Maintenance stands improve access, speed production

Published Aug. 11, 2006
By Bill Orndorff
309th Maintenance Wing

HILL AIR FORCE BASE Utah -- Maintaining an airplane that is roughly the length of two tennis courts and as tall as a three-story building can be difficult without the right equipment.

Mechanics working on the C-130 in the 309th Aircraft Maintenance Group expressed this opinion during a transformational project process improvement meeting, and the result is easy-access work stands that improve access and speed project completion.

"The work stands enable mechanics with different skills to work together and there's enough space so two or three operations can be done in one area, speeding up the maintenance process," said Cory Coward, C-130 work leader. "There's open access to the aircraft, so the work is easier to do and can be accomplished quicker."

Indeed, the work stands are so large that one worker, upon seeing the prototype, joked that it was big enough to have its own ZIP code.

Before the work stands were installed, mechanics were suspended from the ceiling using a harness and cable system, used limited access mobile work stands, or had to wait in line to use a scissor lift.

"No harnesses are needed now, except for the forward fuselage areas, so the mechanics have more freedom of movement," Mr. Coward said.

The work stands are custom made to fit the C-130 through a Lean-cellular transformation contract with Standard Aero and prime contractor, Battelle. The Battelle Standard Aero team designed the two aircraft cell, working with the 309 AMXG transformation team members selected from areas involved with the work including maintenance, supply and fuels.

"It provides a solid work surface that is exclusive to the C-130 -- it wasn't a one-size-fits-all stand," said Russell Versemann, C-130 shop mechanic and alternate to the foreman. "The stand is specifically angled the same as C-130 wings."

Work stand use has also helped clean up the work areas and provide better tool control. Tool boxes and parts can now be brought closer to the aircraft and the floor space below the aircraft is less cluttered. The stands are equipped with integrated fire suppression, lighting, electricity and compressed air utilities for tools. Three elevators provide a lift for larger tools and equipment.

Mechanics working on the upper level also have an added comfort -- a fresh-air heating and cooling system, supplied from an elevated system located away from the aircraft with two large flexible tubes extending down from ceiling mounted duct work. The old method required positioning a large portable air conditioning system adjacent to the aircraft and draping hoses from ground level up to the wings. The new system reduces setup time and eliminates ground clutter around the aircraft.

"The heating and cooling system is especially helpful for those working with fuels," Mr. Versemann said. "It was a good team effort from management down to the workers on the floor -- we've worked out the bugs and talked things through so they could be fixed quickly. It was a hard sell for those who had done the work on a lift since the beginning, but once they adapted to the stands, it has gained steam.

"It adds miles to the workers' attitudes when they can do their job in a clean environment with everything in its place." The area has two work stands comprising a single work cell on the north end of Bldg. 225, and an additional cell with two aircraft work stands is planned for the south end.

The work stands are made from steel and aluminum and with the wing sections on wheels that can be locked in place. "The rear potion of the stand, for the tail section, is steel and is floor mounted," said Tom Whitney, 309 AMXG industrial engineer. "The forward areas for the wings, made from aluminum, are repositionable. The stands are designed to leave the aircraft's wings and horizontal stab on the stands instead of lowering them to the floor as before. A dedicated crane in the work area services the two aircraft cell."

Aircraft stay on the stands for about three months before being sent for flight test and other external work. Total program depot maintenance for the C-130 takes about 140 days.

Depot maintenance