Innovative maintainer Sergeant invents safer tools to save time, money

  • Published
  • By Staff Sgt. Patrick Harrower
  • 60th Air Mobility Wing Public Affairs
TRAVIS AIR FORCE BASE , Calif. --  When the Air Force was founded, early Airman had a pioneering spirit that embraced change and welcomed challenge. That same spirit can be found here today in the 60th Maintenance Squadron hydraulic systems shop.

"We always look for ways to improve our processes," said Master Sgt. Spacey Walker, 60th MXS hydraulic systems section chief. "If our people see something that doesn't work right, or as good as it could, we give them full range to make improvements."

Recently deficiency was noted with a tool that removes special insulator caps from the brake pistons on a C-17 Globemaster III.

"The technical data called for a tool that was prone to breaking and would frequently be put on backorder when the hydraulic shop requested more.

"We always use the technical orders," said Tech. Sgt. Matthew Stechelin, 60th MXS hydraulic systems shop supervisor, "but the tool the job called for just did not work properly."

The new tool Sgt. Stechelin designed cut the work time down from one hour to less than half a minute while also preventing expensive damage to the brake assembly.

"Damaged brake assemblies can cost thousands of dollars," said Sergeant Stechelin. "This tool allows us to save time and money by using precision force instead of uncontrolled impact. Since there is no impact, damage to the brake is minimized and the process is ultimately safer."

Another issue in the hydraulic shop concerned the safety of the Airmen and Sergeant Stechelin decided to make more changes.

A fully assembled C-17 brake assembly can weigh more than 200 pounds and requires two Airmen to lift it off the building station. The lifting and twisting action left the Airmen vulnerable to back injuries.

A wench was designed to lift the brake assembly, but it attached to sensitive brake parts and still required the Airmen to do much of the lifting, said Sgt. Stechelin.

Sergeant Stechelin designed a simple hoist system that made the process easier and safer for the Airmen performing the job. The new hoist also connects to sturdier parts of the brake assembly and cuts the risk of damage.

Sergeant Stechelin used his experience to redesign both tools and is using his resources to get the new tools manufactured and approved for usage in every C-17 hydraulic shop across the Air Force.

One of the resources Sergeant Stechelin is using is the Air Force Innovative Development through Employee Awareness Program, which gives cash awards to Airmen whose ideas save money for the Air Force.

Of his monetary compensations, 100 percent will go to a charity that works to prevent and cure rare genetic disorders, said Sergeant Stechelin.

Sergeant Stechelin said this will be the first of many donations raised through his inventions around the shop.

"Just because a plane has been around for 40 years doesn't mean that improvements can't be made," said Sergeant Walker. "[Sergeant Stechelin] has a lot of processes in the works and is always looking for new ideas to improve the work center."

Whether it's a safety concern or a matter of efficiency, when all the proper channels are utilized, any Airmen can make changes across the Air Force.