One good IDEA deserves another Dover civilian wins Air Force-level award for innovation

  • Published
  • By Capt. Jamal Beck
  • 436th AW Public Affairs
DOVER AIR FORCE BASE, Del. --  One man's belief that there is always room for improvement and his initiative to convert suggestions to savings recently earned him the 2005 Air Force Exceptional Innovator Award.

In November 2005, Air Mobility Command nominated Ernest Phillips, 436th Component Maintenance Squadron accessory shop chief, for an award based on his innovative procedures to rework link housings and refurbish fan blade parts for General Electric TF-39 engines.

The AFEIA recognizes the most outstanding Air Force innovator who contributed to continual performance improvement through the Air Force Innovative Development through Employee Awareness Program. The IDEA program encourages creative thinking and makes innovative ideas - especially those fostering continuous process improvement, economies and productivity - available to benefit the Air Force.

His three-step process of sandblasting, inspecting and recoating fan blade retainers eliminated the need to procure 1,234 engine retainers per year, transforming multiple components into serviceable assets, improving scheduling capability, streamlining technician work procedures and reducing waste and engine rebuild times, allowing for a first-year savings of over $250,000.

"Before the AFTO (Air Force Technical Order) 22 was approved, the fan blade retainers had to be thrown away at a cost of $95.03 each, and with 40 retainers per assembly, a cost of $3801.20," said Mr. Phillips. "Now these retainers can be recoated and reused at a considerable savings for the Air Force.

The milling of thrust reverser link arms allowed the jet engine shop to continue building TF-39 engines to meet its AMC monthly production.

"If this had not been approved, engine production would have been halted, thus not meeting AMC expectations," said Mr. Phillips.

As creative an idea as it was, he wasn't looking for recognition, but a better way to do a better job.

"I was on vacation and actually received a call from James Morgan, the IDEA program manager, informing me that I had been selected. I didn't think I had a chance to win at AMC level, let alone Air Force," said Mr. Phillips.

His coworkers were just as excited as he was once he learned that these ideas were approved.

"Mr. Phillips is a long time supporter of the IDEA program at Dover Air Force Base," said Margie Porreca, interim IDEA program manager. "He leads the way in making improvements for the wing and benefiting from the extra cash at the same time."

Mr. Phillips plans to use the $25,000 awarded through the program to help pay his daughter's college tuition.

Opportunities to save money, manpower and boost morale may be found even in routine tasks.

"Any process or procedure has room for improvement," stated Mr. Phillips. "I considered the IDEA program to make changes in how parts were repaired rather than thrown away, saving the Air Force money and man hours that could be used elsewhere."

Lt. Gen. Roger A. Brady, Air Force deputy chief of staff for manpower and personnel, presented plaques to the winners during a ceremony at the Pentagon April 13.

Some information obtained from the Air Force Manpower Agency Public Affairs.

For more information on the IDEA program or to submit an IDEA, call 677-4040 or go to the IDEA Web site at https://ipds.mont.disa.mil/IPDS/dv_new_home_page.