AFREP team saves millions

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SEYMOUR JOHNSON AIR FORCE BASE, N.C. (ACCNS) --  They've been called many things: dumpster divers, pirates, and scavengers. But name-calling aside, they saved the base $9.2 million last year.

They are the 4th Fighter Wing's Air Force Repair Enhancement Program, part of the 4th Maintenance Group.

"The idea of the program is to shift the way people think about equipment repair and replacement," said Master Sgt. Wyatt Wertz, base AFREP manager. "Instead of scrapping old or broken parts and ordering new ones, we find the problem and fix it."

AFREP, previously known as Gold Flag, got its start in 1992, according to Sergeant Wertz. It began with the need to be able to repair circuit cards beyond the component level. Prior to AFREP, the cards had to be sent off base, which wasted time and money.

"Once technicians were trained to repair the cards, they started working on other equipment and the program grew exponentially," said Sergeant Wertz. "Now, AFREP technicians repair anything from radar smart cards to base projectors."

Several base agencies sing the praises of the AFREP crew.

"AFREP makes our job much easier," said Master Sgt. Thomas Miller, a specialist flight chief with the 333rd Aircraft Maintenance Unit. "We had an F-15E return with a videotape stuck in its tape recorder. We took the recorder to the shop and they popped it out on the spot."

All AFREP technicians attend a six-week course at Davis-Monthan Air Force Base, Ariz.

"This is where the technicians obtain their NASA Level-2 soldering certification," said Sergeant Wertz. "That level is required to do the types of repairs that come our way."

A Level-5 certification is reserved for technicians working on the space shuttle.

One item that often finds its way to the shop is a multi-purpose display. These are the video monitors found in the F-15E that display several items like threat targets and radar images.

"A small, plastic connector in the display breaks easily," said Tech. Sgt. Rodney Kuhnau, lead circuit card repair technician. "We used to send the entire display to the depot. Sending it would cost the Air Force $55,000 in exchange costs and the display would be gone for about 30 days. Now, we replace the connector here in four hours, and the part costs $13."

The displays are a prime example of how the program works, Sergeant Kuhnau said.

This resourcefulness is one reason Seymour Johnson leads the pack in saving Air Force money, Sergeant Wertz added.

In fiscal year 2003, the base AFREP team saved Seymour and the Air Force $9.2 million. For FY04, the savings are projected at $7 million. According to Sgt. Wertz, the Air Force average per base a year is only $300,000.

"There are two main reasons this program is so successful here," said Sgt. Wertz. "First, we get a great deal of support from the base leadership. Second, the continuity and experience here is outstanding."

AFREP is considered a special duty, and shops at other bases normally only allow three years in the shop, said Sgt. Wertz. However, at Seymour, two technicians have over eight years of experience, and one has almost four.

The shop also works closely with the Innovative Development through Employee Awareness program.

"For most IDEAs, we do the research and most of the leg work," said Sgt. Wertz. "In the last year, we helped 10 ideas win $10,000 each."

The idea for replacing the connector in the multi-purpose display is one of the IDEA projects AFREP completed and implemented.

"Even though what we do is just a small part, the impact is huge on the overall mission," said Sgt. Kunhau.