C-130 team installs 40 center wing boxes Published Sept. 16, 2011 By Jenny Gordon 78th Air Base Wing Public Affairs ROBINS AIR FORCE BASE, Ga. -- If you haven't paid a visit to see what the C-130 team in the 560th Aircraft Maintenance Squadron is doing lately, then chances are you'd be surprised at how much has changed. Just two years ago, there were roughly 70 to 80 mechanics working in the center wing box replacement program. Today's numbers are at a little more than 300 civil service workers and contractors, working in four different hangars on various phases of wing box work. A total of 40 center wing boxes have been installed at Robins, with 11 currently in progress on aircraft in the 402nd Aircraft Maintenance Group. The wing box program is an essential and invaluable one, as maintainers in the 560th have been working steadily during the last few years to improve the way work flows. "In 2010 and 2011, not only did we produce a lot of airplanes, but we came through a huge training curve and made a lot of process improvements in order to satisfy the customer," said Scott Latimer, 560th AXMS C-130 team lead. The wing box, which has a service life of 38,000 flying hours, is the structure that sits atop an aircraft, attaching the wings to the fuselage. When the actual wing box comes from the manufacturer, it measures 42 feet, and sits empty until outfitted with the various ducting, plumbing, wires and other components. Once on a plane, it can weigh as much as 25,000 pounds. The total cost of a center wing box kit is $6.7 million, which includes the installation cost. In fiscal 2010 and 2011 to date, 36 planes were turned out with a new wing box, which currently results in a 220-day turnaround for speedline airplanes, and 300 days for programmed depot maintenance airplanes. There are two different programs - speedline, which involves center wing box work only, and PDM - in conjunction with center wing box replacement. "Not only were we undergoing a huge learning curve," said Latimer, "but we were still trying to learn how to do business, take on this additional work and train the work force at the same time. I'm proud to say that we're finally there." Some of those process improvements during the program's early days involved figuring out how to work on other components at the same time, while not just focusing on the fixture itself, said Latimer. Discussion also focused on finding ways to not take the plane apart so much with speedline replacements, resulting in time savings. One example included the need to not take down an airplane ramp and door during a plane's first phase of work. Electrical build-up, which occurs in the third and final phase of the process, was also moved earlier, which saved time. Towing planes was also looked at, since keeping it in one place longer resulted in more work being done. "Through process improvement, and listening to our mechanics and giving employees more ownership, the program has become successful," said Latimer. On the acquisition side, to date Robins has procured 98 center wing box kits, according to Megan Hilderbrand, C-130 Mods program manager. Six of those kits will be installed on planes for the U.S. Coast Guard. Their first plane is scheduled to arrive for maintenance at Robins in October. The center wing box program is slated to be around for several decades, providing continued work for sheet metal workers, electricians, engineers and the like. It is scheduled to continue into the 2040s, with work to be done on 304 total aircraft, said Hilderbrand.