Munitions Manufacturing A Call for Modernization (2002) / Chapter Skim
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7 Benchmarks and Metrics
7 Benchmarks and Metrics
Pages 110-131
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From page 110... ...
prepared by the TIME program can be thought of as an important first step in defining, through highlevel descriptions- or benchmarks the advancements that the integrated munitions enterprise will require to bring its capability to a par with commercial enterprises during the next 5 to 10 years. The program additionally makes clear that it intends to update these architectures as the capabilities of commercial systems and enterprises improve.
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From page 111... ...
The committee considered only those recommendations that pertain to the munitions industry. VISIONARY MANUFACTURING CHALLENGES FOR 2020 The purpose of this section is to assess the goals and accomplishments of the TIME program in relation to the findings of the Visionary Manufacturing study.
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From page 112... ...
Furthermore, the TIME committee noticed a lack of consideration for life-cyc~e costs and environmental concerns as part of the concurrent design and manufacturing process. Presentations to the Tl ME committee by program representatives outlined a vision in which future munitions manufacturing systems must be totally integrated, encompassing all of the elements of agile manufacturing as well as employing Web-based management of a virtual enterprise structure.
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From page 113... ...
Readiness in the military sense may not directly map onto the concept of concurrency in the same way that it does in bringing new commercial products to market. Recommenclation: As recommended in the Visionary Manufacturing report, the TIME program should adopt concurrency as a central tenet of its plans for upgrading the munitions industry and implement its use throughout the product realization cycle, with appropriate consideration of the full life cycle economic and environmental impacts.
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From page 114... ...
However, at present, commercial software falls far short of creating the information sharing and manipulation capabilities suggested by the Visionary Manufacturing report, although extensive commercial sector work is under way in these fields. Furthermore, the TIME enterprise architecture provides few details regarding the required capabilities of the new software that is needed to achieve the
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From page 115... ...
The TIME program does not address issues of past, present, or future environmental problems associated with munitions manufacturing. Passing mention was made in presentations to the TIME committee of achieving near zero waste and "green bullets," however, no supporting detail was provided.
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From page 116... ...
These issues must be successfully addressed prior to or early in the implementation phase. Recommenclation: The TIME program should develop appropriate detailed plans that will enable rapid reconfiguration of the munitions industry as needed to meet changing national priorities.
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From page 117... ...
Clearly, innovative, flexible processes and process modeling and control will be essential for future munitions manufacturing and should be addressed. The Visionary Manufacturing report suggests that manufacturing operations during the next 20 years will likely need to become proficient in the following: Development of "designer materials" by varying material composition throughout fabrication, joining, and assembly operations.
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From page 118... ...
Nine technology areas were identified in the Visionary Manufacturing report as the most important for meeting the grand challenges: 1. Adaptable, integrated equipment, processes, and systems that can be readily reconfigurecl.
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From page 119... ...
munitions enterprise. Given severe budgetary constraints, the TIME program cannot be expected to be immediately and fully responsive to all of the challenges posed in the Visionary Manufacturing study.
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From page 120... ...
The two sections of the Defense Manufacturing report selected as benchmarks include those technical and organizational capabilities and commercial advances that TIME program managers are in a position to pursue or acquire if they so choose. Required Manufacturing Capabilities The Defense Manufacturing study identified six broad categories of defense manufacturing capabilities that are defense unique or defense critical:
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From page 121... ...
The Defense Manufacturing report identified numerous specific advancements needed in electronics processing, whereas TIME will correctly be concerned with a more generic product realization environment for munitions manufacturing and sustainment. In the opinion of the committee, if all of TlME's stated objectives are eventually achieved, the resulting product realization environment would facilitate the attainment of the specific advances in electronic processes identified in the Defense Manufacturing report.
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From page 122... ...
122 Munitions Manufacturing TABLE 7-1 Broacl Categories of Required Defense Manufacturing Capabilities _ Category Manufacturing Capabilities Composites processing and repair Electronics processes Information technology systems Design methods and processes for low-cost structural composites Design methods for low-cost composite materials Composite materials for advanced propulsion systems Low-cost composite surfaces for tactical missiles Automated composite repairs On-system, on-site composite repair technologies that are affordable and efficient Intelligent health monitoring systems Electronic systems able to withstand high g loads and severe vibration environments High-density packaging for functional elements using monolithic microwave integrated circuits Electronics packaging with increased structural reliability Built-in test diagnostics Commercial programmable network protocols to replace existing buses and networks Software engineering tools to facilitate upgrades Lightweight chip-on-board technology for miniaturization High-precision, high-reliability connectors, back planes, and traces Interruption-free connector systems Optical interconnections for ultra-high data rates Designs to prevent dendritic growth in high-density electronics Manufacturing technology for liquid crystal displays Commercial software systems to replace proprietary systems Systems architecture that permits secure use of commercial off-the-shelf computers, software, and networks Defense logistics systems that are interoperable with the diverse systems used by suppliers Network management and control protocols to ensure data security in distributed design and manufacturing operations Databases containing weapons systems life-cycle costs for integration into design systems Production process capabilities and cost databases for integration into design systems Product data models and storage and retrieval architectures capable of handling data seamlessly Product structure directories that are open and meet commercial standards Intelligent agents for locating and retrieving information Automated reverse-engineering systems based on scanning of the actual part
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From page 123... ...
Benchmarks and Metrics 123 Information technology Nonrecurring manufacturing process control with single systems (continued) view management, single numbering system, and visual statusing system Sustainment Repair techniques for aging systems Nonintrusive, real-time monitoring techniques for flight loads and damage Maintenance and upgrade technologies for aging systems Automated validation tools to replace flight testing Avionics packaging with increased structural reliability and reduced connector problems for aging systems Built-in-test diagnostics for aging systems Modular components to facilitate maintenance of aging systems Software engineering tools to facilitate upgrades Design, modeling, and Product models that enable accurate life-cycle simulation performance versus cost trade-offs Integrated product and process development Virtual prototyping System designs based on common subsystems Process simulations based on finite-element analysis of materials characteristics during forming Product models that enable stealth versus other performance characteristics trade-offs Designs for affordable, high-performance radomes and infrared windows Designs for affordable, easy-to-install electro-optical systems with minimum drag and signature Product models with multiple levels of resolution to enable simulation-based designs Parametric modeling to enable design trade-offs Integrated product, tool, and manufacturing process designs Design methods that incorporate tolerance stack-ups Computer-aided design systems that integrate design, production processes, measurement processes Production processes Affordable processing methods for launch equipment with reduced drag and signature H igh-yield, robust fuse prod uction process Methods for precise filling of explosives in munitions Automated filling of explosives in munitions to increase safety, improve process yield, and ensure performance Methods to reduce cycle time and nonrecurring costs in production processes Precise, automated methods for applying low observability coatings Affordable manufacturing techniques, processes, and tools that can form complex shapes Conformal mold line technology Manufacturing processes for multilayer boards
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From page 124... ...
· Systems architecture that permits secure use of commercial off-theshelf computers, software, and networks, and network management and control protocols to ensure data security in distributed cle sign and manufacturing operations. The Tl ME program is beginning to address the issues of computer security and "need-to-know," using COTS hardware, software, and networks wherever possible.
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From page 125... ...
PDM systems tend to be time consuming, costly, and difficult to implement ancl maintain. It will be hard to implement a PDM system within the scope of the entire integrated munitions enterprise.
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From page 126... ...
The TIME program intends to implement systems that facilitate and enable "design optimization," including access to lifecycle cost databases that will enable trade-offs such as performance versus life-cycle costs. Integrated product and process development.
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From page 127... ...
Methods for precise filling of explosives in munitions. The enhanced product realization process integral to the TIME initiative would contribute to the achievement of this capability.
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From page 128... ...
· Affordable manufacturing techniques, processes, and tools that can form complex shapes. Although typically not required in the munitions industry and not an explicit goal of the TIME initiative, the enhanced product realization process integral to the TIME initiative would contribute to the achievement of this capability.
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From page 129... ...
Advanced approaches to product design, including life-cycle design, integrated product and process development, three-dimensional digital product models, simulation and modeling, and rapid prototyping. All of these approaches are integral parts of the TIME product realization architecture.
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Special emphasis shou~cl be placed on enlarging and upgrading munitions industry technical personnel in this critically important area. Production processes.
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From page 131... ...
(NRC 1999J and Visionary Manufacturing Challenges for 2020 (NRC 1998) —were intentionally conceptual and futuristic, containing considerable speculation regarding possible acivances in manufacturing processes, systems, ancl enterprises over the next 10 to 20 years.
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