Mike Boorda

  • The cost of maintaining Navy ships is measured in billions of dollars and millions of man-hours. Requiring sailors to perform excessive, unnecessary, and often counter-productive maintenance does more than waste money. It also wastes that most precious of commodities — sailors' time. This problem is being addressed by the U.S. Navy through the Surface Ship Maintenance Effectiveness Review (SURFMER) program. Since October 1996, SURFMER has reduced sailor performed planned maintenance workload on surface ships and aircraft carriers by more than 35 percent, and more than 2.3 million man-hours annually. At the same time, it has improved sailors' quality of life — a top Navy leadership priority.

    SURFMER began as a pilot program onboard USS Yorktown (CG-48), a CG-47 Aegis class cruiser designated as the "Smart Ship." The objectives of the Smart Ship program included reducing sailor workload, saving money, and improving the sailors' quality of life through demonstrations of innovative policies, processes, and technology. The Naval Sea Systems Command (NAVSEA) realized this was the perfect opportunity to perform a Reliability Centered Maintenance (RCM) review of CG-47 cruiser class scheduled maintenance requirements.

    RCM as an engineering discipline was originated by United Airlines during the 1960s. The Federal Aviation Administration (FAA) was contemplating a vastly expanded program of scheduled maintenance to match the expanded passenger capacity of the Boeing 747 aircraft being introduced at the time. With FAA approval, United developed a rational, more cost-effective approach to preventive maintenance requirements development that became known as Reliability Centered Maintenance, or RCM. The Department of Defense subsequently mandated the use of RCM for developing planned maintenance requirements for equipment throughout the services in 1984. American Management Systems (AMS), a company with a unique 20-year public and private sector partnership with the Navy, was a major player in the Navy's adoption of RCM for preventive maintenance of shipboard systems. NAVSEA tasked AMS to develop an RCM-based process that would examine shipboard planned maintenance requirements of currently in-service equipment and systems for possible reduction. This led to creation of the RCM Backfit process, piloted onboard Yorktown and ultimately implemented fleet-wide through SURFMER. RCM Backfit is an engineered, logical, and repeatable process, applied to systems already in service, addressing age degradation of the system under review, applicability of the prescribed maintenance tasks, and effectiveness of those tasks.

    In 1996, AMS engineers under NAVSEA direction, used RCM Backfit and reviewed the entire Yorktown Planned Maintenance System (PMS) work package. This stem-tostern and truck-to-keel review included more than 5,000 tasks. The engineers eliminated unnecessary tasks and rescoped or rescheduled others. Some equipment required less intrusive maintenance than existing PMS called for, others required less frequent maintenance. By the time the AMS team completed its analysis, a 46.7 percent reduction in planned maintenance man-hours was identified and implemented aboard Yorktown.

    Navy engineers then validated the Yorktown results for implementation aboard all other ships of the CG-47 Class.

    The result was a 38 percent reduction in maintenance man-hours across the class. The Chief of Naval Operations (CNO) at the time of Smart Ship, admiral Mike Boorda. directed that initiatives successfully demonstrated on Yorktown should be shared. As a result, in 1996, in NAVSEA implemented SURFMER across the entire Navy surface fleet.

    Beginning in October 1996, SURFMER engineers began a systematic review of all scheduled maintenance requirements. Instead of performing reviews on a ship-by-ship basis as was done with the Yorktown pilot project, NAVSEA implemented SURFMER system- by-system, applying the resulting revamped maintenance procedures fleet-wide. Typically, SURFMER reviews are conducted on site, at Navy in-service engineering activities such as the Naval Surface Warfare Center detachment in Philadelphia.

    In addition to application of a repeatable engineered process, SURFMER's success depends upon close teamwork between NAVSEA and AMS RCM Backfit trainers and mentors, Navy inservice engineers, and fleet sailors with current deckplate operating experience.

    These three groups work together during an intensive week-long SURFMER cycle to gain proficiency in the RCM Backfit methodology. Two days of RCM Backfit training is followed by three days of analysis of specific maintenance requirements for systems under review. At the end of the week, Navy engineers submit their changes to the Navy's PMS system for implementation in the fleet. Revisions are entered into the PMS management information system and distributed periodically to fleet units via CD-ROM by Fleet Technical Support Centers in Norfolk, Va. and San Diego Calif.

    To date, 27 SURFMER Cycles have been completed. The most recent being Cycle 27, which occurred the week of February 7, at the Naval Surface Warfare Center detachment in Philadelphia.

    Systems reviewed during Cycle 27 included distilling plants (flash type), mooring and towing gear, electrical gear, shop equipment, SONAR domes, waste heat boilers, and boat handling gear.

    SURFMER has allowed sailors more time to perform truly necessary maintenance, and while having more free time to spend on liberty while deployed and with loved ones while in homeport.

    MR1 Margaret Buffa, an MR (machinery repair petty officer) from USS Gunston Hall (LSD-44), a Cycle 27 participant said, "I'm the only MR on my ship right now and have to do a lot of maintenance. I love the maintenance workload reduction I've seen from SURFMER. It has made my life easier, and the equipment still works just as well." Time savings achieved by SURFMER to date exceed 2.3 million man-hours per year, (see chart on page 20) In addition to the time savings, associated maintenance-related consumable (e.g., oils, greases, solvents, rags, etc.) and HAZMAT disposal costs have been significantly reduced as well.

    The bottom line: SURFMER achieves real, measurable results, with tangible benefits to fleet sailors. SURFMER, by its nature, is a continuous improvement process — systems originally reviewed in 1996-1997 are being revisited in current cycles. The revisits sometimes yield more reductions, by percentage, than the first time around as Navy engineers become more proficient in the process and more confident in the results. The next step is to institutionalize the SURFMER methodology across the Navy's engineering community, so that it becomes the everyday way of conducting business.

    Ariana Baseman is a freelance writer based in Silver Spring, MD

  • MR Feb-24#6  that have plagued the industry 
Mike Kozlowski  
challenges)
    February 2024 - Maritime Reporter and Engineering News page: 6

    the spate of stern tube [email protected] | +1.516.441.7254 energy transition and some of the unique damage cases that have plagued the industry Mike Kozlowski challenges around greenhouse gas emissions in recent years. As she writes, it might be [email protected] | +1.561.733.2477 and

  • MN Feb-24#26  and advisories about ways to 
Mike Corrigan is Interferry’s)
    February 2024 - Marine News page: 26

    interaction with the ro-ro industry. He said LASH has es and trailers) on 15,400 ferry vessels. published numerous reports and advisories about ways to Mike Corrigan is Interferry’s CEO, based in Canada. improve vessel safety. Corrigan was asked about passenger vessel safety issues Corrigan said that one

  • MN Feb-24#4  can always change, of 
Mike Kozlowski       •  kozlowski@mar)
    February 2024 - Marine News page: 4

    .com Tel: 561-732-1659 Fax: 561-732-8063 try grow. I take this as a good sign. The future has yet to be written. Conditions can always change, of Mike Kozlowski • [email protected] Tel: 561-733-2477 Fax: 561-732-9670 course, especially on the political side where the outlook is

  • MT Jan-24#4  send address correc-  
Mike Kozlowski
tions to Marine)
    January 2024 - Marine Technology Reporter page: 4

    of the tel: (212) 477-6700 Tel: +1 (631) 472- 2715 CFS. NON-POSTAL AND MILITARY publisher. fax: (212) 254-6271 FACILITIES send address correc- Mike Kozlowski tions to Marine Technology Re- Copyright © 2024 New Wave [email protected] porter, 850 Montauk Hwy., #867, Media. Tel: (561) 733-2477 Subs

  • MR Jan-24#6  that it is not necessarily 
Mike Kozlowski  
inspiring successes)
    January 2024 - Maritime Reporter and Engineering News page: 6

    Tricia Garrett [email protected] | +1.516.441.7254 insights not simply on the press release fuel, and is clear that it is not necessarily Mike Kozlowski inspiring successes, but also on the number the CapEx cost of the new and emerging [email protected] | +1.561.733.2477 of hurdles

  • MT Nov-23#4  send address correc-  
Mike Kozlowski
tions to Marine)
    November 2023 - Marine Technology Reporter page: 4

    of the tel: (212) 477-6700 Tel: +1 (631) 472- 2715 CFS. NON-POSTAL AND MILITARY publisher. fax: (212) 254-6271 FACILITIES send address correc- Mike Kozlowski tions to Marine Technology Re- Copyright © 2023 New Wave [email protected] porter, 850 Montauk Hwy., #867, Media. Tel: (561) 733-2477 Subs

  • MR Dec-23#6  and digital technologies is 
Mike Kozlowski  
kozlowski@marinelink)
    December 2023 - Maritime Reporter and Engineering News page: 6

    . Now: The proliferation [email protected]; +1 561-732-1659 interest groups with an agenda that have the of connectivity and digital technologies is Mike Kozlowski [email protected]; +1 561-733-2477 funding and the know-how to make a lot transforming this business faster than all Gary Lewis

  • MN Nov-23#18  by the U.S. Depart- sentatives Mike Ezell (R-Miss.) and Troy)
    November 2023 - Marine News page: 18

    Infrastructure Development ports and marine terminals, in late July of this year, Repre- Program (PIDP) that is administered by the U.S. Depart- sentatives Mike Ezell (R-Miss.) and Troy Carter (D-La.) in- ment of Transportation through its Maritime Administra- troduced in the U.S. House of Representatives H

  • MN Nov-23#10  tender package released
Mike HooksLorraine HooksCutter)
    November 2023 - Marine News page: 10

    (LA)In service 2022 The Dutra GroupTBDHopper10,464 cyTBDIn ? nal development Callan MarineAdmiral NimitzHopper16,000 cyTBDShipyard tender package released Mike HooksLorraine HooksCutter Suction27-inchMobile Pulley Works (AL)In service June 2023 Curtin MaritimeDB AvalonClamshell-Conrad (LA)In service 2022 Cashman

  • MN Nov-23#8  over this time 
According The Mike Hooks Report, an analysis)
    November 2023 - Marine News page: 8

    for solid project work- Gerhardt added. loads in both the public and private sectors. “While there have been peaks and valleys over this time According The Mike Hooks Report, an analysis of the period due to funding and level of need, there has been FY22 U.S. federal dredging market compiled in Septem- a steady

  • MN Nov-23#4  to deliver the ships on 
Mike Kozlowski       •  kozlowski@mar)
    November 2023 - Marine News page: 4

    as construction manager to take responsibility for shipyard selection and ensure that commercial best practices are utilized to deliver the ships on Mike Kozlowski • [email protected] Tel: 561-733-2477 Fax: 561-732-9670 time and on budget. And it worked! Gary Lewis • lewis@offshore

  • MR Nov-23#6 . There are many stories 
Mike Kozlowski  
kozlowski@marinelink)
    November 2023 - Maritime Reporter and Engineering News page: 6

    , too, on the military [email protected]; +1 561-732-1659 bridge of a ship and give this emerging tech- side of the business. There are many stories Mike Kozlowski [email protected]; +1 561-733-2477 nology a trial run, to see its potential, to see to come from Eric’s early October swing Gary

  • MT Sep-23#54  run from ocean landers  MIKE in the Sirena Deep of the)
    September 2023 - Marine Technology Reporter page: 54

    front of the vehicle, obscuring the pilot’s view. Cameron’s DEEPSEA CHALLENGE Expedition with DOV Underwater camera applications run from ocean landers MIKE in the Sirena Deep of the Mariana Trench in 2012. (this column’s focus), AUVs (closely related to ocean land- ers), ROVs, ? sh farms, IOOS Nodes, inshore

  • MT Sep-23#4  850 Montauk Hwy., #867,  Media.
Mike Kozlowski
kozlowski@marinelink)
    September 2023 - Marine Technology Reporter page: 4

    +1 (631) 472- 2715 FACILITIES send address correc- tions to Marine Technology Re- Copyright © 2023 New Wave porter, 850 Montauk Hwy., #867, Media. Mike Kozlowski [email protected] Subscription: Tel: (561) 733-2477 All rights reserved. No part of this publication may be reproduced or transmitted

  • MN Oct-23#4  continued growth in U.S. 
Mike Kozlowski       •  kozlowski@mar)
    October 2023 - Marine News page: 4

    [email protected] Tel: 561-732-1659 Fax: 561-732-8063 Information Administration (EIA) is expecting continued growth in U.S. Mike Kozlowski • [email protected] crude oil production, exceeding 13 million barrels per day for the ? rst time Tel: 561-733-2477

  • MR Sep-23#6  Technology; and James Szybist, 
Mike Kozlowski  
kozlowski@marinelink)
    September 2023 - Maritime Reporter and Engineering News page: 6

    , FMD’s VP and GM of Fairbanks [email protected]; +1 561-732-1659 excellent insights on the ship, its facilities Morse Technology; and James Szybist, Mike Kozlowski [email protected]; +1 561-733-2477 and its role in helping to shape the maritime Section Head, Propulsion Science, ORNL, Gary Lewis

  • MN Jun-23#43  Tyler joined 
NOAA has selected Mike Brennan, 
the board on)
    June 2023 - Marine News page: 43

    BMT Chairman Brennan Named National BMT appointed Ian Tyler as chair- Hurricane Center Director man of BMT Group Ltd. Tyler joined NOAA has selected Mike Brennan, the board on May 1 and will assume the Ph.D., to serve as the next director of Karri Hamilton role of Chairman in early June. NOAA’s National

  • MN Jun-23#11 , and executives such as Mike Ellis,  in what we need)
    June 2023 - Marine News page: 11

    is no shortage of challenges confronting the U.S. aware, and we’re working together. There’s no disagreement barging industry, and executives such as Mike Ellis, in what we need to do, and there’s not even a disagreement T CEO at American Commercial Barge Line (ACBL), are in terms of funding today,

  • MN Jun-23#10 Insights
Mike
QQQQQQQQQAAA
&
Ellis
CEO,
American Commercial)
    June 2023 - Marine News page: 10

    Insights Mike QQQQQQQQQAAA & Ellis CEO, American Commercial Barge Line Mike Ellis, ACBL’s CEO since August 2020, is well-known in the U.S. maritime industry. He was previously executive VP and marine group leader at Savage Services Corporation until Savage sold its inland business to Kirby in April of

  • MN Jun-23#4  opportunity to speak with Mike Ellis, 
Contributing Writers
CEO)
    June 2023 - Marine News page: 4

    as much as possible in Editor Eric Haun • [email protected] print. This recently happened when I had Tel: 212-477-6700 the opportunity to speak with Mike Ellis, Contributing Writers CEO at American Commercial Barge Line. Tom Ewing, James Kearns, Barry Parker, Jeff Vogel He provided me with enough

  • MN Jun-23#2   
48   Advertisers Index
       Mike Ellis, CEO,    
On the)
    June 2023 - Marine News page: 2

    Grady S. Hurley, Jones Walker LLP 46 Classi? ed Advertising 10 Insights: 38 Tech File: Autonomous 48 Advertisers Index Mike Ellis, CEO, On the Cover “Surf drill practice”, by John Deckert. A U.S. Coast Guard motor lifeboat crew enters the off Salman Creek Beach near

  • MN Jun-23#Cover  Open
Interview
ACBL CEO Mike Elli)
    June 2023 - Marine News page: Cover

    Up a Large Fleet of Small Craft Autonomous Vessels Recognizing and Meeting the Challenges Dredging Keeping the Mississippi Open Interview ACBL CEO Mike Elli

  • MR Aug-23#6  
in the future is not advised.
Mike Kozlowski  
business of)
    August 2023 - Maritime Reporter and Engineering News page: 6

    your ? eet is going to look and operate [email protected]; +1 561-732-1659 Don earlier this year on the topic of the in the future is not advised. Mike Kozlowski business of measuring ship emissions covers August is our traditional look inside [email protected]; +1 561-733-2477 a lot of ground

  • MN Aug-23#43  deployed on both coastal resto-
Mike Hooks
ration and navigation)
    August 2023 - Marine News page: 43

    , which constructed the dredge equipment. The 300- by 50-foot Lorraine Hooks, with a dredging depth of 75 feet, will be deployed on both coastal resto- Mike Hooks ration and navigation dredging projects in Louisiana and A new cutter suction dredge (CSD) has been christened for across the Gulf region to