EXTREME MAKEOVER
Most manufacturing processes at Lake City were developed before World War II, and well before the proliferation of computers and the internet. Much of the current manufacturing equipment uses mechanically controlled processes, requiring deliberate re-engineering to adjust; a common manufacturing tech- nology used in the 1940s when Lake City was established. Computers (program- mable logic controllers) control modern manufacturing systems and are networked to enable statistical process control. Currently, “touch labor”— i.e., a Lake City employee—distributes propellant to the equipment that loads the projec- tiles into cases. Employees manually pour gunpowder down chutes that lead to the equipment that assembles bullets.
Modernization will remove that touch labor from many processes and operations, thus reducing risk.
Delivering modern ammunition technol- ogies will require a culture that embraces modernization and cutting-edge technol- ogies, especially as we scale up production to the requisite volumes.
Other industries are far ahead of us when comparing manufacturing technolo- gies, process efficiencies and safety. As we prepare to design a new facility, we are confronted with a long list of strin- gent regulations specific to establishing manufacturing capabilities on govern- ment installations, in addition to all industry standards. But if we are to align with industry, then we must capitalize on modern processes and infrastructure and when appropriate, challenge specific regu- lations that impede our ability to leverage industry best practices that are safe and efficient, and that contribute to manufac- turing a quality product.
NEW CARTRIDGES
The cartridges to be manufactured at Lake City are the hybrid brass and stainless steel, and the plastic injection molded and cased telescoped version. They are different from the traditional brass cases used in 5.56 mm, 7.62 mm and .50-caliber applications. (Image courtesy of Project Manager Maneuver Ammunition Systems)
MANUFACTURING TECHNOLOGY OPPORTUNITIES As we prepare for NGSW ammunition production, we have a unique opportu- nity to serve as a model for modernization across the spectrum of government-owned, contractor-operated ammunition manu- facturing facilities. Some of the specific manufacturing processes and technolo- gies we will implement are manufacturing process controls enabling greater flexibility within manufacturing processes.
We will implement computer-automated monitoring and on-the-fly fine tuning of manufacturing processes. Tis is an enor- mous leap in manufacturing capability from the current mechanically controlled bullet assembly machines. We will stream- line the order fulfillment process to build
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THE GOCO RELATIONSHIP
Government-owned, contractor- operated (GOCO) facilities were established to reduce supply chain risk and ensure critical ammuni- tion is available in times of need. GOCOs are owned or leased by the government and operated by industry partners, resulting in reduced cost and risk for the government. GOCOs usually have significant capacity for production that industry is unwilling to main- tain given historic fluctuations in demand. For example, in fiscal year 2000, the requirement for small caliber ammunition was approximately 275 million rounds, which increased by one billion in 2002 to support the wars is Iraq and Afghanistan; a fluctuation so sudden and significant that industry was not able to meet the requirement within capacity and time constraints.
in scheduling efficiencies not currently realized at Lake City. Manufacturing systems will incorporate the latest genera- tion of automation processes and systems for raw materials handling and delivery, as well as work in process and finished goods.
We will implement fully autonomous delivery and handling of all explosive materials, increasing workforce safety by separating mass explosives from people. New manufacturing systems will support iterative process improvements.
Most importantly, to tie all systems together, we will use open network archi- tecture coupled with f lexible systems to enable iteration and incorporation of
Army AL&T Magazine
Summer 2021
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