TINKER AIR FORCE BASE, Okla. -- TINKER AIR FORCE BASE, Okla. – As the 552nd Air Control Wing continues its vital role in national defense, the Air Force Repair Enhancement Program (AFREP) is indispensable in keeping the E-3 Sentry AWACS fleet operational. With parts increasingly challenging to source due to the aging airframe and shrinking sustainment footprint, AFREP's innovative approach to maintenance and repair has saved millions for the Air Force while ensuring the readiness of critical airborne command and control missions.
The E-3 Sentry, renowned for its unique ability to provide all-weather surveillance, command, control, and communications, is a cornerstone of the U.S. military's air superiority. However, as the fleet ages, finding parts for the aircraft becomes a growing challenge, leading to potential gaps in readiness. That's where AFREP steps in.
"AFREP is all about finding ways to extend the life of critical parts and equipment that would otherwise be discarded or take months to replace," said TSgt Daniel Lamey, AFREP manager for the 552nd Logistics Support Squadron. "We take parts that are coded for disposal—XB3 assets—and either fix them ourselves or secure contracts to have them repaired. This allows us to put them back into the supply system and save the Air Force a significant amount of money."
Lamey points to a recent example involving a component initially marked for disposal. "One of our AWACS parts, coded as XB3, was worth around $50,000. We were essentially throwing that money away each time it needed replacement," Lamey explained. "But by fixing it in-house, we saved the Air Force that amount every time the part needed servicing."
Beyond the financial savings, AFREP also plays a crucial role in maintaining mission readiness for the 552nd ACW, especially as contracts with suppliers expire and there are delays or challenges in finding new suppliers. "Our fleet is downsizing, and without contractors willing to support smaller numbers of aircraft, it's left to us to find creative solutions to keep our jets flying," Lamey said.
As a result, AFREP has taken on even more responsibilities, expanding its scope beyond traditional aircraft parts. The team has repaired hydraulic systems, communication panels, and complex circuit cards, all vital to the AWACS' unique capabilities.
"Every part we fix helps sustain the fleet and reduce downtime," Lamey said. "Whether it's a fire loop sensor or an intercom disconnect panel, our job is to keep the planes mission-ready."
The value of AFREP extends beyond just the repair shop. The program funds necessary operational improvements by funneling savings back into the wing. Last year, the AFREP office generated $1.8 million in cost savings for the 552nd ACW, which was used to purchase a wide variety of items to include cold-weather gear, personal protective equipment, and even gym equipment to maintain the well-being and readiness of Airmen.
"Everything we save goes right back into the wing," said Lamey. "This helps support our mission and the people who make it happen."
In addition to sustaining the current fleet, AFREP is preparing for future challenges by working with other agencies across the Air Force. SSgt Tyler Goldsborough, the 552nd Maintenance Group's Continuing Process Improvement (CPI) manager, highlighted how AFREP's partnership drives new innovations.
"We've been working closely with AFREP on expanding their capabilities," Goldsborough said. "For example, they recently acquired a Huntron machine, which is used to repair circuit cards, a critical component in many of our E-3 parts. When AFREP needed a custom holder for round microchips that couldn't fit the standard stand, we designed one with 3D printing to support their repairs."
By combining CPI's process-improvement strategies with AFREP's technical know-how, the 552nd MXG has implemented time-saving and cost-efficient solutions across the fleet. "We're not just fixing parts," Goldsborough added. "We're finding ways to do it better and faster."
With global threats evolving, the 552nd ACW remains crucial in ensuring U.S. air superiority. The E-3 Sentry's ability to provide surveillance and command capabilities in real-time is critical to mission success. However, this mission depends on keeping the fleet airborne, and AFREP's efforts are vital to making that happen.
“The problem sets we face in sustaining this aging airframe, while employing it for our worldwide mission require outside-the-box thinking and persistent problem-solving," said Tom Fisher, 552 MXG Deputy Director of Maintenance. “Whether it’s through improved weapon system readiness, or the opportunities presented via repair cost-savings, every Airman in our Wing benefits from the solutions the AFREP team is able to find.”
The 552nd's reliance on AFREP will only grow as parts become more scarce. As Lamey emphasized, "AFREP is here to ensure that no matter what challenges we face with supply shortages, we have the tools and the skills to keep the fleet flying."
With AFREP's support, the 552nd ACW will continue to fulfill its mission, ensuring air dominance and providing real-time command and control to warfighters around the globe.