Achievement Award Winners
2004 Award Recipients
Lean Depot Repair
Lean Depot Repair successes have triggered a major shift in how repair work is performed at the Warner Robins Air Logistics Center (WR-ALC). Lean practices have revolutionized Programmed Depot Maintenance lines for F-15 and C-5 aircraft, generating dramatic payback for the customer. Reduced cycle time and cost are the primary benefits, shifting critical warfighting assets out of maintenance and into fully operational status available for supporting global deployment requirements. For instance, a C-5, when mission-ready, can be deployed within 90 minutes to help project global power and global reach. Other benefits include:
- C-5 aircraft returned to the warfighter on time increased from 25 percent in fiscal year 2000 to 100 percent in fiscal year 2004.
- Average flow time for depot maintenance on C-5s for the Air Mobility Command was reduced from 339 days in fiscal year 2000 to an average of 240 days in fiscal year 2004, freeing up 3 aircraft, a significant portion of this small, but valuable fleet.
- On-time return of F-15 aircraft to the warfighter increased from 12 percent in fiscal year 2000 to 80 percent in 2004.
- 22 additional F-15s were freed up - the equivalent of an additional squadron.
Upon viewing these achievements, WR-ALC has elected to extend Lean to its C-130 aircraft operations and to critical "non-factory" operations like pass-and-ID. WR-ALC cost avoidance, exceeding $12 million in the first two years of Lean deployment, are traceable to overtime reductions and other efficiencies. Top WR-ALC leadership has vigorously embraced Lean and has adopted Lean deployment as one of their three top depot priorities. True teamwork among personnel from Air Force ManTech, WR-ALC, and Simpler Consulting has directly facilitated program success.
Lean depot practices are being expanded across the DoD, including Army arsenals and depots, Navy air depots, and shipyards.
Government / Industry Team Members:
- Lee Alves - Simpler Consulting, Inc.
- Brenchley L. Boden II - Air Force Research Laboratory
- John Crabill - Air Force Research Laboratory
- Frances A. Duntz - HQ Air Force Materiel Command/XR
- Persis A. Elwood - Air Force Research Laboratory
- Laura Leising - Air Force Research Laboratory
- Team Robins - Warner Robins Air Logistics Center
- Debra K. Walker - HQ Air Force Materiel Command/Logistics
Uniform Cannon Tube Profile Verification
The project goal was to establish an automated procedure (hardware and software) for consistently shaping new (production) tank gun barrels as well as verifying fielded barrels to enable a 15-point improvement in the probability of hit on the first shot. Verification of twenty fleet-representative barrel centerlines resulted in a 20-fold tighter tolerance and a 65 percent reduction in impact dispersion across the fleet of tanks. The team has developed faster and more precise barrel straightness measurement equipment, with the design, engineering, and fabrication of barrel verification machines scheduled for incorporation into the barrel manufacturing process at Watervliet Arsenal. Test firings indicate barrel verification will provide accuracy improvements that are unequaled in the past twenty years. All U.S. Army Abrams Tank units will benefit from planned implementation.
The tighter grouping of round impacts resulted in probability of hit increases ranging from 21 percent to 54 percent for the six common round types. The average reduction in tube-to-tube center of impact for the six common round types is over 50 percent.
Testimonials from Army:
- "[barrel verification is] the only real dramatic improvement in tank fleet accuracy since the introduction of the M1 Abrams full solution fire control system." - Col. Szydloski, TRADOC System Manager (TSM) for the Abrams tank
- "[barrel verification provides] the largest improvement in loss-exchange ratio since the introduction of night vision technology" - Col. Carson, FT. Knox
- "this [technology] is the type of quantum leap forward we're looking for." - Col. McCoy, PM CS
- "I thought we squeezed every inch of accuracy out of the M256, but the barrel verification initiative provides the biggest improvement to come along in years." - William Brooks, Close Combat Analysis Division Chief, (AMSAA)
Government / Industry Team Members:
- Dr. Mark Bundy - Army Research Laboratory
- Paul Durkin - Army Aberdeen Test Center
- Thomas Erline (Retired) - Army Research Laboratory
- James Garner - Army Research Laboratory
- Robert Kaste - Army Research Laboratory
- Terry Marrs - Army Aberdeen Test Center
- Vincent Olmstead - Army Benet Laboratory
- Albert Pomey - Directorate of Training, Doctrine, and Combat Development, Fort Knox
- Walter Roy - Army Research Laboratory
- David Webb - Army Research Laboratory
2004 Defense Manufacturing Technology Achievement Award Nominees
The manufacturing technology project nominees that were considered for the sixth annual award were completed and/or demonstrated in FY04 or FY05. The nominees were:
- Advances in Metal Mold Rapid Tooling for Tank Track Inserts - Army
- Application of Commercial Parts Obsolescence (CPOM) - Air Force
- Composite Manufacturing Technology for the Expeditionary Fighting Vehicle Rear Door - Navy
- Infrared Cooled and Uncooled Staring Sensors - Army
- Joint ManTech for MicroMechanical-Based Inertial Measurement Units (IMU) - Air Force
- Lean Depot Repair - Air Force
- Metals Affordability Initiative - Air Force
- Nickel Metal Hybrid Battery for F-16 - Air Force
- Uniform Cannon Tube Profile Verification - Army