analysis Tool (STAT) function is used to evaluate sensitivities on certain parameters. Sensitivity iterations can be run on a single item, a group of items (LRUs for example), or all items. Options include MTBF, Unit Price, MTTR, TAT, and more. After clicking “Run”, a chart populates on the right side of the screen to show the change in cost for each iteration. Exporting to Excel allows users to view the costs and maintenance policies associated with each iteration.

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Document the inputs, assumptions, outputs, and recommendations of the analysis.

Use COMPASS Inputs spreadsheet provided by CECOM G8 Systems Analysis to obtain necessary system data.

Step 1 – Collect Data

Step 2 – Model Baseline

Step 3 – Identify Alternatives*

Step 4 – Model Alternatives*

Step 5 – Run Sensitivities*

Step 6 – Documentation

Make recommendations to include path forward (e.g. how to change policy, timeline, etc.). Step 7 – Execution

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Identify Alternatives

Once the current maintenance policy is modeled in COMPASS to act as a baseline, the team should identify several alternatives to evaluate the potential cost savings of adapting a new maintenance policy. Common alternatives include all-organic, all-contractor, partnership, forward repair, FSR support, screening of items, allowing floats (sparing the End Item as a whole), etc.

Observations from Baseline

In looking at the COMPASS results from the baseline, areas of concern may become apparent as potential issues. Some key places to look in the COMPASS outputs listed below:

• Total Cost Summary – Which categories account for the majority of costs? Are there any options to mitigate these major cost drivers?

• Limitations – Are items only allowed to be repaired by certain repairmen, in certain places, or only at one depot facility? Are there any options to mitigate these limitations?

Can the Maintenance Policy Change?

There may be several possible alternatives which the program office may be interested in exploring. It is best to explore all options, even if they seem infeasible, in order to fully investigate potential cost savings. In identifying these alternatives, consider the following questions, as additional data may be necessary:

• Is additional support equipment needed? Test set, clean room, etc?

• Can any items be opened or repaired in the field?

• Would technical data need to be acquired, and is it available? How much would it cost to obtain?

Collect Additional Data

Data which was collected for the baseline may be insufficient for modeling the selected alternatives. Therefore, a second round of data collection may be necessary based on outstanding needs such as contractor costs, technical data costs, support equipment information, etc.

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Document the inputs, assumptions, outputs, and recommendations of the analysis.

Use COMPASS Inputs spreadsheet provided by CECOM G8 Systems Analysis to obtain necessary system data.

Step 1 – Collect Data

Step 2 – Model Baseline

Step 3 – Identify Alternatives*

Step 4 – Model Alternatives*

Step 5 – Run Sensitivities*

Step 6 – Documentation

Make recommendations to include path forward (e.g. how to change policy, timeline, etc.). Step 7 – Execution

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Use COMPASS to Model Alternatives

Use COMPASS to model the chosen alternatives identified in Step 3. Refer back to Step 2 for assistance with COMPASS. Some helpful tips and tricks to help accurate modeling within COMPASS are below:

• To account for the cost of a technical data package (TDP) in the case of organic repair, there are two options within COMPASS depending on the detail of the TDP:

o If the TDP is an overall cost for the system, add a “dummy” piece of support equipment and enter the TDP cost as the One Time Development Cost. Enter all 0s (zeroes) for the Inputs By Echelon. Add this SE to each part so that any time organic repair is chosen, the government is charged for the full TDP.

o If the TDP is broken down by part, enter the cost of the TDP in the Test Program Set (TPS) Development Cost for each part (LRU/SRU). In this case, only the portion of the TDP which is necessary to repair that part is charged to the government.

• To force a repair to or away from a certain echelon for one or multiple parts, add a piece of support equipment with a descriptive name (e.g. ForceDepot). This support equipment should have a minimal unit price (e.g. $0 or $0.01) and 2080 available hours. In the Annual Maintenance Cost column, enter high numbers (e.g. $10,000,000) for disallowed echelons, and $0 for allowed echelons. Be sure that the support equipment is marked as Not Common so that the item will incur the entire maintenance cost if a disallowed echelon is chosen. In doing this, COMPASS will not choose the disallowed echelons because the annual maintenance costs are not economical.

• To add the option for contractor repair, ensure that the contractor cost per repair includes everything from labor and parts to profit and administrative costs. Contractor initial set-up cost includes items such as facilities, test equipment, and initial spares (if the contractor charges the government for these), and any other items which are charged to the government.

• To add the option of a field support representative (FSR), enter the information as a peculiar repairman and add it to the parts and level that it is allowed to repair.

• To add a forward supply point/repair facility such as a regional support center (RSC) or forward repair activity (FRA), model it at the GSU level.

To model the system at a different reliability, ensure that the MTBFs change proportionately and the End Item MTBF reasonably matches with the Derived MTBF.

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Document the inputs, assumptions, outputs, and recommendations of the analysis.

Use COMPASS Inputs spreadsheet provided by CECOM G8 Systems Analysis to obtain necessary system data.

Step 1 – Collect Data

Step 2 – Model Baseline

Step 3 – Identify Alternatives*

Step 4 – Model Alternatives*

Step 5 – Run Sensitivities*

Step 6 – Documentation

Make recommendations to include path forward (e.g. how to change policy, timeline, etc.). Step 7 – Execution

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Analyzing the Alternatives

Once the baseline and alternatives have been modeled in COMPASS, the user can compare the results and run sensitivities on the uncertain data points such as labor rates, repair times, etc.

Run Sensitivities

There is often a degree of uncertainty in the data inputs as some data points are difficult to obtain or simply highly variable. Running sensitivities on these uncertainties can help determine the fidelity of an alternative – for example, if COMPASS optimizes to organic repair even with an unreasonably high common labor rate, it is safe to say that organic repair is the best option. However, if the optimal maintenance policy changes with a slight change to OpTempo, the alternative would be considered sensitive to changes and the user may reconsider utilizing that alternative. Sensitivities are often run on labor rates (to include contractor cost of repair), response times, repair turnaround times, reliability, OpTempo, etc. In looking at the COMPASS outputs for major cost drivers, the user can determine which sensitivities are worth investigating.

Analyze Results

After running the baseline, alternatives, and sensitivities, comparing the results will show the most economical way(s) to sustain the system. While one alternative may provide the least costly maintenance policy, it may be infeasible to implement that approach. For example, COMPASS may show that changing the policy from all-contractor repair to all-organic repair is the best option, however it may prove more costly when external factors such as facilities, training, and policy change are taken into consideration. The user should work with the PM and decision-makers to determine if it is truly beneficial to implement the maintenance policy.

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Document the inputs, assumptions, outputs, and recommendations of the analysis.

Use COMPASS Inputs spreadsheet provided by CECOM G8 Systems Analysis to obtain necessary system data.

Step 1 – Collect Data

Step 2 – Model Baseline

Step 3 – Identify Alternatives*

Step 4 – Model Alternatives*

Step 5 – Run Sensitivities*

Step 6 – Documentation

Make recommendations to include path forward (e.g. how to change policy, timeline, etc.). Step 7 – Execution

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Document the Analysis

Regardless of the type of analysis, documentation should always accompany the COMPASS model. The documentation should outline the assumptions, methodologies, results, and interpretations. It is also helpful to include the data inputs, and even the COMPASS model itself within the document.

- 49 -

Document the inputs, assumptions, outputs, and recommendations of the analysis.

Use COMPASS Inputs spreadsheet provided by CECOM G8 Systems Analysis to obtain necessary system data.

Step 1 – Collect Data

Step 2 – Model Baseline

Step 3 – Identify Alternatives*

Step 4 – Model Alternatives*

Step 5 – Run Sensitivities*

Step 6 – Documentation

Make recommendations to include path forward (e.g. how to change policy, timeline, etc.). Step 7 – Execution

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Execute the Recommendation

Once a decision as to the sustainment policy going forward has been made, an execution plan will assist in the implementation of the decision.