Innovation Council
2010 Innovation Award Winner:
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With the loss of HH-60J airframe CG-6020 in 2004 during the daring Alaskan
rescue of the crew of the Malaysian freighter, Selandang Ayu, CWO Montgomery
Everson (ret) of the Medium Range Recovery (MRR) Projects Cell at the Aviation
Logistics Center (ALC), looked for innovative ways to fill the Service's
critical need aircraft gap. Collaborating with CG-41 and CG-71, “Monty” Everson
completed a thorough engineering analysis and determined that the Navy's SH-60F
Seahawk could be viably converted into the Coast Guard’s unique MH-60T
configuration for $12M less that than procuring a brand new helicopter through
the original equipment manufacturer (OEM).
Sikorsky's production line had stopped producing these aircraft in the early
1990's so the Aviation Logistics Center turned to the Navy as they were
experiencing their own fleet recapitalization, including retirement of the
SH-60F helicopter. Everson realized the Coast Guard had the necessary industrial
fixtures, processes and technical experience to convert the SH-60F into the
Coast Guard's MH-60T. Working closely with the OEM, Sikorsky, and Naval Air
Systems Command (NAVAIR) but with no proven roadmap, Everson developed a
comprehensive procedure to modify significant portions of the 60F, including the
cabin subfloor, left hand bulkhead and nose area to meet the Coast Guard's
MH-60T's engineered specifications. No other military service or Sikorsky had
ever undertaken such a vast technical task.
The first replacement aircraft, CG-6043, affectionately called Franken Hawk,
began flying operationally in September 2009. When visiting Elizabeth City, one
cannot pick out which of the 60's is not an original Coast Guard helicopter; it
is seamless to the fleet.
The closest available aircraft version - the MH-60R - would cost the Coast Guard
approximately $45 million to acquire. Not only expensive, there would be no
standardization across the rotor wing fleet. Everson's process yielded a
replacement aircraft including the avionics upgrade package for the Coast Guard
fleet under budget for approximately $18 million.
Not a one-time deal, the Coast Guard has acquired two additional Navy SH-60F
hulls with extremely low flight hours. The Coast Guard has already converted the
second hull and is currently in the PDM process and will become the CG-6044. The
third hull arrived at Aviation Logistics Center mid October where it is
currently being disassembled for conversion.
In addition to the huge cost savings is the savings in delivery time. This new
process of converting retired Navy helicopters reduces the delivery time for
future aircraft by approximately 18 months.
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