FRCE Keeps Fleet Super Hornets Battle-Ready

Fleet Readiness Center East (FRCE) has successfully addressed high-priority backorders of auxiliary power units (APU) for the F/A-18E/F Super Hornet, significantly enhancing the platform’s mission readiness.

Issues with parts and materials availability for the APU previously grounded several Navy Super Hornets, resulting in high-priority Issue Priority Group 1 (IPG-1) backorders.

Scott Barry, co-lead for PMA-265’s Propulsion and Power Integrated Project Team, recognized FRCE’s efforts to expedite part deliveries, refine inspection methods, and boost process efficiencies, enabling the rapid elimination of IPG-1s within a year.

PMA-265 oversees acquiring, delivering, and sustaining F/A-18 and EA-18G aircraft for the U.S. Navy, Marine Corps aviators, and international partners, maintaining mission readiness.

FRCE’s collaboration with the Defense Logistics Agency (DLA) and Naval Supply Systems Command (NAVSUP) led to exceeding production expectations, producing more APUs than requested to fill critical gaps.

“The Super Hornets are vital to the Navy’s carrier air wing,” FRCE Commanding Officer Capt. James Belmont stated. “Ensuring they remain mission-ready is our top priority. The collective effort was essential in delivering the needed APUs to warfighters.”

An APU functions as a gas turbine engine providing independent power to the aircraft during ground operations and certain flight phases.

An integrated product team from FRCE, PMA-265, DLA, and NAVSUP was formed to secure APU availability.

“We faced significant challenges in increasing depot repair throughput amid supply constraints,” said FRCE Components Division Director Lenny Domitrovits. “We needed to expedite these repairs swiftly. It was a massive collaborative effort.”

Overcoming supply hurdles involved ensuring an adequate parts supply for APU repairs. Sean Doss, a component planner at FRCE, mentioned the complexity of managing over 540 parts listed on the APU’s bill of materials.

“A bill of material details all necessary parts for a component overhaul,” Doss explained. “It ensures we know precisely what’s needed for complete rework if required.”

Domitrovits praised DLA’s timely supply of necessary parts despite tight deadlines.

Barry highlighted the pivotal role of FRCE and DLA collaboration in maintaining APU stock and operational Super Hornets.

“By joining forces, FRCE and DLA tackled supply constraints aggressively, significantly enhancing the depot repair throughput,” Barry noted.

The team also focused on improving procedures for APU induction, rework, and dispatch, with engineers and logisticians addressing issues from new tooling needs to efficient testing of completed units.

“We encouraged innovative ideas to boost efficiency and production amid constrained resources,” Domitrovits said. “Every team contributed unique solutions.”

Doss emphasized inter-disciplinary cooperation to expedite APU repairs and meet fleet demands promptly while maintaining quality standards.

“Instead of sticking to specific roles, we collaborated fluidly to ensure timely APU delivery to the fleet,” Doss said.

The focus on reducing turnaround time remains paramount.

FRCE artisans in the Engine Driven Compressor and Gas Turbine Shop scaled up monthly APU production for the Super Hornet, enhancing processes, utilizing new tools, and training staff to meet demands.

“Our experienced artisans excelled, surpassing monthly targets consistently,” Shop Supervisor Justin Rimmer acknowledged. “New fixtures, tooling, and additional staff were pivotal.”

Despite the diverse workload, including units for other aircraft, artisans maintained high standards.

“Balancing multiple responsibilities, our team ensured timely, high-quality APU production,” Rimmer said.

Domitrovits attributed team dedication to supporting warfighter readiness as a key motivator.

“Meeting IPG-1 resolutions ahead of schedule showcased the team’s extraordinary capability,” Domitrovits stated. “Our work directly impacts mission readiness, equipping warfighters to perform their duties effectively.”

As North Carolina’s largest maintenance and technical services provider, FRCE employs over 4,000 personnel and exceeds $1 billion in annual revenue, supporting the U.S. Navy as an integral part of the Naval Air Systems Command and Fleet Readiness Centers.

Learn more at www.navair.navy.mil/frce