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Diversified Products for the National Defense
40mm Reliability Trends in the
System Contract
NDIA Small Arms Forum
June 2, 2015
Presented by: Matt Eckel
Diversified Products for the National Defense
Premise
The high reliability of the US Army’s ARDEC
designed 40mm fuzes and tactical cartridges
has been demonstrated through 10 years of
two Systems Contracts.
Photo: US Army
Diversified Products for the National Defense
From Break-out to System Contract
In 2005, the US Army awarded the largest
ever Small Business Set-Aside System
Contract. The new Prime Contractor
assumed responsibility for overall 40mm
cartridge reliability results.
M918 M430A1 M385 M781 M433 M583A1 M661 M662 M992 M585
Diversified Products for the National Defense
Bottom Line Up Front
• Implementation of System Management
Contract has confirmed 40mm System
Capability and Warfighter Utility
Diversified Products for the National Defense
Bottom Line Up Front
• Performance – Repeatability and
Reliability Exceeding Requirements
• Availability – Production Rate and
Schedule Meets US Army Needs
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Reliability
Two Types of Reliability:
Functional
High Order Main Charge Detonation
Safety
It detonates when it supposed to, safe to
handle, and compliant to MIL-STD-1316
Diversified Products for the National Defense
M433 HEDP 40mm Cartridge
The Specification Reliability Requirement1:
M433 HEDP Low Velocity - .958
AMTEC Reliability2 - .993
1 MIL-DTL-50872 2 114 LATs over 9 years representing 2.9 Million units
Diversified Products for the National Defense
M433 HEDP LAT Results
0
500,000
1,000,000
1,500,000
2,000,000
2,500,000
3,000,000
3,500,000
0.950
0.955
0.960
0.965
0.970
0.975
0.980
0.985
0.990
0.995
1.000
07 08 09 10 11 12 13 14 15
Cu
mu
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tity
Re
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ility
Production Year
M433 HEDP Cartridge
Reliability
Specification
Cum Quantity
Diversified Products for the National Defense
M430A1 HEDP 40mm Cartridge
The Specification Reliability Requirement1:
M430A1 HEDP High Velocity - .968
AMTEC Reliability2 - .995
1 MIL-DTL-50863 2 307 LATs over 10 years representing 14.7 Million units
Diversified Products for the National Defense
M430A1 HEDP LAT Results
0
2,000,000
4,000,000
6,000,000
8,000,000
10,000,000
12,000,000
14,000,000
0.950
0.955
0.960
0.965
0.970
0.975
0.980
0.985
0.990
0.995
1.000
06 07 08 09 10 11 12 13 14 15
Cu
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tity
Re
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ility
Production Year
M430A1 HEDP CARTRIDGE
Reliability
Specification
Cum Quantity
Diversified Products for the National Defense
M550 PIBD Fuze
The Specification Reliability Requirement1:
M550 PIBD Fuze Low Velocity - .962
AMTEC Reliability2 - .999
1 MIL-DTL-50869 2 68 LATs over 9 years representing
3.9 Million units
Diversified Products for the National Defense
M550 Fuze LAT Results
0
500,000
1,000,000
1,500,000
2,000,000
2,500,000
3,000,000
3,500,000
4,000,000
4,500,000
0.950
0.955
0.960
0.965
0.970
0.975
0.980
0.985
0.990
0.995
1.000
07 08 09 10 11 12 13 14 15
Cu
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tity
Re
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Year of Production
M550 PIBD FUZE
Reliability
Specification
Cum Quantity
Diversified Products for the National Defense
M549A1 PIBD Fuze
The Specification Reliability Requirement1:
M549A1 PIBD Fuze High Velocity - .968
AMTEC Reliability2 - .998
1 MIL-DTL-32175 2 104 LATs over 9 years representing
13.2 Million units
Diversified Products for the National Defense
M549A1 Fuze LAT Results
0
2,000,000
4,000,000
6,000,000
8,000,000
10,000,000
12,000,000
14,000,000
0.950
0.955
0.960
0.965
0.970
0.975
0.980
0.985
0.990
0.995
1.000
07 08 09 10 11 12 13 14 15
Cu
mu
lati
ve Q
uan
tity
Re
liab
ility
Production Year
M549A1 PIBD FUZE
Reliability
Specification
Cum Quantity
Diversified Products for the National Defense
Reliability Contributors
Contributors to High Reliability:
• 10+ years of Contractor “Lessons Learned“
• Increased Automation
• Robust Inspection Criteria
• Variability Reduction
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Reliability Contributors
Contractor “Lessons Learned“
• Process Improvements have occurred at
all levels from component manufacturing
to Cartridge LAP
• Inspection and Sampling
• Integrated Product Team (IPT)
• Engineering Change Proposals (ECP)
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Reliability Contributors
Contractor “Lessons Learned“
• Fuze Modeling Addressed Stack-up
Tolerance Issues
• Capitalization Improvements in Assembly
Equipment Capabilities
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Reliability Contributors
Increased Use of
Automation
• Sensors
• Auto Recognition
cameras
• Digital X-Ray
• Robots
• Networking
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Reliability Contributors
Inspection Criteria
• Critical Characteristics Control Plans
• Automatic Acceptance Inspection
Equipment (AAIE)
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Reliability Contributors
Variability Reduction
• The System Contractor and suppliers have
imposed tighter tolerances than allowed in
the TDP based on analysis of key
characteristics that drive variability
• Charge Evaluation Charge Verification
(CECV) & Automated Propellant Loading
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Benefits Realized
Program:
• Repeatability and Reliability Demonstrated
to exceed Requirements
• Subject Matter Expertise (SME’s)
Strengthened
• Production Continuity through Single Fuze
Manufacturer
• Mature Supply Chain Management
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Benefits Realized
Warfighter:
• Ammunition Available – Inventory
Established
• Performance Repeatability
• Operational Safety
• Weapon Interface –Stoppage/Jam Risk
Minimized
• CONFIDENCE IN 40MM
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Conclusion
Under the current management teams of the
U.S. Army Product Director for Medium
Caliber Ammunition, ARDEC, and the System
Prime Contractor, the fuze safety, arming,
and functional reliability characteristics of the
40mm fuzes and their integration with the
high explosive cartridges have been
demonstrated to exceed the published
military specification requirements.