ARMY AMMUNITION PLANT MODERNIZATION PLAN


SETTING STRATEGIC OBJECTIVES Te strategy centers on meeting the following objectives:


1. Increase manufacturing safety and readiness to meet current and future requirements.


2. Modernize and transform production processes, incorporat- ing best practices from industry.


3. Isolate energetic mass from people. 4. Remove personnel from energetic operations and replace manual operations with automation.


5. Ensure graceful degradation and resilient operations. 6. Design production processes to minimize the concentration of energetic materials in any one place.


7. Incorporate redundancy where possible and practicable.


8. Improve flexibility, maintainability and sustainability. 9. Integrate state-of-the-art technology and equipment. 10. Implement a proactive preventive maintenance program and use predictive maintenance to improve overall system perfor- mance and sustainability.


11. Design production lines that can be alternatively used for multiple products with minimum retooling and reconfig- uration of the physical system.


12. Reduce cost of operations. 13. Identify processes and equipment that reduce the cost of operating the facilities.


14. Identify efficiencies to reduce labor, material and energy costs. 15. Secure supply chain. 16. Mitigate single point failures. 17. Investigate U.S.-based production and vertical integration.


Each year, modernization projects are prioritized based on scor- ing calculated from weighted criteria and measured against two factors: first, the significance of mitigating the deficiency or consequence if the project is not executed (i.e., magnitude of the benefit or consequence), and second, the likelihood or prob- ability the benefit or consequence will occur if the project is not executed. Tese two metrics are multiplied, along with the corre- sponding scoring criteria weight, and then summed to produce a final score as illustrated in Figure 1, page 104.


Immediate safety and environmental compliance issues are considered “must-fund projects” and are prioritized above all other projects.


Project ranking is a critical process to ensure that funding is used in the most effective and efficient way possible. More than 100 modernization projects valued at $1.5 billion are in execution,


Construction of new facilities is critical for enabling continued production of ammunition.


102 Army AL&T Magazine Fall 2022 OUT WITH THE OLD


The new nitrocellulose production facility at Radford AAP in Virginia is scheduled to come online by the end of the year. The new facility will expand the production capacity above current levels, increase operational efficiencies, minimize steam and water consumption, minimize direct-labor utilization thereby improving operational safety, minimize waste streams and emissions, and improve the quality work environment. The new facility will also mitigate the risks of continued reliance on the legacy plant which has served far beyond its original design life expectancy. (Photos courtesy of JPEO A&A)


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