AMARC reclamation earns DoD best-in-class for continuous process improvement

Published Dec. 6, 2005
By Rob Raine
Aerospace Maintenance and Regeneration Center Public Affairs

DAVIS-MONTHAN AIR FORCE BASE, Ariz. (AFMCNS) -- By reclaiming nearly 42,000 aircraft parts during fiscal years 2004 and 2005, the Aerospace Maintenance and Regeneration Center team saved the government $1.257 billion, while providing direct and often sole-source parts support to American and allied warfighters.

As a result, the Center earned the 2005 Department of Defense Maintenance Symposium Recognition of Air Force Units for LEAN Continuous Process Improvement, or CPI.

"It is my distinct pleasure to announce the organizations that have been selected for recognition," said Lt. Gen. Donald J. Wetekam, Deputy Chief of Staff for Installations and Logistics, Headquarters U.S. Air Force, Washington, D.C. "These units represent the best in class for lean process improvement implementation."

At an October 26 symposium ceremony in Birmingham, Ala., the Honorable P. Jackson Bell, Deputy Under Secretary of Defense for Logistics and Materiel Readiness, presented the award to AMARC Commander, Col. Tony Panek, Lynne Avant from shipping and Rafael "Ray" Narvaez from reclamation who represented the AMARC team.

"AMARC highlighted the changes and improvement in the reclamation process for this nomination," said Colonel Panek. "I'm very proud of the men and women of AMARC. They played an active role in the LEAN teams. They came up with ideas and recommendations to achieve these types of improvements and savings."

Some highlights from the Center's award package included a reduction in processing time to an average of less than 24 hours from the time the customer requests a part or parts until the time AMARC ships the part for Pacing MICAPS and JCS coded parts.

Through continuous process improvement, the AMARC team shipped over 35 percent of all Priority 1-3 parts in less than 48 hours; prior to the event, fewer than 10 percent shipped in 48 hours and the average was 10.2 days.

Further, the Center reduced parts reclamation time for Priority 4-8 parts to 5 days, representing a 75 percent reduction in customer lead time. Likewise, they reduced parts reclamation time required for Priority 9-15 from 22 days to 5.8 days, a 74 percent reduction in customer lead time.

During the nomination window, the AMARC team returned 10,600 Priority 1-15 parts valued at over $267M, and 4,800 "save list" parts (parts identified by item managers as critical parts) valued at $177M to air logistic centers, item managers, the supply chain, and other DoD customers.

In keeping safety as an essential element of mission accomplishment, the team reduced safety mishaps (first aid, lost days, definitive care) from 11 in FY04 to 1 (when the award was submitted) for FY05.

"We are now raising the bar a few notches higher and I'm looking forward to our future successes," Colonel Panek said in congratulating the AMARC team.

"I want to echo Colonel Panek's congratulations," said AMARC Center Director Sam Malone. "The improvement in reclamation has been outstanding with the customer clearly in their focus."

Both Colonel Panek and Mr. Malone identified the improvement in numerous work centers, production support and administrative functions, as evidence of how the AMARC team has embraced process improvement.

"Our willingness to challenge the status quo and make positive change for the Air Force will keep AMARC as a critical supplier of products and services to the warfighter," said Mr. Malone. "Great job reclamation team and great job AMARC."

"Earning an award is great but this award highlights AMARC doing its mission and doing it well...in this case getting parts to the warfighter in a timely manner," said Colonel Panek. "Way to go AMARC!"