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RD-RI37 6 Mi MRNUFRCTURING' METHODS & TECHNOLOGY PROJECT EXECUTION i/2 REPORT FIRST CY 83(U) ARMY INDUSTRIAL BASE ENGINEERING ACTIVITY ROCK ISLAND IL C FULLER NOV 83 UNCLASSIFIED F/G 13/8 NL Elllllllllllil lllllhEllEllEE

Elllllllllllil lllllhEllEllEE · REPORT FIRST CY 83(U) ARMY INDUSTRIAL BASE ... is included in Appendix IV to this report. The Project Officer for this task ... Engineering Training

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RD-RI37 6 Mi MRNUFRCTURING' METHODS & TECHNOLOGY PROJECT EXECUTION i/2REPORT FIRST CY 83(U) ARMY INDUSTRIAL BASE ENGINEERINGACTIVITY ROCK ISLAND IL C FULLER NOV 83

UNCLASSIFIED F/G 13/8 NL

ElllllllllllillllllhEllEllEE

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MIRCP EOUINTS HR

NAIOA BUEA OF.ADRD-%

11111 _%

% MU 227 i-

N U.S. ARMYMATERIEL DEVELOPMENT

AND READINESS COMMAND

H! iANUFACTURING

5JETHODS &

9 ECHNOLOGY

PROJECT EXECUTIONREPORT

FIRST CV 83A

PREPARED BY NOVEMBER 1983USA INDUSTRIAL BASE ENGINEERING ACTIVITY

4', MANUFACTURING TECHNOLOGY DIVISION

A LE Copy ROCK ISLAND, ILLINOIS 61299,* 1, I E C . .. ..

a -

- . -- - -.- r - ~-. .- r-. V7. W - 7'. f , . .

UNCLASqITFEDSK CURITY CLAWSFICATION OF THIS PAGE (WMan Date Enterec)

REPORT DOCUMENTATION PAGE BFR

I. REPORT RNNMER 12. GOVT ACCESSION NO. 3. RECIPIENT'S CATALOG NUMBER

FIRST CY83 l4b A1i~36 I3 ____________

4. TITLE (811 Subttle S. TYPE Of REPORT &PERIOD COVERED

SemiannualMANUFACTURING METHODS &TECHNOLOGY 1 Jan 83 - 31 Jun 83PROJECT EXECUTION REPORT 6. PERFORMING ORG. REPORT NUMBER

7. AUTHOR(a) U. CONTRACT OR GRANT NUMUIER(.)

Cecilia Fuller N/A

9. PERFORMING ORGANIZATION NAME AND ADDRESS 10. PROGRAM ELEMENT PROJECT. TASKAREA & WORK UNIT NUMBERS

US Army Industrial Base Engineering ActivityATTN: DRXIB-MT N/ARock Island, IL 61299

It. CONTROLLING OFFICE NAME AND ADDRESS 12- REPORT DATEUS Army Industrial Base Engineering Activity November 1983ATTN: DRXIB-MT IS. NUMBER OF PAGES

Rock Island, IL 61299 180M4 MONITORING AGENCY NAME A AODRESS(if dlifareal from Controllind Office) 1S. SECURITY CLASS. (of tis report)US Army Materiel Development & Readiness CommandATTN: DkCMT, Office of Manufacturing Technology UNCLASSIFIED5001 Eisenhower Avenue 150. DECL ASSI FICATION/ DOWNGRADING

Alexandria, VA 22333 SHDL /

C. DISTRIBUTION STATEMENT (of Oiol Report)

DISTRIBUTION UNLIMITED

17. DISTRIBUTION STATEMENT (of the abstract uttered in Block 20, It different ifom, Report)

DISTRIBUTION UNLIMITED .-

14. SUPPLEMNTARY NOTES

N/A

AC'KY ORS (Cotiue a reverse sid it necesr a Idetify' by block numbe)

is document is a summary compilation of the Manufacturing Methods andTec ology Program Project Status Reports (RCS DRCMT-301) submitted to IBEA fromDARCOM major Army subcommands and project managers. Each page of the comput-erized section lists project number, title, status, funding, and projected comr- ..

pletion date. Summary pages give information relating to the overall DARCOMprogramo. N

DD M9 oo~ MOS~OSLT UNCLASSIFIED

SECUITY CLASSIFICATION OF THIS PAGE (When Data Sneered)

DEPARTMENT OF THE ARMYNfl ~~US ARMY IN4DUSTRIAL BASE ENGINEERING ACtiVfTY 1 o 8

ROCK ISLAND. IWUNOIS S12N 8 O 16

aftv TO

AT~tTIOW OF:

SU&JET: Manufacturing Methods and Technology (13T) program projectExecution Report, First Half CY83

SZE DISTRIBUTION

1. Reference At 700-90, Paragraph 3-4j(l), 15 Mar 82, subject: Logistics,Army Industrial Preparedness Program.

2. The Project Execution Report is a sumary compilation of the Off ProjectStatus Reports (RCS DRQIT-301) submitted to ISEA from DARCOM major ArmySubcomads (SUNNACXII) and project managers. This document Is used asa man-age0210nt tool for mitoring trends Of the MfT Program and Includes a discus-*Ion of the overall DARCOK Program. There are separate sections in the reportshowing projects that are am, active, and completed.

3. The submission of status reports is required by AR 700-90 to be made toIDEA within 2-1/2 months after the reporting period. For this document, that .*-

date was 15 Sep 83. Due to the extremely large number of delinquent Inputs(over 33Z of the projects) the cutoff date was extended to 30 Sep 83. Whilethe extension resulted In reducing the delinquents to 52, it also delayed thepublication,

4. Persons who are Interested in the details of an Individual projactshould contact the Manufacturing Technology representative at the SUIMACOM. -

A list of those representatives is included in Appendix IV to this report.The Project Officer for this task Is Cecilia Fuller, AUTOVOK 793-6521.

FOIL TER DIRECTOR:

I)I hill V. '5'iii

Chief Manufacturing Technology Division

A ro

%5

TABLE OF COTINTS"

Page

DISCUSSION . . . . . . . .".... . . . . . . . ........ 1PROJECTS ADDED Ist HALF, CY83 . . . . . . . . . . . . . . . . .. 13

FINAL STATUS REPORTS RECEIVED DURING 1st HALF, CY83 . . . . . . . 31

SUIARY PROJECT STATUS REPORTS .................. 49

Management Engineering Training ActivityArmy Depot Systems Command......... . . . . . . . . 51 0"

Mobility Equipment R&D Command. ................ 55

Electronics R&D Command .. ........ . .......... 59

Army Material and Mechanics Research Center . . ........ 67

Test and Evaluation Command........ . . . . . . . . . 83

Aviation R&D CommandTroop Support & Aviation Materiel Readiness Command . . . . . 91

Communications & Electronics Command . . . . . . . . . . . . . 99

Missile Command . . . . . . . . . . . . . . . . . . . . . . 103

Tank-Automotive Command . .. . . . . . . . . . . . . . . . 109

Armament, Munitions & Chemical Command (Ammunition). . . . . . 119

Armament, Munitions & Chemical Command (Weapons) . ...... 141

APPENDICES . . . . . . . . . . . . . . . . . . . 155

I - Command Identification . . . . . . . . . . . . . . . . . 157

II - Project Slippage Stu ..... ............. 161

III - User's Guide . . . . . . . . . . . . . . . . . . . . . . 165

IV - Army MMT Program Representatives . . . . . . . . . . . . 169

DISTRIBUTION . . . . . . . . . . . . . . ....... . . . . . 175

t'

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J..p~~kW'j?_- .. ; ' .' -%.%," - -, , U * ,.. .- .. •**~ *% * .. *- •. * .*-,. - •. . . . . . -

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DISCUSSION

Background

The Army Manufacturing Methods and Technology (MMT) Program wasestablished in 1964 as a part of the Army Production Base Support (PBS)Program. The MT Program has goals of improving existing manufacturingtechnology, translating new technology into production line processes, andsupporting the modernization and expansion of the military hardware produc-tion base. The program is governed by the provisions of AR 700-90, Chapter3.

Composition of the Report

This 121T Project Execution Report provides the status summaries of 448active projects which have a total authorized cost of $235,288,200. TotalMMT program statistics, as well as the summaries of the active projects arealso included. The report is compiled, edited, and published for HQ,DAR OM by the Manufacturing Technology Division of the Army Industrial BaseEngineering Activity (IBEA) in accordance with AR 700-90, paragraph3-4j (1).

Distribution of this report is extended to Army materiel developers andusers and to counterparts in the Navy and the Air Force. Inquiries on thedetailed technical aspects of any individual project may be answered by theMMT Program representative of the action command under which the projectwas completed or is being executed. Inquiries or suggestions concerningthis report or other facets of the !MT Program may also be directed to theManufacturing Technology Division of IBEA.

The report is composed of. three major sections:

a. Projects Added 1st Half, CY83 - A list divided by organization ofall projects funded during the first half of CY83. Included is a narrativeof the problem for each project.

b. Final Status Reports Received During 1st Half, CY83 - A list di-vided by organization of all projects for which final status reports werereceived during the first half of CY83. Included is a narrative of thefinal status for each project.

c. Summary Project Status Report - These reports are divided by orga-nization and include a summary of funding by fiscal year and a narrativestatus of the work accomplished during the six month period for each activeproject.

.j:. -.

* *•

MMT Program History

Figures 1 and 2 depict the size and growth of the MMT Program since

1970. These charts last appeared in the October 1982 Project ExecutionReport and are updated here to include FY83 funding. Figure 1 showsfunding levels and Figure 2 deals with number of projects. In each fig-

ure, the upper curve represents all of the MMT projects for each fiscalyear shown. The lower curve represents only those projects which initi- ""'ated a new effort during the fiscal year shown. The difference betweenthe two curves on each figure represents those approved dollars (Figure

1) and number of projects (Figure 2) which were approved in the fiscal

year as follow-on projects to efforts initiated in prior years.

In the early years, these charts show a great increase in dollars,

especially from FY71 to F174. Then, there is no appreciable growth in

the HMT Program between FY74 and FY80. The funding level increases again

HISTORY OF APPROVED PROJECT FUNDING

90

so

70

1602-.i

30 -\ "

10

070 71 2 73 7 75 7 77 76 719 60 1 62 3

- ALL MM PROJECTS FISCAL YEARMMT PROJECTSWHICH INMATENEW WORK EFFORTS

Figure 1

2

4, *-,* . .....-. ",..'....... ....... r- ..... "..... . .. *...-.• . ". .... .,...i ,,

HISTORY OF NUMBER OF FUNDED PROJECTS,,-10

160

130120

110

100Sso-

50

4030

10

. '+ , ,

707172737 47A57677 76 7696061682687-ALL MMT PRECTS FISCAL YEAR

-M-T PRJECTSWHICH INMATENEW WORK EFFORTS

Figure 2

through FY81 and FY82, ranging from the FY80 level of $67 million to $86million in FY82. These increases vere felt to be the result of a renewed,active coitmitment to take action on improving Defense manufacturing pro-ductivity. However, in FY83 the funding level dropped dramatically to $38 :.

million. This was the result of a last minute conversion of the FY83 MMTProgram to the R&D account. The net result of Congressional action toinitially line-out" the T Procurement account with subsequent Program.-reinstatement in the R&D account was a decrease of $70 million worth ofplanned work.

40-.

Starting in FY72, less than 50% of each year's budget has been spenton initiating new work efforts. The majority of each year's funds hasbeen spent for follow-on projects to efforts initiated in prior years.From FY74 to FY80 this trend, to a degree, reflected the fact that while

3

O. o*-o -

9•~4 -- AL N -POJ S ISA YA

--- MT ROJCTSI

VC NATix4

individual work efforts were becoming more costly due to inflation andtechnical complexity, the overall budget had remained relatively constantpermitting the initiation of fewer new work efforts. With an increasingbudget in FY81 and 82, one night have expected that this gap would de-crease. However, the advent and execution of complex large doliar,multi-year "systems" projects continued to keep the initiation of newwork efforts low and the total number of new projects fairly constant.With the great reduction of funds in FY83, priority was placed on fundingfollow-on work so that inefficient work discontinuity could be kept to aminimum. As a result, in FY83, the funding level for initiating new workefforts was only $12 million. This represented less than 1/3 of thetotal funding, the lowest value to date.

.... .

I

4

Status Report Submissions

There are two areas which have been of concern in the past: (1) de-linquent status reports, and (2) final status reports without technicalreports. Figure 3 sumarizes by Coimand these two situations.

STATUS REPORT (RCS DIR24T 301 ) SUBM ISSIODNS -

Number of Tech Number and (M*301 *301 Number and MS Number Rpts Submitted of Delinquent

Reports Reports of Delinquent of Final w/Finai Status TechnicalComand Required Submitted 301 Reports 301 Reports Reports Reports

MIETA 7 7 0 (0%) 0

DESCOM 9 9 0 (0%) 0

IIERADOOM 10 10 0 (0%) 1 0 1 (100%)

ERADOM# 52 46 6 (12%) 10 3 7 (70%)

A1W54 1 (20%) 0

NIMS 4 4 0 (00) 4 0 4 (100%)

TECOM 3 3 0 (0%) 0

AVRADCOM 47 41 6 (13%) 7 6 1 (14%)

TSARCOM 2 2 0 (0%) 0

(ZOOM 11 11 0 (0%) 0

11100W 39 3 4 (10%) 7 6 1 (14%) *

TACOM 61 58 3 05%) 14 6 8 (57%)

MNCC0M 155 150 5 (3%) 30 14 16 (53%)

M4000M 103 102 1 (1%) 5 1 4 (80%)(Weapons)

TOTAL 5 0 42 26 -05%) 78 3 42 (54%)

F Igure 3

D0ooB not Include FY83 projects which were recently funded and which did not require astatus report.

"'Delinquency rate reflects a 2 week extension of the cutoff date. Actual dmlinquency asof the regulatory cutoff date was 166 reports or 33%.

5 %

% % . ~ . \ ~ -*-- *~.** .* - . . .-.-. . . . -

According to this figure, there was only a 5% delinquency in receiptof 301 report. or 26 reports not submitted by the cutoff date. Thisappears to be an improvement over the 8% from last reporting period anddefinitely better than the 18% from the reporting period previous to thatone. However, this "improvement" is the result of an extension in thecutoff date from 15 September 1983 (already 2-1/2 months from the end ofthe report period, 30 Jun) to 30 September 1983. This extension wasnecessary in order to include the reports f rom TACG( and ERADCXh1 whichhad not yet been received by 15 September. The actual delinquency was33Z or 166 reports, a significant increase from the previous two report-Ing periods. The extension was granted since it was felt that a compiledreport with 1/3 of the input missing would not be meaningful. Unfortu-nately, receipt of 1/4 of the total reports 2 weeks past an alreadygenerous cutoff date delayed the data entry and analysis with a resultant -

2 to 4 week delay over the normal report publication.

Accuracy of MHT summary information for management depends on a com-plete submission of all the project status reports for each Command. Anydeliiuquency creates a void in the information presented in the compiledreport. Therefore, steps are taken to remind the Commands of the submis-sion of these reports. In June 1983, a call letter was mailed out toeach SUBMACOM. Enclosed with this letter was a computerized listing ofthe projects for which a status report was required for this reportingperiod. Also, phone calls were made in August to those commands whosesubmission had not yet been received. Even with the reminders, the gen-eral trend has been that more and more of the reports are submitted laterand later. Even though the two reports prior to this one have shown lessdelinquencies (18% and 87), this has mainly been as a result of the re-vised AR. 700-90, 15 Mar 82, giving the Commands an extended 2 1/2 months

.4 from the end of the reporting period to submit their status reports.Delinquency and timeliness are areas that must be improved in order toinsure a useful review of the progression of the MMT Program.

Relative to the second area of concern, there has always been a re-quirement that a technical report be prepared for each project.* Thetechnical report is an accepted vehicle, and In some cases the only vehi-cle, for true technology transfer and its importance cannot be over-stated. In May 1981, a letter from the Directorate of Manufacturing

* Technology reinforced the requirement that final status reports will notbe submitted without a completed technical report. Of the Ill final sta-tus reports submitted during the previous reporting period, 59 of them,or 53% did not have technical reports included. For this period, asnoted in Figure 3, 78 final status reports were received with 42 of them,or 54% being delinquent the technical report. The percentage of delin-quency has not improved. Greater strides will have to be made if truetechnology transfer is expected to occur. The 78 projects for whichfinal status reports were received during this period can be found in aseparate section on page 31 where the final work status is given for each

project.

6

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= . .- ~ .. .. s iL

Program Summary

Manufacturing Methods and Technology (MHT) projects and effcs aremajor elements of the Army's Manufacturing Technology (MANTECH) Program.AR 700-90 succinctly describes the HANTECH objective as the improvementof the industrial readiness and efficiency of the production base forArmy materiel. Further defined objectives are stated in the Statement ofPrinciples for the DOD Manufacturing Technology Program. This Statement,originating at the Deputy Under Secretary of Defense level, not only 'establishes ground rules for the Program but highlights the level ofemphasis that the Program receives.

To attain the objectives described in the Statement of Principles,the Army funds discrete work units, called "Projects," on a yearlybasis. These projects, identified by a seven-digit number, contain workrequests, which upon completion will- result in an end product whose tech-nical transfer can he effected. At times, in order to have a total workpackage which is implementable, (i.e., which can achieve the payback forwhich the work was funded) the scope can be of such a magnitude thattotal funding in one fiscal year can be an inefficient use of resources.

In this event, the total work might be multi-year funded, (i.e., bemore than one project, each having a technically transferrable end prod-uct). These total implementable work units are called "Efforts". Theseefforts can consist of many projects or just be one project, depending onthe amount of work required to achieve the implementable technical goal.Efforts are identified by a four-digit number which is the same as thelast four digits of a project or projects which make up the effort.

The following three charts (Figures 4-6) summarize MMT projectreporting and funding status for the 1st Half of CY83. These summariesinclude data from the major Army subcommands (SUBMACOM) that have activeprojects and the A}MRC and ANETA sponsored projects. Cumulative figurespertaining to project distribution and expenditures of funds on contractand in-house are provided. Projects that were closed out during thereporting period are not included in the data used for these summaries.On the following three charts, comparisons are made between parallelreporting periods (lst half, CY82 and lst half, CY83) in order to observethe project number and funding changes that occur within each Comnand andwithin the total program.

7

~tc~~r,4r .............. '

A summary of the MKT Program (Figure 4) indicates that both the nun-ber of active projects and amount of project funds have decreased by 18%

. in comparison with the 1st half of CY82. This significant decrease isbasically attributed to the problem associated with the conversion of theFY83 MHT Program to the R&D account. With the greatly reduced FY83budget, fewer new projects were approved during this period than were .4'

approved during the same period last year. In addition, project close-outs have increased by 17Z, 78 projects in Ist half CY83 versus 65 proj- . - -

ects in 1st half CY82. The combined effect of these two actions resultin a marked decrease in the active program.

MMT PFIGRA4 SUMMARY

Nuffber of Projects Funding Status

Organization Ist Half Ist Half Percent 1st Half Ist Half Percent

CY82 CY83 Change CY82 CY83 Change

AMETA/DESCOM 15 17 13 5,192,000 4,970,000 -4

MERADODM 18 9 -50 6.191,800 3,819,100 -38

ERADCOM 44 42 -5 27,166,900 26,353,100 -3

AMMRC 5 5 0 13,734,500 14,713,700 7

NLBS 5 0 -100 643,500 0 -100--

TECOM - 3 3 0 1,614,000 1,929,000 20

AVRADOOWTSAR0M 71 44 -38 28,739,500 24,901,500 -13

OECOM 11 11 0 8,222,900 8,723,900 6

MICOM 46 32 -30 24,083,500 17,356,500 -28

TACOM 68 59 -13 31,022,900 29,577,000 -5

ACOOM (Amm) 156 128 -18 116,934,300 78,399,900 -33

4ICCOM (Weapons) 105 98 -7 23,802,400 24,544,500 3

TOTAL 547 448 -18 287,348,200 235,288,200 -18

4 Figure 4

It can be noted that the largest decreases in number of projects wereAMCCOM (Ammo) and AVRADCOH/TSARCOH while the large decrease percentage-wise was NLABS. NLABS had a 100% decrease because they closed out all of 41

8

747

%%.

.. 4. .4.

*'* , % -,.' ' .h.* . % ;, % 4.- . *..- .J. ~ .-.. .... ....

.- . . 1 ..,.--

their remaining projects and had no new projects funded. Dollarwise thelargest decrease was AMCCOS (Amo) with $38.5 million. All increases invalue were quite small, the largest being ANHIC with $1 million.

A breakout of the active projects by fiscal year is shown in Figure5. Over the past few years there has been a continued emphasis on clos-

. ing out older projects. Currently, data is provided to DARCOIl everyquarter listing the active projects funded in FY79 and prior to monitorfor completion. The success of this DARCOM follow-up is shown by compar-ing the fiscal years 75-79 for the lst half CY82 with the currentperiod. A year ago, there were 112 active projects for these fiscalyears. There were only 47 projects for these years reported during the1st h lf CY83. This is a 58% reduction in older projects. In additionthe active FY80 projects were reduced 551 during the sam period.

ACTIVE PIDJECTS BY FISCAL YEAR

Organization 73 76 7T 77 78 79 80 81 82 83 TOTAL

N4ETA/DESCOM 1 1 1 1 3 7 3 17

NERADCOM 2 2 3 2 9

ERADCOI 1 3 3 4 6 6 8 11 42

M410C 1 2 1 1 5

*TECOM 1 1 1 3

AYRADCOWTSARCOM 1 2 13 22 6 44

CECOM 1 1 1 4 2 2 11

MIcOM 1 2 9 12 8 32

TACOM 1 1 3 4 14 21 15 59

N4CCOM (Ammo) 1 3 11 18 26 44 25 128

AMCCON(Weapons) I 2 1 22 2 16 9

TOTAL 0 2 1 7 10 27 49 102 162 88 448

Ist CY82 . j I I I I* TOTAL 4~ 31' 14126 164 109 1156 1170 1 0154

Figure 5

9S * . . .. .. . . . . . . . . .

. . . . . . . . . . .. . . . . . . I''

Figure 6 indicates at what rate the project funds are being expended.Over the past three years, the active MKT program has shown an increasingcontractor participation. The data from this period supports the contin-uance of that trend. For the lot CY82 period, the contractor and in-house figures were $148 million vs. $139 million. For the lot CY83 period,

PROGRAM FUNDING EXPENDITURES(MILLIONS)

Remainig*No. of Authorized Actual Contracts* (In-House + Planned Contract)

rganizution Projects Funding' Amount Expended Amount Expended

MNETA/OESCOM 17 $ 5.0 S 3.7 S 2.0 (55%) S 1.3 S 0.5 (37%)

MERADOOM 9 3.8 3.2 2.7 (855) 0.6 0.3 (55%)

ERADOOM 42 26.4 20.9 14.2 (68%) 5.4 2.0 (36%)

N4MC 5 14.7 5.9 ' 8.8 '

TECOM 3 1.9 0.0 0.0 (0%) 1.9 1.7 (86%)

AVRADXNMTSARCOM 44 24.9 20.3 10.6 (52%) 4.6 2.1 (44%)

4-'CECOM 11 8.7 6.1 3.0 (48%) 2.6 0.4 (16%)

MICOM 32 17.4 12.2 8.7 (70%) 5.1 2.4 (46%)

TACOM 59 29.6 19.2 11.2 (58%) 10.4 2.3 (22%)

AMCCOM (Ammo) 128 78.4 42.8 28.6 (66%) 33.6 16.4 (45%)

MNCOM (Weapons) 98 24.5 7.8 4.0 (51%) 16.7 5.5 (33%)

TOTAL 448 $235.3 $142.1 $95.0 (60%) $ 91.0 $33.6 (37%)

1st CY82TOTAL 547 $287.2 $148.3 588.5 (60%) $139.0 $40.7 (29%)

FIgure 6

*AII figures rounded to one delmel place. .,

P*NMIRC MIT reporting system did not Individually Identify either In-house expenditures or

contract expenditures.

10

, . -,. , . . w.. .- ,. . ". .. . ., .-. . . • -. . . .. - . " . . - . . . . . - ... .: ..

. . . . .. . . ..t• . -. o --

these same respective values are an even more diverse $142 million vs.$91 million. This is in part due to the extended cutoff date which re-sulted in less apparent delinquencies, which in turn resulted in moreprojects having funds cited on contract than that which was true duringthe comparison report period. Figure 6 shows that compared -to the sameperiod last year, contractor expenditures are the same, 60%, and in-houseexpenditures are up (29% vs. 37%). Again these improved figures can be

related to some degree to the inclusion of more current data which re-sulted from less report delinquencies (an apparent 5% this period). Itshould also be noted that the numbers in the two expenditure columns willbe lower than the actual values because the ANMRC ?ffT expenditures arenot identified in their reporting system. The 26 delinquent projectsalso have an impact on this chart. There would have been additionalin-house and contract funds expended that were not reported to IBEA.

44

N N

,pi' o-4-"

II -'

: .

MNT PROGRAM

PROJECTS ADDED 1ST HALF, CY83

'w

13

- A K - - All,

-I~ -7 _ . .-. q 17 77K L~c--

PROJECTS ADDED IN 1ST HALF, CY83

AMETA

D 83 S052ARMY ENGINEERING DESIGN HANDBOOKS FOR PRODUCTION SUPPORT

TECHNICAL SCIENTIFIC AND ENGINEERING DATA IS CONTINALLYBEING GENERATED WITHIN THE ARMY AND NEEDS TO BE COLLECTEDIN APPROPRIATE DOCMENTS.

DESCOM

G 83 0002CAN APPLICATION OF ROBOTICS TO SHELTER REFINISHING

SPRAY PAINTING AND SANDING OF ALUM SKINNED MILITARYCONTAINERS IS LABOR INTENSIVE &ND CREATES A HARSH WORKINGENVIRONMENT. DEVICES TO SENSE PRESENCE AND ABSENCE OF PAINT* TO CONTROL HEAT BUILD-UP TO PREVENT ALUM SKINDELAMINATION ARE NEEDED.

G 83 7001AUTO DYNAMOMETER CONTROL F/STANDARDIZED INSPECT TEST (CAM)

ALL ENGINES ARE TORN DOWN WHILE 20% COULD bE RESTURED TOOPERATION WITHOUT PHYSICAL TEARDOWN. TEARDOWN IS 1/3 COST.F OVERHAUL. ALL ENGINES REBUILT REQUIRE A 4 HOURDYNAMOMETER OPERATIONAL TEST CYCLE.

ERADCON

H 83 3010HYBRID MODULATOR FOR PULSED IMPATT MILLIMETER WAVE SOURCES

TO ESTABLISH A MANUFACTURING CAPABILITY FOR PRODUCTION OF

IMPATT DIODES WHICH ARE UNIFORIA ENOUGH TO BE FIELDREPLACEABLE IN ARMY SYSTES.

H 83 5019LASER-CUT SUBSTRATES FOR KICROWAVE TUBES

PRESENT CFA JAMMER TUBES EMPLOY HIGH COST, PRECISION ANODD:CIRCUITS LIMITING UTILIZA7ION IN OPTIMIZED EW SYSTEMS. HIGHPERFORMANCE AND LOW WEIGHT AT MINIMUM COST IS REQUIRED TOFIELD DESIRED EU SYSTEMS.

9. 15% % .q

04~~ opJI

PROJECTS ADDED IN 1ST HALF, CY83(CONTINUED)

H 83 510794 GHZ PULSED POWER COMBINER

DIODE PARAMETERS VARY GRE&TLY FROM UNIT TO UNIT. PACKAGINGMETHODS ARE UNSATISFACTORY FOR COMBINER CIRCUITS. TUNINGCUBNINER ELEMENTS AND ADJUSTING ASSOCIATED MODULATINGCIRCUITS TAKES WEEKS OF EFFORT TO OBTAIN REQUIREDPERFORMANCE LEVELS.

H 83 5109PRECISION LOW-COST SAW DELAY LINES FOR UHF APPLICATIONS

BROADBAND SAW DELAY LINES ARE REQUIRED FOR SIGNAL STORAGEDEVICE BANDWIDTH IS FIXED BY NEED TO STORE SIGNALS FOR ATEN MICROSECOND DURATION FOR SIGNALS RANGING OVER 500 MHZBAND. DEVICE INSERTION LOSS AND MULTIPLE TRANSMITREFLECTIONS MUST BE MINIMAL

H 83 5111VAPOR GROWTH FOR 3RD GENERATION PHOTOCATHODE

LIQUID EPITAXIAL GROWTH PROCESS REQUIRES- A)LARGE ANDCOSTLY HIGH TEMP REACTORSJ B)L&RGE QUANTITIES OF SATURATIONMELT MATERIALS, C) COSTLY QUALITY GALLIUM ARSENIDESUBSTRATESt D)LENGTHY OPERATION PROCESS PER SINGLE GROWTH.*1q

Ii 83 5151LIQUID PHASE EPITAXY OF HGCDTE F/COMMON MODULE DET ARRAYS

LOW YIELD ON CURRENT METHOD OF MANUFACTURE OF COMMON MODULEDETECTOR ARRAYS. GROWTH OF HGCDTE CRYSTALS REQUIRES MANUALLAPPING, POLISHING + THINNING TO ACHIEVE PERFORMANCESPECIFICAT IONS.

hi 83 5162EXJAM BATTERY MANUFACTURING TECHNOLOGY* PHASE II

PRESENT R AND D MODELS OF UNATTENDED EXPENDABLE JAMMERRESERVE POWER SUPPLY (UEJPS) ARE HAND MADE I OR 2 AT ATIME. UNLESS FABRICAION/ASSEMBLY ARE PRODUCTION ENGINEERED-

LABOR COSTS WILL MAKE THE BATTERY PROHIBITIVELY EXPENSIVE.

I- 83 5168AUTOMATIC RETICLE INSPECTION SYSTEM, PHASE I

THERE IS NO WAY TO CHECK TAPE-GENERATED RETICLE PATTERNSAGAINST THE COMPUTER-GENERATED MASTER TAPE. VISUALINSPECTION OF RETICLES FOR PINHOLES OR DUST PARTICLES ISVERY DIFFICULT.

16

PROJECTS ADDED IN IST HALF, CY83(CONTINUED)

h 83 5174CAN SPUTTERING CONTROL FOR ZNO

GAS MIXTURE, ZNO PURITY + SPUTTERING PARAMETERS AREMANUALLY MONITORED USING A MASS ANALYZER. CORRECTIONS INFLOW + DEPOSITION PROCESSES ARE SLOW AND PERFORMED AFTERUCCURRENCE.

H 83 5180MMT FOR METAL DEWAR AND UNBONDED LEADS

THE GOLD WIRE BONDED CONNECTIOkS ARE MADE BY HAND WHICH ISA TEDIOUS AND EXPENSIVE PROCESS. THE GLASS STEM IS HANDFASHIONED AND IS PRONE TO DAMAGE.

H 83 5196INDUSTRIAL PRODUCTIVITY IMPROVEMENT - ELECTRONICS

MANY ELECTRONICS ITEMS PRODUCED FOR ARMY ARE BUILT INFACTORIES NOT USING MODERX METUODS AND EQUIPMENT9 AUTOMATICMATERIALS HANDLING SYSTEMS, OR COMPUTERIZED MANAGEMENTINFORMATION SYSTEMS. THESE PLANTS MUST BE UPDATED TOIMPROVE PRODUCTIVITY.

AMMRC

M 83 6350MATERIALS TESTING TECHNOLOGY (NTT)

DESTRUCTIVE AND CERTAIN CONVENTIONAL NON-DESTRUCTIVE ,TESTING TECHNIQUES ARE RESPECTIVELY UNSUITED AND INADEQUATEUR HARD TO BE ADAPTED TO ON-LINE PRODUCTION TESTING USAGE.

TECOM

C 83 5071TECOM PRUDUCTION TEST METHODOLOGY ENGINEERING MEASURES

ARTILLERYVEHICLE AND ELECTRONIC CONVENTIONAL TESTCAPABILITIES NEED TO BE UPGRADED TO PROVIDE MORE TIMELYACCURATE TEST DATA FOR THE TEST AND EVALUATION PROCESS.

AVRADCOM"

1 83 1298HIGH TEMPERATURE VACUUM ChRBURIZING "::

6EAR CARBURIZING IS PRESEKTLY CARRIED OUT WITH A RELATIVELYSLOW ENDOTHERMIC PROCESS, TYPICALLY AT 1100 DEG F, WHICHREQUIRES SURFACE PROTECTION AGAINST DECARBURIZING DURINGTHE CYCLE OR A POST HEAT TREAT REMOVAL OF THE DECARBURIZED

LAYER. 1 7 ,.*--.-.

. .. . ,I , - . . . , . - . . . ./ . . ' . . . . . ' . . - . ' . ' . " . . . • . - . , . . - " -% ' .

PROJECTS ADDED IN IST HALF, CY83(CONTINUED)

1 83 1382LOW-COST COMPOSITE MAIN RUTOR bLADE FUR THE UH-60A

MANUFACTURING TECHNOLOGY FUR COCURING GLASS AND GRAPHITEFILAkENT WOUND MAIN ROTOR BLADES HAS NOT BEEN ESTABLISHEDFOR THE PRODUCTION ENVIRONMENT.

C M3 R389PRODUCTION OF ALUMINUM AIRFRAME COMP (SUPERPLASTIC FORMING)

CURRENT METHODS OF MAEHINIkNG ALUMINIUM FORGINGS ARE,.:.EXPENSIVE AND REQUIRE AN EXCESSIVE NUMBER UF PARTS.

1 83 7427ATTAK HELICOPTER PRODUCTIVITY IMPROVEMENT (API) PROGRAM

THE MANUFACTURING FACILITIESt METHODS, AND PRODUCTIONMANAGEMENT SYSTEMS OF PRIKE CONTRACTORS ARE NOT IN THELATEST STATE-OF-THE-ART CUNDITION. THIS RESULTS IN HIGHCOST AND LATE DELIVERY.

1 83 1433MMT - IPI PGM - BELL HELILOPTERt INC. - AHIP

THE MANUFACTURING FACILITIES, METHODS AND PRODUCTIONMANAGEMENT SYSTEMS AT BELL HELICOPTER TEXTRONt INC ARE NOTUP TO THE LEVEL IN THE GENERAL AEROSPACE INDUSTRY. THISRESULTS IN HIGH COST AND SLOW DELIVERY.

1 83 1465ADVANCED COMPOSITE SENSOR SUPPORT STRUCTURE (ACS-3)

THE CURRENT PROTOTYPE SENSOR SUPPORT STRUCTURE 15 COMPOSEDOF BERYLLIUM WHICH IS TOXIC9 EXPENSIVE AND SOLE SOURCESUPPLIED.

CECOM

F 83 3068INCREASE PRODUCIBILITY OF VARACTORS AND PIN DIODES

PRESENTLY AVAILABLE VARACTORS AND PIN DIODES MADE BYSILICON DIODE TECHNOLOGY &RE EXPENSIVE. THE IR PRODUCTIONTECHNIQUES ARE VERY LABOR INTENSIVE, YIELDS ARE LOW, ANDUNIFORMITY IS POOR. MATCHING REQUIRES EXTENSIVE TESTING.

18

--. ..% :,." , .,' . :. .'. ,- -.% ... , .- -.-.- ,- .-..-. .- -." .° . . .. . : . . .. - .. - -

PROJECTS ADDED IN 1ST HALFt CY83(CONTINUED)

F 83 3094COMMUNICATIONS TECHNOLOGY TECHNOD FOR JTIDS

COMMUNICATIONS EGUIPHENT IS MANUFACTURED USING LABORIhTENSIVE, LOW VOLUME PROCESSES. MACHINES ARE OLD ANDUNAUTUMATED. NEW METHODS, PROCESSES AND EQUIPMENT ARENEEDED.

:4MICOM :.q

3 83 IC51REPLACEMENT OF ASBESTOS IN ROCKET MOTOR INSULATIONS

PRESENT ASBESTOS CONTAINING INSULATORS CAN NO LONGER BEMANUFACTURED AFTER 1981 DUE ITS BEING IDENTIFIED AS ACARCINOGEN. THUS THE GOVT HAS LOST THE CAPABILITY OF USINGINSULATING MATERIALS THAT HAS PROVEN TO BE AN EXCELLENTTHERMAL BARRIER.

3 83 1060ELECTRICAL TEST AND SCREENING OF CHIPS

ONE UNRELIABLE CHIP IN MILITARY ELECTRONIC ASSEMBLIESCAUSES REJECTION OR DESTRUCTION OF THE ENTIRE PACKAGE.PRESENT MEANS FOR DETERMINING CHIP RELIABILITY OR INTEGRITYIS A PROBE TESTING TECHNILUE WHICH IS TIME CONSUMING ANDDESTRUCTIVE.

3 83 1072MULTIPLE HIGH iELIABILITYILOW VOLUME LSI MANUFACTURING (CAM)

PRESENT PROCESSES FOR LSI CIRCUITS DO NUT ADEQUATELYSUPPORT MILITARY NEEDS. L51 MFG FACILITIES ARE STRUCTUREDTO HANDLE HIGH VOLUME RUNS IN A SINGLE PROCESS TECHNOLOGY.

3 83 1086COBALT REPLACEMENT IN MARAGING STEEL-ROCKET MOTOR COMPONENTS

CURRENT HIGH PERFORMANCE ROCKEI MOTOR COMPUINENTS UTILIZEMARAGING STEELS IN LARGE QUANTITIES. COBALTt ONE OF THE KEYINGREDIENTS COMES FROM POLITICALLY SENSITIVE AREAS AND 156ECUMING DIFFICULT TO OBTAIN.

3 83 1089INTEGRAL ROCKET MOTOR COMPOSITE ATTACHMENTS

CURRENT FILAMENT WOUND COMPOSIIE ROCKET MOTOR CASES REQUIREFORGED METAL POLE PIECESt NOZZLE CLOSURE ATTACHMENT RINGS,AND OTHER ATTACHMENT RINGS. THESE COMPONENTS ARE EXPENSIVE,AND REQUIRE LONG LEAD TIME PROCUREMENT.

19

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PROJECTS ADDED IN 1ST HALF, CY83383 1126 (CONTINUED)

t 3 83 1126WOUND ELASTOMER INSULATOR PROCESS

LARGE TACTICAL ROCKET MOTOR INSULATORS ARE COSTLY, LACKDESIGN CHANGE FLEXIBILITY AND SUFFER LONG LEAD TIMES.CURRENT PROCESSES INVOLVE BONDING TOGETHER FINISHEDSECTIONS OR LAY-UP OF GREEN STOCK FOLLOWED BY STITCHING,CURING AND FINISHING TO SIZE.

3 83 3115ENGINEERING FOR METROLOGY AND CALIBRATION

MEASUREMENT SCIENCES OR METROLOGY MUST BE CONTINUALLYADVANCED IN RELEVANT TECHNOLOGY AREAS TO KEEP PACE WITHMANY ARMY PROGRAMS. ,.

383 3449ALTERNATE PROCESS FOR IPDI

A NUMBER OF CHEMICAL INGREDIENTS USED IN SOLID ROCKETPROPELLANTS HAVE BECOME UNAVAILIABLE BECAUSE SOME OF THEREAGENTS ARE HAZARDOUS.

TACOM

483 5005COMPUTER AIDED DESIGN FOR COLD FORGED GEARS (PHASE 11)

MACHINING AND OTHER PROCESSES ADD COST TO THE FINISHEDCQMPONENT.

4 83 5053ADIABATIC DIESEL ENGINE COMPONENTS (PHASE 11)

FABRICATION OF HIGH EFFICIENCY, HIGH TEMPERATURE DIESELENGINES REQUIRES ADVANCED MATERIALS. ENGINES FABRICATEDWITH CERAMIC COMPONENTS HAVE BEEN DEMONSTRATED IN R+D BUTMANUFACTURING METHODS FOR SERIAL PRODUCTION COMPONENTS ARELACKING.

4 83 5068NEW ANTI-CORROSIVE MATERI4LS AND TECHNIQUES (PHASE I1)

METALLIC COMPONENTS ARE DETERIORATED BY THE ENVIRONMENT.

20 4

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-~ - - ~ - . - . - - ~ ~ . - - - -- . - -. '

PROJECTS ADDLD IN 1ST HALF, CY83(CONTINUED)

4 83 5075,-"MILITARY ELASTOMERS FOR TRACK VEHICLES

TRACK LIFE IS HELD AT ITS PRESENT LEVEL BY FAILURE OFRUBBER COMPONENTS SUCH AS BUSHINGS, PADS AND BLOCKS.

4 83 5082FLEX MACHINING SYS (FMS) PILOT LINE F/TLV COMPS (CAM) (PH V)

PARTS FOR TRACKED COMBAT VEHICLES ARE TYPICALLY NOTMANUFACTURED IN LARGE UANTITIES. BECAUSE OF THIS, MASS PDNTECHNOLOGIES THAT RESULT IN LOWER PDN COSTS ARE NOT USED.

4 83 5090IMPROVED AND COST EFFECTIVE MACHINING TECHNOLOGY (PHASE V)

MACHINE DATA ON NEWER MATERIALS AND NEW REMOVAL RATES ARENOT ESTABLISHED.

4 83 5091HEAVY ALUMINUM PLATE FABRICATION (PHASE I)

MANY COMBAT AND TACTICAL VEHICLE HULLS AND THEIR COMPONENTSARE FABRICATED FROM HEAVY ALUMINUM PLATE. CUTTING THISHEAVY ALUMINUM PLATE TO SPECIFIED CONTOURS AND WELDING THEPIECES TOGETHER REQUIRES A GREAT DEAL OF MANUAL LABOR.

4 83 6054ADVANCED METROLOGY SYSTEMS INTEGRATION (PHASE i)

THE METROLOGY METHODS USED IN MILITARY VEHICLE MANUFACTURE,IN GENERAL, EMPLOYS CONTALT GAUGES MANUALLY EMPLOYED. THISREPRESENTS A SUBSTANTIAL PART OF THE COST OF OUR MILITARYVEHICLES.

4 83 6057ABRAMS Ml COMdAT VEHICL&

MATERIALS AND MANUFACTURING PROCESSES EMPLOYED IN THE MFGOF THE MI CAN BE IMPROVED BY INCORPORATING NEW TECHNOLOGIESTO THE CURRENT SYSTEM. THIS WILL ENABLE THE MI TO BEPRODUCED MORE ECONOMICALLY.

4, 83 6059M2 AND M3 FIGHTING VEHICLE SYSTEM

MATERIALS AND MANUFACTURING PROCESSES EMPLOYED IN THE MFGOF THE FVS CAN BE IMPROVED BY INCORPURATING NEWTECHNOLOGIES TO THE CURRENT SYSTEM. THIS WILL ENABLE THEFVS TO BE MANUFACTURED MORE ECONOMICALLY.

21

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.-. . . . -.. -. -. .. . . .. . - ,.- -. . . - '

.... .; ... - . -,: ... ...-, .. ., - . - . : . . ,.. -.- -.- •: ... . . . . .- - ..- - .,.. -..... ., ° . .

PROJECTS ADDED IN IST HALF, CY83(CONTINUED)

4 .3 6079AGT-15UO ENGINE

THE NEED TO REDUCE COST AND IMPROVE PERFORMANCE OF THEAGT-1500 TURBINE ENGINE REQUIRES NEWER AND MORE INNOVATIVEMANUFACTURING TECHNOLOGY.

4 63 6095ABRAMS TRANSMISSION PRUDULTIVITY IMPROVEMENTS (PHASE 1)

A NUMBER OF TECHNOLOGICAL AREAS HAVE BEEN IDENTIFIED WHICHCAN BE APPLIED AS COST REDUCING MEASURES OR AS A MEANS OFIMPROVING THE MANUFACTURE COST OF THE Ml ABRAMTRANSMISSION.

4 83 6 10 7 , ..N

IMPROVED MBT TRACK

INCREASED VEHICLE PERFORMANCE REQUIREMENTS NECESSITATEHIGHER PERFORMANCE TRACKS THAN THOSE AVAILABLE TODAY. TOIMPLEMENT NEW METAL COMPOSITE9 HIGHER STRENGTH FERROUSALLOYS, AND TITANIUM NEW MANUFACTURING PROCESSES MUST BEESTABLISHED.

4 83 6121CAD/CAM FOR THE BRADLEY FIGHTING VEHICLE

MANUFACTURING TECHNIQUES FOR THE BFV ARE IN NEED OFIMPROVEMENT IN THE AREA M4TERIAL SELECTION, MANUFACTURINGPRINCIPALS, AND 6IUALITY CUNTROL. IN ADDITION CURRENTTECHNIQUES ARE EXTREMELY LABOR INTENSIVE.

48317001ADVANCED CERAMIC ARMOR COMPONENTS FOR COMBAT VEHICLES

A NUMBER OF MATEiRIAL COMBINATIONS FOR ARMOR HAVE BEENDEVELOPED BUT ARE NOT COMMERCIALY AVAILABLE.

AMCCOM (AMMO) ...

5 83 0900AUTOMATED MULTIPLE FILTER LIFE TESTER

THERL IS A LOW TEST RATE CAPACITY AND AN INCREASINGd VULUMEUF TESTING FOR THE CURRENT FILTER LIFE TEST EQUIPMENT. '

22.......................................-. °-

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PROJECTS ADDED IN 1ST HALF, CY83" I(CONTINUED)

S 43 0913 _ ,

SPIN COATING OF UECON AGEhT COhTAINER5

CURRENT METALLIC DECUN AGLNT CONTAINERS CORRODE BEFORE THEREQUIRED SHELF LIFE OF THE AGENTS IS REACHED. ALTERNATIVE

CONTAINERS ARE NOT AVAILABLEt BUT PLASTIC LINERS HAVE BEENSHOWN TO EXTEND THE LIFE OF CURRENT CONTAINERS. IGNIFICANTLY.

5 43 0924-MANUFACTURING PROCESS FOR GAS MASK CANISTERS

THE CANADIAN GAS MASK CANISTER IS BEING ADAPTED TO THE USSTANDARDS UNDER A MACI PREGRAM. THE CANADIANS ARE HAVINGDIFFICULTY PRODUCING THE CANISTERS RESULTING IN HIGH REJECTRATE.

5 83 0925PROTECTIVE MASK LEAKAGE TESTING

CURRENT GAS MASK TESTER DIJES NOT SIMULATE THE ACTUAL FIELDUSE AND 15 NOT SENSITIVE ENOUGH TO DETECT SMALL LEAKS

5 83 1295MODERNIZATION OF CHARCOAL FILTER TEST EQUIPMENT

CHARCOAL FILTER TESTING EQUIPMENT NEEDED TO PROVIDE TESTINGCAPABILITY FOR VARIOUS CHEMICAL AGENTS DOES NOT EXIST.

5 83 1348SUPER TROPICAL BLEACH

THERE IS A MAJOR SHORTFALL BETWEEN THE FY78 REQUIREMENTS -.FOR TIIS ITEM AND THE QUANTITY OF IMPORTED CHLORINATED LIMEKNONN TO BE AVAILIABLE.

5 83 1701BULK TRANSFER OF CHEMICAL MATERIALS

CURRENT TECHNIQUE FOR RETRIEVAL WEIGHING AND TRANSPORTING• " ~PYROTECHNIC CHEMICAL COJNSTITUELTS AR, ACCOMPLISHED BY LABOR -'-~

INTENSIVE OPERATION AND ARE UNSAFE.

5 83 1709IMPROVED PROCESSING OF PYROTECHNIC MIXTURES

ACCIDENTAL INVITATION OF MIXTURES DURING PROCESSING IS ASERIOUS PERSONNEL SAFETY PROBLEM DUE TO EXPOSURE TO FIREAND EXPLOSIVE HAZARDS.

23

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% •,', .. +i, ,, -, .- ° . - . ".. .'... . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . .,.. . . .... . . . . . . -. .... . . , ,

PROJECTS ADDED IN IST HALF, CY8..(LONTINUED)

5 83 4061NITRUGUANIDINE PROCESS OPTIMIZATION

A NITRIGUANIDINE FACILITY IS UkDER CONSTRUCTION AT SAAP TUBE OPERATIONAL IN FY80. IT UTILIZES PROCESSES NOTPREVIOUSLY USED COMMERICALLY AND IT CONTAINS MANYRECIRCULATION AND SUPPORT LOOPS, THE OPERATION OF WHICH ARESTRON(LY INTERDEPENDENT.

5 83 4062AUTO MANUFACTURE SYSTEM FUR MORTAR INCREMENT CONTAINERS

THE MANUFACTURE AND ASSEMBLY OF THE 60/81MM PROP CHAR6EINCREMENT CONTAINER IS LABOR IKTENSIVE AND DOES NOT MEETPRODUCTION REQUIREMENTS.

5 83 4298EVALUATIUN OF DIMETHYLNITROSAMINE DISPOSAL ON HAAP B-LINE

EFFLUENT FROM AMMONIA RECEVERY COLUMN CONTAINS SIGNIFICANTAMOUNTS OF DMN. DMN IS ONE OF THE EPA CONSENT DECREECOMPOUNDS FOR WHICH WATER QUALITY CRITERIA MUST BEPROVIDED. EPA INSISTS ON LEVELS BELOW 0.3 PPd.

5 83 4444bODY FOR M42/M46 GRENADE

THE PRESENT METHOD OF PRODUCING THE BODY FOR THE M46 ANDM42 GRENADE IS COSTLY.

5 83 4449PROCESS IMPROVEMENT FOR COMP C-4

THE EXISTING FACILITIES WHICH &RE COMMON TO THE MANUFACTUREOF COMP B AND THE OTHER RCX COMPOSITION WOULD LIMIT THEAVAILABILITY OF THESE ITEMS BELOW THEIR MOB REQUIREMENTS.

5 83 4453DETERMINE SPACING OF MUNITION ITEMS TO PREVENT PROPAGATION

THE EXISTING SAFETY MANUAL (AMCR 385-100) HAS BECOMEANTIQUATED BY RECENT ADVANCES IN WEAPONS TECHNOLOGY. THEREIS A NEED TO UPGRADE ACCILENTAL DETONATION SUPRESSIONCRITER IA.

5 83 4489ADVANCED POLLUTION ABATEMENT TECHNOLOGY F/DARCOM FACILITIES

MUCH WORK HAS BEEN DONE IN THE PROPELLANTS AND EXPLOSIVESPLANTS TO MEET THE POLLUTION ABATEMENT STANDARDS. HOWEVER,ALL OF THE GOALS HAVE NOT YET BEEN MET.

'-I,

24

* L7

- . . . *. * o * .

PRUJECTS ADUL IN 1ST HALF, CY83(CONTIWUED)

5 83 4511DISPOSAL UF FINAL SLUDGE FROM 4CIU RECOVERY OPERATIONS

SODIUM HYDROXIDE IS PRESENTLY UStU TO NEUTRALIZE NITRICACID IN WEAK ACETIC ACID PRIOR TO ITS PRIMAkY DISTILLATION - "AND IN THE FINAL SLUDGE TV KILL THE WASTE RDX. A BY PRODUCTOF THIS REACTION IS A LOW GRADE SDIUM NITRATE.

5 83 4529MANUFACTURE OF PRECISION CONES FOR HEAT PROJECTILES

THE HEAT PROJECTILE LINER MUST BE HELD TO .003 IN ANY.,%TRANSVERSE PLANE AND WITHIN .006 ALONG ITS LENGTH. THETOLERANCES ARE AT THE EXTkEME LIMIT OF ACCURACY. THE XM815LINER REQUIRES PRECISION AN ORBER OF MAGNITUDE GREATER(.00U5).

5 83 4533LOVA PROPELLANT PROCESSING

PDN OF SOLVENT PROCESS BINDER BASED LOVA PROPELLANTREQUIRES PRECISE CLASSIFICATION OF IN-PROCESS MATERIALS IN

ORDER TO ASSIGN AVAILABLE PDN EACILITIES. THE USE OFUNCONVENTIONAL SOLVENTS RAISES CONCERN ABOUT POLLUTIONCONTROL.

5 83 4534SAWS BULLET CONVERSION OF SCAMP EQUIPMENT

AN AMERICANIZED VERSION OF BELGIUM SS-109 WILL BE USED INTHE SAW SYSTEM. THIS EFFLRT IS DIRECTED TOWARD DEVELOPMENTOF CONVENTIONAL PROCESSES TO MASS PRODUCE SAWS AMMUNITIONUN SCAMP EQUIPMENT.

5 83 4538

5.56 SAWS LINK ORIENTER AND FEED SYSTEM

THE M27 LINKS ARE MANUALLY ORIENTED AND PACKED AT THE LiNK

MANUFACTURERS. AT THE LOADING PLANT, LINKS MUST BE MANUALLYUNPACKED AND FED INTO THE LINKING MACHINES, WHICH IS TIMECONSUMING AND COSTLY.

5 83 4540CAC03 COATING OF 7.62MM B/LL PkOPELLANT

A SAFE AND EFFICIENT PROCESS IS NOT CURRENTLY AVAILABLE FORTHE CLATING OF 7.62MM bALL PROPELLANT WITH CALCIUMCARBONATE.

25

wrd' '% *=" 4<• % .-w' , .i,, - .................... " ..... """" " "'"""""""" . . .. . .. """"

PROJECTS ADDk( IN IST HALF, CY83(CONTINUED)

5 33 4547 "'PROC TECH FOR XM76 IR SCREENING GREN £ XM49 SMOKE GENERATOR

NEW IR SMOKE SCREENING TELHNOLOGY NEEDED.

5 83 4548PYRO SAFETY ENHANCEMENT

PYROTECHNIC MIXING REQUIRES INCREASED PERSONNEL SAFETYFEATURES.

5 83 4563PROCESS INPROVEMENT FOR TANK DU PENETRATURS

, CURRENT PRODUCTION PROCESSES ARE INCAPABLE OF MEETING TIMECYCLES AND QUANTITIES OF D/U PROJECTILES AS PLANNED IN

," FACILITIZATION STUDIES.

5 83 4605PROPELLANT BED DEPTH CONTROL IN CASBL AIR DRY

kADFORD AAP HAS ENCOUNTERED PROBLEMS IN CONTROLLING BEDDEPTH DURING DRYING OF SINGLE BASE PROPELLANT.

AMCCOM (WPNS)

6 8311724GROUP TECHNOLOGY OF WEAPON SYSTEMS (CAM)

A PROLIFERATION OF DESIGNS AND PARTS EXIST FOR THEPRODUCTION OF CANNON. UNIQUE MANUFACTURING ROUTINGS AREGENERATED FOR EACH COMPONENT AND CUSTOM TOOLING ANDFIXTURING IS REQUIRED.

6 83 7985SMALL ARMS WEAPONS NEW PRECESS PRODUCTION TECHNOLOGY

GUN BARREL MFG PROCEDURES REFLECT ANTIQUATED TECHNOLOGY ANDRELY ON MASS REMOVAL OF MATERIAL BY CONVENTIONAL MACHININGMETHODS. CURRENT EQUIP REPRESENTS 1940-50 TECHNOLOGY. NEWMATERIALS COMPOUND THE PRLBLEM.

6 83 8102APPL OF POWDER METALLURGY FORGING TO WEAPON COMPONENTS

FORGINGS AND CASTINGS ARE FABRICATED OVERSIZE ANDSUBSEQUENTLY MACHINED DOWN TO FINAL DIMENSIONS. FINALCOMPONENT CONFIGURATION IhVOLVES A LARGE AMOUNT Of MANPOWERAND MACHINES TO REMOVE ALLiOY STEEL AS CHIPS.

26

,. ..,.

- " -' "" " " " " " "' " " ."-""" "":" - ' "' "" " . ** " ."' " . _:; ."': ".. . ,:.','. . . . ' S ,. .;-.-,'-,-.., : ..-- '-

4. -A -7

,: PROJECTS ADDED IN IST HALFt CY83(LONTIKUED)

6 83 8103 LHIGH VELOCITY MACHINING

SPEED iaF MACHINING CANNON TUBES IS LIMITED WITH CURRENTEQUIPMENT.

6 S3 8120ADAPTIVE CONTROL TECHNOLOGY (CAM)

CURRENT GRINDING PROCESSES DO NOT TAKE ADVANTAGE OF THEGRINDING WHEEL CUTTING EFFICIENCY. PRECISION TOLERANCES AREUIFFICULT TO HOLD DUE TO PART HEATING. WHEEL WEAR RATESINCREASE EXPONENTIALLY WITH FEED RATES AND LIMITPRODUCTIVITY.

"4 6 83 8154COMPUTER INTEGRATED MANUF4CTURING (CIM) FOR CANNON

NUMERICAL CONTROL MACHINE TOOLS OFFER MANY ADVANTAGES OVERCONVENTIONAL MACHINE TOOLS BUT HAVE CERTAIN DISADVANTAGES.ONE PROBLEM AREA IS GETTING MACHINE INSTRUCTIONS TO THEMACHINE TOOL AND COLLECTING MANAGEMENT INFORMATION.*1-

6 83 8231IMPROVED CASTING TECHNOLOGY (CAD/CAM)

4.' EXCESSIVE METAL MUST BE MELTED IN CASTING OPERATIONS. THEYIELD RATIO OF SOME CASTS IS TOO LOW AND THE GATES ANDRISERS TOO DIFFICULT TO CLT OFF. MATERIAL PROPERTIES OFTEN

VARY WITH CASTING PROCEDURES.

6 83 8243COMPUTER CONTROL FOR ELECTRODEPOSITION SYSTEMS

CHROMIUM PLATING OF CANNON BARRELS IS A COMPLICATED.MULTI-STAGE PROCESS WHICH IS M4NUALLY CONTROLLED. MANUALMANIPULATION OF VALVE STRkSS, ETC., IS SLOWt SOMETIMESHAZARDOUS, AND CAN RESULT IN DEGRADED DEPOSIT QUALITY DUETU HUMAN ERROR.

• " 6 S3 8245

SAPPLICATION OF EROSION RESIS LOW CONTRACTION CHROMIUM PLATE

HIGH CONTRACTION CHRONIUM COATING IS CURRENTLY USED TO "77RESIST EROSION IN GUN BORES. INHERENT PROPERTIES MAKE THE

COATING SUSCEPTIBLE TO SHEARING AND FLAKING.

27,. -4 '- - .. ,

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777M.. u

PROJECTS ADDED IN ]ST HALF, CY83(CONTINUED)

6 83 8251IMPROVED MELTING PRACTICES

THERE IS A HIGH REJECTION RATE FOR CASTING POURED AT RIABECAUSE MODERN TECHNIQUES ARE NOT USED TD MEASURE ANDCONTROL PROCESS PARAMETERS AND POROSITY.

6 83 8305INTEGRATED MANUFACTURING SYSTEM (IMS) - (CAM)

MI SYSTEMS ARE APPLIED LOCALLY BUT THERE IS NO uATAMANAGEMENT SYSTEM FOR THE ENTIRE MFG ACTIVITY. THISINCREASES COST DUE TO LONG LEAD TIMESt SCHEDULEINTERRUPTIONS AND SHORTAGES OF MACHINE AVAILABILTY, LABOR -

AND MATERIAL.

683 8306ON-LINE PRODUCTION INFORMATION SYSTEM - RIA (CAM)

THE MANUFACTURING DATA BASE CANNOT BE ACCESSED THROUGH ANON-LINE DATA BASE SYSTEM, MAKING INTEGRATION OF AUTOMATEDSYSTEMS FOR PROCESS PLANNINGsTIME STDS GENERATION,FACILITIES/MOBILIZATION PLANNING AND PRODUCTION CONTROLSIMULATION DIFFICULT.

6 83 8324PROCESS CONTROLS FOR POWDERED METAL WEAPON COMPONENTS

PRESENT METHODS OF PRODUCING WEAPON COMPONENTS IS MAINLY BYMACHINING FROM WROUGHT STLCK. THIS IS A HIGH COST METHODWHICH PRODUCES MUCH ALLOY STEEL SCRAP.

6 b3 8351IMP MANUFACTURE OF QUADRANT FLATS AND MUZZLE BRAKE KEYWAY

PRESENT METHODS OF MACHINING FLATS AND KEYWAYS REQUIRE TWOSET-UPS ON TWO SEPARATE MACHINE TOOLS WITH ATTENDAKTMATERIEL HANDLING REQUIREMENTS.

6 83 8352SKIVING (METAL SHAVING) GUN TUBE BORES

INTERMEDIATE TUBE BORE HUING OPERATIONS FUR SURFACE FINISHAND SIZE CONTRUL ARE A TIME CONSUMING9 COSTLY METAL REMOVALPROCE5. COUNTERBORING OPLRATIONS PRIOR TO SWAGEAUTOFRETTAGE ARE ALSO SLUk, TIME CONSUMING, AND HIGH INTOOLING COSTS.

%.. N,28 '''-

-' ',,i'Z -.. ,-,.- -',: -.- .---.-- ' -. - -- -. -." - "-. -. -. -'-"-- "-" . -- ," " . -*-" . -" . .*"., - . - -. - - • • .

' ' ' ! ! , ' ' " " ''r ' ' " - a' ' - ' " ,, ''"r ',, "

, ". °,, % ",, ' ' ' '"' ' . " "" -, "°, ". . °-. °

-. '.

* PROJECTS ADDED IN 1ST HALF, CY83(CONTIkUEU)

6 83 8354CUTTING OF HOT ROTARY FORGE TUbES I

CUTT-aFF OF M4UZZLE AND BREECH ENDS OF ROTARY FORGED TUBES1S A COSTLY AND INEFFICIEkT OPERATION PRIOR TO HEATTREATING.

TOTAL PROJECTS ADDED AN 1ST HALF9 EY83 88

I'29

MMT PROGRAM .FINAL STATUS REPORTS RECEIVED DURING 1ST HALF, CY83

31

FINAL STATUS REPORTS RECEIVED DURING 1ST HALF, CY83

HER AD CON

E 79 3709CONTINUOUS LENGTH FUEL HOSE

RETURNED THIS STATUS REPORT TO THE COMMAND FORCLARIFICATION OF FUNDING AND WORK ACCOMPLISHED.

°. -

ERADCUM

H 8O 3012INFRA-RED SOURCE FOR AN/ALQ-144

ILC TECHNOLOGY MACHINED OVER 200 CYLINDRICAL GRAPHITEHEATER ELEMENTS USING IN-PROCESS RESISTANCE MEASUREMENTS TOATTAIN EXCELLENT YEILD. UbION CARBIDE MADE OVER 5 BORONNITRIDE COATING RUNS SINCE 12180. THE CONTRACT WASTERMINATED. NO TECH REPORI.

I- 81 303110.6 UM CO-2 TEA LASERS

RAYTHEON ESTABLISHED TECHNIQUES FOR FORMINGt SEALING ANDPROCESSING CERAMIC LASER HOUSINGS. WORKED ON ALIGNMENT OFELECTRODES, MIRRORS AND ELECTRICAL CONNECTIONS. C32 LASERSPROVIDE SMOKE PENETRATION, THERMAL IMAGE COMPATIBILITY -EYE SAFE OPERATION.

H 79 5000PRODUCTION HOT FORGING OF ALKALI HALIDE LENSES

HIGHLY SUCCESSFUL PROCESSES FOR PRESSING IR LENSES TO SHAPEHAVE BEEN DEVELOPED BY HO&EYWELL. A NOMINAL PRODUCTION RATEOF 100 LENSES PER SHIFT W45 ATTAINED. NO OPTICAL FINISHINGWAS REQUIRED. A NEW TESTING METHOD ANALYZES THE LENSSURFACE.

I- 19 5042 -.LARGE DIAMETER NEODYMIUM VAG LASER CRYSTAL BOULES

LITTON BUILT NEW STATIONS FUR GROWING 50MM DIAMETER ND-YAGBOULES BY THE CZOCHRALSKI METHOD. 30 RODS CUT FROM BOULESWERE TESTED BY GOVT AND FLUND ACCEPTABLE. ALL WORKCOMPLETED EXCEPT FINAL REPORT. DEMO HELD MAR 83.APPLICATION IS AN/GVS-5.

4 33

.. . " .. . .. . .. .

.... :7-.;.

FINAL STATUS REPORTS RECEIVED DURING 1ST HALF, CYb3

(CONT INUED)

H 81 5110COMMON MODULE DETECTOR ARRAYS

HONEYWELL IMPROVED YIELD OF DEIECTOR ARRAYS FROM 1 TO 15PCT + FROM 0 TO 4 BLANKS/DAY. THE MERC-CAD-TELLURIDE ISMADE INTO ARRAYS HAVING 6Ct 120 AND 180 ELEMENTS. COOLERSFROM 3 FIRMS WERE TESTED AND CHARACTERIZED FOR MICROPHONICSFROM VIBRATION.

H 80 9563MINATURE HIGH VOLTAGE POWER SUPPLYS FOR NIGHT VISION GOGGLES

K.M DELIVERED THE PILOT RUN SAMPLES. AN END OF CONTRACTDEMONSTRATION WAS HELD JUNE 299 1983.

H 80 9586THIRD GENERATION LOW COST IMAGE INTENSIFIER TUBES

VARO DEMONSTRATED CAPABILITY TO BUILD TUBES WITH SPEC.PHOTUCATHODE SENSITIVITYt THAT ARE STABLE WHEN SUBJECTED TOHIGH LIGHT LEVELS + HIGH TEMPERATURES. ALL EFFORT HAS BEENDISCONTINUED SINCE JAN 83. FINAL REPORT WAS ACCEPTED BYGOVT. IN JUL 83.

2 76 9766DEPOSITION OF A HI VOLTAGE INSULATING LAYER FOR THICK FILMS

ERIE TECHS INABILITY TO PRODUCE HYBRID MULTIPLIER MODULESWAS RESOLVED WITH ALTERNATE DEIIGN. FEWER PARTS HAS REDUCEDCOST. MODULES ARE BUILT + TESTED SEPARATELY PRIOR TO USE INPOWER SUPPLIES FOR IMAGE INTENSIFIER TUBES. FINAL REPORT ISAPPROVED.

2 77 9809MEAS TECHNIQ FOR CHMICALS IN MEG PROC FOR SOLID ST MICROWV

THE CORRELATION BETWEEN LEVEL OF CONTAMINANTS ANDELECTRICAL PERFORMANCE OF PIN DIODES WAS NOT DEMONSTRATED.THIS WAS PRIMARILY DUE TO INSUFFICIENT DATA BASE.

I- 79 9844CMOS CIRCUITS USING SILICON ON SAPPHIRE -SOS-TECHNOLOGY

ROCKWELL FOUND OPTIMUM EPITAXIAL GROWTH CONDITIONS FORUNION CARBIDES REACTOR AND A FAST, PRODUCTION ORIENTED UVTEST FOR FILM QUALITY. CMHS-SOS LSI CIRCUITS WERE BUILTWITH GOOD 15-25 PERCENT YIELD. UV TEST OF FILM QUALITY IS AGOOD TEST.

34

FINAL STATUS REPORTS RECEIVED DURING 1ST HALF, CY83

(CONTINUED) -.- -

KLAB,-LI

0 80 8063IMPROVED METHODS OF MANUFACTURING BUTYL RUBBER HANDWEAR "

IT WAS CONCLUDED THAT THE INJECTION MOLDING PROCESS COULDNOT BE APPLIED SUCCESSFULLY TO THE FABRICATION OF BUTYLRUBBER GLOVES. THE CONTRACT WAS CANCELLEDt AND ALL WORK HASBEEN TERMINATED.

0 81 8063IMPROVED METHODS OF MANUFACTURING BUTYL RUBBER HANDWEAR

IT WAS CONCLUDED JTHAT THE INJECTION MOLDING PROCESS COULDNOT BE APPLIED SUCCESSFULLY TO THE FABRICATION OF BUTYLRUBBER GLOVES. THE CONTRACT WAS CANCELLED, AND ALL WORK HASBEEN TERMINATED.

C 79 8066CONTINUOUS FILAMENT HELMET PREFORM

CONTRACT IS COMPLETED. THE PROPOSED NEW METHOD DID NOT

PROVE SUCCESSFUL. THE MMT WORK IS COMPLETED AND NO FURTHERWORK IS PLANNED. A TECHNILAL REPORT WILL NOT BE PUBLISHEDDUE TO THE PROPRIETARY NAZURE OF THE WORK.

80 8066CONTINUOUS FILAMENT HELMEI PREFORM

HELMETS TESTED MET THE V50 REGKTS OF 2000 FT/SEC# BUT BASEDON A CASUALTY REDUCTION POTENTIAL ANALYSIS PERFORMED ATNLABS THEY DO NOT COMPARE FAVORABLY TO THE STANDARD PASGTHELMET MOLDED WITH KEVLAR FABRIC. NO FURTHER WORK WILL BEDONE ON THIS MMT.

TECOM

C 78 5071 37MILITARY VEHICLE ROLL OVER TESTS

*SEE SUBTASK 37 FY83 FGR DATA*

0 79 5071 37MILITARY VEHICLE ROLL OVER TESTS

*SEE SUBTASK 37 FY83 FUR DATA*

. * ...- °

35 ,'

-z s,!

FINAL STATUS REPORTS RECEIVED DURING 1ST HALF, CY83(CONTINUED)

0 79 5071 53LERTIFICATION UF LOUSE CARGO BOUNCE TEST

SEE SU13TASK 53 FY81.

C 79 5011 54ON-LINE SEMI CONDUCTOR TESTING IN NUCLEAR ENVIRONMENT

THE TASK HAS BEEN COMPLETED 4 THE FINAL RPT. APPROVED BYTECOM. THE TASK RESULTED IN DEVELOPING METHODS *PROCEDURESNECESSARY FOR REMOTE TESTSNG OF SEMI-CONDUCTORS IN ANUCLEAR ENVIRONMENT.

C b0 5071 14* SMOKE OBSCURATION TEST PRLCEDURES

SEE SUBTASK 14 FY81.

C 80 5071 43TEST AUTOMATION iEVELOPMEkT

SEE INDIVIDUAL SUBTASK 43 FY83 FOR DATA.

0 805011 45PROD/STAND Of SILE MEAS FJAEROSOL CLOUD PARTICLES OF BIOLOGI

TRAINING Of PRINCIPAL RESEARCHER AT THE MFG. OF P1MC AUTO.PARTICLE ANALYZER WAS OBTAINED AT 1141TIATION Of THE STUDY.COMPARISONS BETWEEN VISUAL SIZING BY EITHER THE PORTIONGRATICULE OR THE CURTAIN MrICROMETER EYEPIECE . AUTUPARTICLEWAS DONE.

C 80 5071 46FERMENTATION METHODOLOGY

SEE INFORMATION UNDER SUB-TASK 46 FY61.

C 80 5011 41PROD/STAND OF ATTENUATED YEE VIRUS -TC-83 STRAIN

A PRUCEDURE WAS DEVELOPED TO PRODUCE UNIFORM BATCHES OF* TC83 VEE VIRAL SLURRIES. 4NFECIIVITY * STABILITY OF TH1E

SLURRIES WERE DETERMINED LJF BOTH STORED + FRESH MATERIALTHE EFFECT OF HUMIDITY *PARTICLE SIZE ON INFECTIVITY OFTHE AEROSOL WAS DONE.

36

FINAL STATUS REPORTS RECEIVED DURING 1ST HALF, CY83(CONTINUED)

0 80 5011 51

GENERAL PURPOSE BIT SLICE MICRO-COMPUTER

SEE INDIVIDUAL SUBTASK 57 FY82.

080 5071 CI58 INFLUENCES ON FUNGAL SPORE GERMINATION

SEE SUBTASK 58 FY81.

C 80 5071 59SOLAR POWERED INSTRUMENTARION VAN

SEE SUSTASK 59 FY82.

0 80 5071 60RECEIVER OPERATING CHARACYERISI1C5 MEASUREMENTS

SEE SUBTASK 60 FY83 FOR DATA.

0 805S071 65PRODUCTION/STANDARDIZATION OF COXIELLA BURNETII SLURRIES

THE SUBTASK 15 COMPLETE. A PROCEDURE WAS DEVELOPED FORPRODUCTION OF UNIFORM BATCHES OF C.O BURI&ETTIO, THEINFECTIVITY + STABILITY Of THESE BATCHES WAS CHECKED BEFORE*AFTER AEROSOLIZATION * FOUND TO BE SATISFACTORY.

0 80 5011 61

INTEROPERABILITY TEST METHODOLOGY

SEE SUBTASK 67 FY83 FOR DATA.

0 80 5071 71

IMPROVED COPPER CRUSHER GAGE

SEE SUBTASK 71 FY83 FOR DATA.

A WRAD CO H

'1 17817036ISOTHERMAL ROLL-FORGING OF COMPRESSOR BLADES

WERK UNDER THIS PROJECT IS FINISHED. TECHNICAL REPORT HASBEEN RECEIVED AND 302 HAS BEEN WRITTEN~ AND PUgLISHED.

37

FINAL STATUS REPORTS RECEIVED DURING IST HALF, CY83(CONTINUED)

1 82 7113COMPOSITE REAR FUSELAGE (CRF) MANUFACTURING TECHNOLOGY

ALL WORK HAS BEEN SUCCESSFULLY COMPLETED EXCEPT FUR THE --

FINAL TECHNICAL REPORT. THE GOVERNMENT/INDUSTRY BRIEFINGWAS HELD. THE COST SAVINGS OF THE CRF ARE 38 PCT AND WEIGHT

SAVINGS ARE 10 PCT. IMPLEMENTATION STEPS ARE BEING TAKEN.

1 171 7238PRECISION FORGED ALUMINIUM POWDER METALLURGY

NO TECHNICAL WORK WAS CARRIED UUT DURING THIS REPORTINGPERIOD AS THE CONTRACT HAS BEEN TERMINATED.

1 1 80 7285CAST TITANIUM COMPRESSOR IMPELLERS

ALL WORK COMPLETED FOR THIS PROJECT.

1 81 7322LOW COST TRANSPIRATION-COOLED EOMBUSTOR LINER

ALL PLANNED WORK FOR THIS PROJECT IS COMPLETE.

1 81 7341STRUCTURAL COMPOSITES FABRICATION GUIDE

ALL WOkK HAS BEEN COMPLETED. THE PROJECT WORK HAS BEENPUBLISHED AS THE THIRD EDITION OF THE COMPOSITESFABRICATION GUIDE. Tt'E GUIDE IS IN THE PROCESS OF BEINGDISTRIBUTED.

1 82 7389PRUDUCTION OF ALUMINUM AIRFRAME COMPONENTS

PHASES 1 AND 2 ARE COMPLEIE. THIS INCLUDES DESIGN CRITERIA,MATERIAL PROCESS CHARACTERIZATION, AND PRELIMINARY DESIGNREFINEMENT TRADE OFF STUDY. THIS IS THE FIRST PROJECT OF ATHREE FY EFFORT.

mICOM

R 80 1018IMPROVED MFG. PROCESSES FOR DRY TUNED ACCELEROMETERS (CAM)

ALL ASPECTS OF THIS PROGRIM HAVE BEEN SUCCESSFULLYCUMPLETED. THE RESULTS HAVE BEEN IMPLEMENTED. THESUSPENSION COST hAS REDUCED BY 72 PERCENT. THE PROGRAM WASEXTREMELY SUCCESSFUL.

38

FINAL STATUS REPORTS RECEIVED DURING 1ST HALF, CYd3(CONT I6d EL))

3 82 1050LOW COST BRAIDED ROCKET MtUTOR COMPONENTS

AN END-OF-PROJECT DEMO WAS HELD AT CONTRACTOR FACILITY INMAY 1983. A MOVIe COVERIN6 PROJECT WORK WAS COMPLETED. THEFIRST YEAR OF PkLUUCTIUN (FY84 FUNDING) WILL SUPPLY 5.25INCH CASES AT RATES EXCEEUING 4000 PER MONTH.MDAC-TITUSVILLE IS PDN SIIE.

3 81 1072MULTIPLE HIGH RELIABILITYILOW VOLUME LS MANUFACTURING (CAM)

INSOUTH MICROSYSTEMS SURVLYED THE IC INDUSTRY, USED P + NPHOTURESIST AND ETCHING PROCESSES, USED MULTI-DOPANT .SOURCES, DID DIFFUSION, OXIDATION,+VAPOR DEPOSITION. USEDPROCESS CONTROL CN SEVERAL EQUIPMENTS. A VAX 11/780 WILLCONTROL THE PROCESSES.

3 81 1088OPTIMILED MANDREL FAB + UTILIZATION F/COMPOSITE MOTOk CASES

STRUCTURAL REQMTS FOR BOTh THE MET(NET) AND INFLATABLEREUSABLE CASE MANDRELS HAVE BEEN DETERMINED FROM SUBSCALETESTING. THE MET FULL SCALE MAkDREL HAS BEEN DESIGNED ANDOPTIMIZED. PROBLEMS WITH OTHER FULL SCALE MANDREL MATLS LEDTO DISCONTINUANCE.

R d0 3142PRODUCTION METHODS FOR LOW COST PAPER MOTOR COMPONENTS

TECHNICAL EFFORT FOR THE UPTION PROGRAM IS COMPLETE. FINALREPORT PREPARED AND ALL METOR IARDWARE DELIVERED. TECHNICALREPORT TR-RK-CR-83-3 COMPLETED AND DISTRIBUTED. A MOVIECOVERING THE PROJECT HAS bEEN COMPLETED.

R 78 3218REDUCE THE FINISHING COST OF FUSED SILICA RADOMES

THE FEASIBILITY OF PRODUCING PATRIOT SIZED RADOMES BY SLIPCASTING HAS BEEN DEMONSTRATED. THIS TECHNIQUE WOULD GREATLYREDUCE FINAL MACHINING COSTS SINCE THE BLANKS ARE NEAR NETSHAPE. IMPLEMENTATION 15 PLANNED FOR THE PATRIOT MISSILERADOME.

3 81 3423LOW COST/HIGH PERFORMANCE CARBON-CARBUN NOZZLES

PROJECT COMPLETE. INTERIM TECH REPORT RK-CR-83-2, 14 SEP82, wAS DISTRIBUTED. WORK CONTINUES UNDER 3823423.

39.. ...

FINAL STATUS REPORTS RECEIVED DURING 1ST HALF, CY83(CONTINUED)

TACOM

4 7T 4568TECHNICAL DATA/CONFIGURATION MANAGEMENT SYSTEM (TD/CMS)

DATA WAS LOADED AND VERIFIED FOR FIFTEEN MAJOR VEHICLESYSTEMS ON THE TACOM TDo/CMS. COMPUTER SOFTWARE PROCEDURESWERE PREPARED AND TESTED. GOVT PERSONNEL WERE TRAINED FOROPERATION OF THE TACUM TDICMS. THE SYSTEM WAS IN FULLOPERATION IN AUG 80.

T 79 5002FABRICATING TORSION SPRINGS FROM HIGH STRENGTH STEELS

THE FINAL TECHNICAL REPORT HAS BEEN RECEIVED AT IBEA ANDTHE 302 SUMMARY HAS BEEN DRAFTED.

T 82 5002FABRICATION OF TORSION BARS FROM HIGH STRENGTH STEEL

THE FINAL TECHNICAL REPORT HAS BEEN RECEIVED AT IBEA ANDTHE 302 SUMMARY HAS BEEN DRAFTED.

7 80 5082

FLEXIBLE MACHINING SYSTEMw PILOT LINE FOR TCV COMPONENTS

THIS PROJECT IS COMPLETE. A FMS HANDBOOK HAS BEENPUBLISHED. SEE MMT PROJECI T 81 5082.

78 5085PRODUCTION TECHNIQUES FOR FABRICATION OF TURBINE RECUPERATOR

WORK ON THIS PROJECT COMPLETED AWAITING TECHNICAL REPORT.

T 80 5085TURBINE RECUPERATOR

ALL WORK IS COMPLETED ON THIS PROJECT AWAITING TECHNICALREPORT.

T 81 5090IMPROVED AND COST EFFECTIVE MACHINING TECHNOLOGY (PHASE I1)

COORDINATED PROJECT WITH SHOULD COST TEAM. CONTACTED MFGSFOR DATA AND HELL MEETINGS TO DISTRIBUTE DATA FORIMPLEMENTATION. RESOLVED PROBLEMS WITH CONTRACTOR ANDCOORDINATED EFFORTS WITH PMA.

40

FINAL STATUS REPORTS RECEIVED DURING 1ST HALFt CY83 -.-.

(CONTINUED)

T 78 5097INTEGRALLY CAST LOW COST COMPRESSOR (PHASE II)

ALL WORK COMPLETED ON THIS PROJECT INCLUDING FINALTECHNICAL REPORT.

T 81 5097INTEGRALLY CAST LOW COST COMPRESSOR (PHASE 111)

ALL ORK COMPLETED ON THIS PROJECT INCLUDING FINALTECHNICAL REPORT.

T 82 6025LASER MANUFACTURING

PROBLEMS WERE ENCOUNTERED WITH GENERAL DYNAMICS LANDSYSTEMS DIVISION. AS A RESULT NO WORK WAS PERFORMED. THEFUNDS WILL BE RETURNED AND REPROGRAMMED.

T 82 6053WELDING SYSTEMS INTEGRATILJN

PROJECT TERMINATED. FUNDS RE-PROGRAMMED TO MEET OTHERPROGRAM NEEDS.

T 81 6057XM1 COMBAT VEHICLE

SEE SUBTASKS.

T 816 057 03AUTOMATED METALLIZING

GENERAL DYNAMICS HAS IMPROVED THE CURRENT METALLIZINGPROCESS, THEREFORE THIS 145K IS NO LONGER COST EFFECTIVEAND THE TASK IS CANCELLED.

T 81 6057 05MACHINE DIAGNOSTICS

FUNDS FOR THE FY81 PORTION OF ]HIS TASK HAVE BEEN USED FOR

ADMINISTRATIVE PURPOSES AND THE TASK WILL CONTINUE WITHFY82 FUNDS.

T 81 6057 13LASER CUTTING

FUNDS FOR THE FY81 PORTION OF IHIS TASK HAVE BEEN USED FOR

ADMINISTRATIVE PURPOSES AND THE TASK WILL CONTINUE WITH

FY82 FUNDS.

41A. .

FINAL STATUS REPORTS RECEIVED DURING IST HALFt CY83 -*-(CONTIkUED)

T 82 6078AUTO DYNAMOMETER CONTROL F/STANDARDIZATION INSP TESTING

THIS FY82 PROJECT WAS FUNDED WITH MMT FUNDS. THE EFFURT,HOWEVER9 HAS bEEN IDENTIFIED AS MAC! AND FUTURE YEARS OFFUNDING ARE STATED AS BEING MACI. AS A RESULT THIS FY82PROJECT WILL NO LONGER BE REPORTED UNDER THE MMT PROGRAM. '-.--,

T 82 6107IMPROVED MBT TRACK

PROJECT wORK, THE PREPARAIION OF FOUR REQUESTS FORPROCUREMENT, WAS COMPLETED. NO TECHNICAL WORK WASACCOMPLISHED.

AMCCOM (AMMO)

5 80 0900AUTOMATED MULTIPLE FILTER LIFE TESTER

THE DESIGN CONCEPT OF THE AUTO1ATED MULTIPLE FILTER LIFETESTER WAS FINALIZED, REVIEWED AND ACCEPTED. LEVEL IDRAWINGS WERE REVIEWED AND ACCEPTED.

5 80 1001PILOT LINE FOR FUZE FLUIDIC POWER SUPPLIES

PHASE I ENGINEERING STUDY WAS COMPLETED. PHASE II TASK I,DEVELOPMENT OF AN INVESTMENT CASTING METHOD AND MOLD FORPRODUCING MAGNET KEEPERS hAS COMPLETED W4ITH AN ESTIMATEDSAVINGS OF 56K PER MAGNET KEEPER PAIR. THE FINAL REPORT WASAPPROVED.

5 80 1003LOW COST MOLDED PACKAGING FOR HYBRID ELECTRONICS

FINAL REPORT DRAFT WAS SUBMITTED TO HDL FOR REVIEW.CORRECTIONS AND CHANGES WERE MADE AND FINAL COPIESPRODUCED.

5 dO 1005 "-""CERAMIC-METAL SUBSTRATES FOR HYBRID ELECTRONICS

ALL PROJECT WORK IS COMPLETE. INDUSTRY DEMiO WAS HELD ATWESTINGHOUSE DESC ON 30 SEPT 82. TECHNICAL REPURT ANDHANDBOOK HAVE BEEN COMPLEIED.

42", - - - - . -- 7 - . . . . . - . . . . .

- -. -... ..

,; .-: ,-,....,--....-:...,: ,. ..-....,-, ..-,- ..-., ..-. .........a .... ..- . . ... ; .... *... ~.. ; .. . ..'t -.1.. .. m. S .. C .- .. ;. . ..

FINAL STATUS REPORTS RECEIVED DURING 1ST HALF, CY83

(CONTINUED)

5 79 1295MODERNIZATION OF CHARCOAL FILTER TEST EQUIPMENT

ORIGINAL DESIGN CONCEPT REWORKED TO COMPLY WITH NEW SAFETY . -REGULATIONS. LEVEL I DRAWINGS FOR CONSTRUCTIUN OF FACILITY """WERE RECEIVED.

8 78 1335MANUFACTURING TECHNIQUES FOR NEW PROTECTIVE MASK

THIS PROJECT HAS BEEN COMPLETED.

5 79 1335

MANUFACTURING TECHNIQUES EOR NEW PROTECTIVE MASK

THIS PROJECT HAS BEEN COMPLETED.

5 80 1335MANUFACTURING TECHNIQUES FOR NEW PROTECTIVE MASK

THIS PROJECT HAS BEEN COMPLETED.

5 81 1335MANUFACTURING TECHNIQUES FOR NEW PROTECTIVE MASK

INITIATED PILOT PROJECTION OF MASK CONPONENTS. FINAL MASKASSEMBLIES BEING TESTED FeR LEAKAGE AND RESISTANCE. LENS

" BONDING EQUIPMENT INSTALLED. INITIAL LENS ASSEMBLIES FAILEDTHE TEST. ADDITICNAL FABRICATIONS PASSED THE TESTS.

5 82 1335MANUFACTURING TECHNIQUES FOR NEW PROTECTIVE MASK

PHYSICAL CONFIGURATION AUDIT IS COMPLETE. TDP BEING UPDATEDTO INCORPORATE RESULTS.

5 79 3961IMPROVED 3-D VIBRATION ACCEPTANCE TEST FOR ART FUZES

PROJ WAS COMPLETED IN DEC 81. 1HE DESIGN AND ENGINEERING- TDP FOR THE 3D-VTS HAS BEEN DELIVERED TO HDL. SUFFICIENT

DEFINITION EXISTS TO COMMENCE PROCUREMENT OF IEMAININGSUBSYSTEMS. VALIDATION OF TOP WILL BE ACCOMPLISHED AS PARTUF THE FY81 PROJECT.

5 80 3961IMPR (3-D) VIB ACCEPT TSTkG F ART FUZES AND S/A MECHANISMS

THIS PROJECT IS PHASE 2 O.F A 3 PHASE EFFORT. PHASE 2 ISCOMPLETE. SEE MMT PROJECT 5 81 3961 FOR EFFORT STATUS. .

.. .,., ,:

43

. . . .. -.

FINAL STATUS REPORTS RECEIVED DURING 1ST HALF, CY83(CONTINUED)

580 4037*PROCESS IMPROVEMENT FOR PLASTIC-BONDED EXPLOSIVES

WATER SLURRY TECHNIQUES WERE DEVELOPED FOR THE FORMULATIONOF PBXC117 AND PBX W109 PRECOAIS. A DIRECT COATING PROCESSFOR PRODUCTION OF PBX-0280 AND LX-14-0 WAS DEVELOPED. ATECH REPORT DESCRIBING THE RESULTS WAS COMPLETED. i..

5 81 4059CONTROL OF NO CRYSTALLIZATION

AN INVESTIGATION OF THE AGGLOMERATION OF NQ WAS CONDUCTEDINCLUDING THE EFFECTS OF HUMIDITY, ADDITIVES, AND COATINGSON CHANGES IN SPECIFIC SURFACE WITH TIME. AGGLOMERATION CANBE PREVENTED BY CUNTROLINu HUMIDITY AND USE OF HYROPI-Ud ICOATINGS.

5 81 4062AUTO MANUFACTURE SYSTEM F[ R MORTAR INCREMENT CONTAINERS

THE TASKS ADDRESSED BY THE FY 81 PROJECT WERE COMPLETEDSATISFACTORILY. A TWO STEP HOT FORMING PAPER MULLING WASD EVELOPEU. IN ADDITION, AIRANGEMENTS WERE FINALIZED iITH -'-

ARMTEC DEF. PROD. TO INSTALL + FINAL ACC. TEST THEPROTOTYPE SLURRY FORMING.

5 81 4062 01SLURRY VACUUM FORMING MFG SYS

THE ORIGINAL DESIGN CONTRACT WAS AMENDED ON I MAY 61 FURFAB. * ASSY OF MODULE I, THE CONTAINER HALF FORMINGMACHINE, MODULE I, THE HOLE PUNCH + TRIM MACHINE. THE FA"+ ASSY EFFORT AT ESD CORP. WAS ACCOMPLISHED hITH NE TELH.PROBLEMS. ..-

5 1 4U062 03 -"

ASSEMBLY SYSTEM

THE ORIGINAL DESIGN CONTRACT AKENDED ON 2 SEPT. 81 FUR THEFAB., ASSY + DEBUGGING OF THE ASSEMBLY SYS. CONSISTING OFFIVE STATIONS. THE PHASE 11 EFFORT WAS EXPANDED ON 7 JUN 8eTO DEVELOP A TRANSLUCENCY INSPECTION DEVICE + A THERMALLEAK DET. GAUGE.

5 81 4062 04

SLURRY VACUUM FORMING OPTIMIZAIION

IN SUPPORT OF THE SLURRY %ACUUK FORMING BASE MFG. SYS.BEING DEVELOPED UNDER CONIKACT WITH ESD CORP. + TOINVESTIGATE WAYS TO IMP ROVE THE 6ASIC SLURRY PROCESS, ACONTRACT WAS AIARDED ON 15 APR. 81 TO EXECUTE PROCESSSTUDIES.

44

,S,.: ... :-

,.:: ,..-,:* '..'.- .. '-.-.' .. '. ',-' '... ' .' ..- "..-.- " -" ...'. .-' -. -.-. ... .-.". :: ::: I

... ;7-77 7 . .

FINAL STATUS REPORTS RECEIVED DURING 1ST HALFt CY83(CONTIkUED)

5 81 4062 05 -"PAPER MOLDING OPTIMIZATIUh

A COMPREHENSIVE PAPER MOLDING PRODUCTION PROCESSOPTIMIZATION PROGRAM WAS PERFORMED BY THE CONTRALTUR TUIMPROVE THE BASIC PAPER MOLDIN6 PROCESS. THIS PROGRAMDEVELOPED A PROCESS THAT ELIMINATED THE USE OF WETTINGAGENTS + THE DRYING REQUIkEMENI.

5 7e 4139APPL OF RADAR TO BALLIST 4CCEPIANCE TESTING OF AMMO-ARBAT

THIS PROGRAM IS COMPLETE. ARBAI IS BEING RETROFITED TUIMPROVE SYSTEM RELIABILITY AND ACCURACY. ARBAT PROVIDESCAPABILITIES NUT AVAILABLE IN UTHER RADAR SYSTEMS.

5 -9 4139APPL OF RADAR TO BALLIST ACCEPIANCE TESTING OF AMMu-ARbAT

THIS PROGRAM IS COMPLETE. ARBAT CAN PROVIDt ACCURATERETRIEVABLE DATAt ANALYSIS IS IIMELY AND AJTOMATIC ANDMEANINGFUL. A RETROFIT PROGRAM IS ON GOING TO IMPROV.RELIABILITY AND ACCURACY REQUIREMENTS.

5 78 4150NEW MANUFACTURING PROCESSES FOR SAWS AMMUNITION

PROTOTYPE TOOLS WERE DEVELOPED FOR COLD FORMING OF THEXM777 STEEL PENETRATOR. DEVELOPMENT AND DEMONSTRATION OFPROTOTYPE SKEWED AXIS ROLL FORI4ING EQUIPMENT WAS ALSOACCOMPLISHED. A PROCESS SIUDY OF BULLET MANUFALTURE WASCOMPLETED.

5 19 4150NEW MANUFACTURIN6 PROCESSES FOR SMALL CALIBER PENETRATORS

A PROTOTYPE CONFIGURATION FOR INCORPORATING THE PENETRATORFEEDING, INSERTING AND FEEDING INTO THE BULLET ASSEMBLYPROCESS WAS EVALUATED AND A FINAL CONFIGURATION SELECTED.THE PROTUTYPE WILL BE DEVELOPED AS A DUPLEX MACHINECONF IGURATION.

5 81 4225RED WATER POLLUTION ABATEMENT SYSTEM . .

DESIGN CRITERIA FROM EVALLATION OF SOLID BOWL CENTRIFUGE,ASH OXIDIZERt FLUE GAS AF.IERBURNER9 PARTICULATE SCRUBdERAND £02 ABSORBER HAVE BEEN INCJRPORATED INTO THE PDB FORTHE MCA FACILITY AT RADFORD AAF. THIS PROJECT IS COMPLETED.

45

, ' ' . . ~ 4 ' .-.4 '-. --4

- -- - .'- - - - . I

FINAL STATUS REPORTS RECEIVED DURING 1ST HALF, CY83(LONTINUED)

5 81 4288

EXPLOSIVE SAFE SEPARATION AND SENSITIVITY CRITERIA

ALL PLANNED SAFE SEPARATION STUDIES HAVE BEEN COMPLETED.FRAGMENT IMPACT STUDIES ALD EXPLOSIVE DUST STUDIES HAVEbEEN COMPLETED AND FINAL REPORIS ARE BEING REVISED.

5 81 4364ON-LINE BIL SEhSORS TU MONITOR MIXED WASTE STREAMS "-

A COITRACT WAS LET FOR THE CALIBRATION OF THE BIOLOGICALMLNITCRING FACILITY TU THE WASIEWATER STkEAMS FROM THECOLLECTED WASTEWATER SYSTEM AND THE CENTRAL WASTEWATERTREATPENT FACILITY. VENTILATORY RATE CHANGE OF BLUEGILL WASLHOStN F/MONITORINIG. -

61 4553PROCESS PARAMETER S FOR CULD DRAWI;NG ALLOY STEELS

PROJECT CANCELLED BY SARPH-PBM-MM BY LETTER DATED 2 MAY 83,DUE TO SIGNIFICANT-SCHEDULE SLIPPAGE, CAUSED BY DELAY.) INMSAAP FORGE SHOP BECOMING OPERATIONAL.

5 82 4553PROCESS PARAMETERS FOR COLD DRAWING ALLOY STEELS

PROJECT CANCELLEb BY SARPM-PBM-MM BY LETTEK DATED 2 MAY 63,DUE TO SIGNIFICANT SCHEDULE SLIPPAGE, CAUSED BY UELAYS INMSAAP FORGE SHOP BECOMING OPERATIUNAL.

5 82 4556THERMAL DEHYDRATION PROCESS SAFETY AND OPERATIONAL REDESIGN

INVESTIGATIONS OF THE THERMAL GEHY OF NC FOUND THAT THEuNIT CUULD BE SAFELY OPER4TED IF PROPER SAFETY MEASURES jWERE TAKEN AND ADHERED Tru.

5 7T 6494NEb CONCEPTS FUR MFR AND INSPECT OF 0MM 5MM 30MM AMMO

SEE PROJECT 5 77 6494 FOR STATS.

5 75 6494MANUFACTURE AND INSPECTIO6 OF CAL.50, 20MM, AND 30MM AMMC

SEE PROJECT 5 77 6494 FOR STATUS.

46

'"* '' ". * ' "C .. .. .. .. .. . ..-. " '. . .-• ". . .. ... -. .,..

* - wW 7.- - . - ---- ---- j---~- -

i.7

FINAL STATUS REPORTS RECEIVED DURING 1ST HALF, CY8"(LONTINUED)

5 76 6494MANUFACTURE AND INSPECTIOh OF CAl..50, 20MMt ANU 30MM AMMO

SEE PROJECT 5 77 6494 FOR STATUS.

5 77 6494NEW CONCEPTS FOR MFR AND INSPECT OF 20MM 25MM 30MM AMMU

PROTOTYPE MACHINES WERE DESIGNED AND MAJOR PORTIONSFABRICATED FOR PR'DUCIliG 20MM AMMUNITION. THE 20MMREQUIREMENTS DROPPED DRAMATICALLY. STUDIES WERE MADE TL SEEIF THE EQUIPMENT COULD BE CONVERTED TO PRUUUCE OTHERROUNDS. PRUJECT WAS TERMIhATED.

579 6634MFG UU ALLOYS FOR LARGE CALIBER ARMOR DEFEATING PROJECTILE

FINAL REPORT 15 IN PROCESS OF bEING REVIEWED. EFFURT BEINGCONTINUED UNDER 5 83 45631 TASK 6.

AMCCOM (WPNS)

6 80 7985 -"

SMALL ARMS WEAPONS NEW PRECESS PRODUCTION TECHNOLOGY

TECHNICAL REPORT RECEIVED. 302 REPORT AND ACCOMPLISHMENTCHART PREPARED.

f 80 8004CU-DEPOSITION OF SOLID LUiRICANTS DURING ANODIZING

WdORK IS COMPLETE. THE TECHNICAL REPORT IS IN THE FINALDRAFT FORM. FINAL PUBLICATION IS FORECAST FOR DECEMBER1983.

6 81 8113ESTABLISHMENT OF ION PLATING PROCESS FOR ARMAMENT PARTS

ESTABLISHMENT OF ION PLATING PROCESS FOR ARMAMENT PARTS.SELECT ARMAMENT COMPONENTS WERE COATED BY THE IUN VAPORDEPOSITION PRO'ESS. COATED ITEMS HAVE BEEN EVALUATED. ATECHNICAL REPORT IS BEING PREPARED.

6 81 6165STANDARDS FOR DIAMOND TURUIED OPTICAL PARTS

FABRICATION OF OPTICAL STANDARDS HAVE BEEN COMPLETED. TOTALINTEGRATED SCATTER TECHNIQUE HAS BEEN DEMONSTRATED ON ALABORATORY SYSTEM USING OPTICAL STNDS. RESULTS WERECOMPARED WITH NBS PROFILOKETRY TECHNIQUES REVIEW IN .-.PROGRESS FOR THE TEST DATS.

47

?7T -7-77 77-7

FINAL STATUS REPORTS RECEIVED DURING 1ST HALF, CY63

f ol1 8341 1iHULLU. CYLINDER CUT OFF M4CHINE

WORK HAS BEEN LOMPLETEU AND A FINAL TECHNI1CAL REPORT HASBEEN PREPARED. AS A RESULT OF THE EXECUTION UF THISPROJECT, A PERFORMANCE PRLCUREI4ENT SPECIFICATION HAS dEENPREPARED.

TOTAL PROJECTS COMPLETED IN 16T HALF, CY83 78

448

-9-

4N48

R~~ PROJET STATUS REPOT

X9

49

F.

MANUFACTURING METHODS AND TECHNOLOGY PROGRAM

SUMMARY PROJECT STATUS REPORT

b,-

r.

The Summary Project Status Report for each major Army subcommand

(SUBMACOM) is preceded by the tabulated SUBMACOM AMT project funding

status. The accuracy of funding amounts is based on the individual

project status reports. The status as reported here is the IBEA

condensation of information contained in the report or other cow-

ments as deemed useful. If a status report was not provided, a per-

tinent comment was made so that the project would be printed.

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DRI6 ti3 MANUFACTURING METHODS & TECHNOLOGY PROJECT EXECUTION 2/21i REPORT FIRST CV 83(U) ARMY INDUSTRIAL BASE ENGINEERING

ACTIVITY ROCK ISLAND IL C FULLER NOV 83

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APPENDIX I: (dIHAND IDENTIFICATION

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.4 APPENDIX: ARMY ACT ION COMAND/ACTIVITY IDENTIFICATION

Action Command Identifier Acronym Command t

Management Engineering Training Activity AMETA D

Mobility R&D Command MERADCOM E

Depot Systems Command DESCOM G

*Electronics R&D Command ERADCOM H

Army Materials and Mechanics AI4MRC MResearch Center

*Natick R&D Laboratories NLABS Q

*Test & Evaluation Command TECOM 0

Aviation R&D Command AVRADCOM1

Communications & Electronics Command CECOM 2

Missile Command MICOM 3

Armament, Munitions, & Chemical AMCCOM5

*4 Command (Munitions) (Ammo) --

Armament, Munitions, & Chemical AMCCOM 6Comnd (Weapons) (Wpns)

Troop Support & Aviation TSARCOM 7Materiel Readiness Command

NOTE: Abbreviation -R&D -Research and Development

q. 159

Awew1IX 11: PROJECT SLIPPAGE STUIWY

161

PLUJCT .LIFlFAK STUD

The purpose of this study is to monitor trends in the timeliness of the .124T Project Execution. Figure .1 is a slippage profile for each command andfor the program as a whole. The column with the fewest number of projectsis the "No Data" column. The percentage in this column is derived from thefew FY83 projects that were recently funded and therefore required no sta-tus reports. The larger number in the "0 Mo" column is a reflection of thenew FY83 program for which first status reports have been received. When icombined with the figures from the "0 Ho" column, you have that part of theprogram for which no slippage problems exist. The remaining five columns - -

indicate slippage for projects FY82 and prior that have not yet been com-pleted. The number of months that a project has slipped is calculated bydetermining the difference between the projected completion date cited onthe first status report and the revised completion date cited on the cur- .rent status report. The largest variation is the 7-12 mos. column with a 5percentage point increase in lst CY83. In the past the figures in theslippage columns have remained very consistent from period to period. Thusthe 5 percentage point increase in the "7-12 Mo" column at the expense ofthe decrease in the combined "No Data - 0 Mo" columns must be consideredsignificant. The last three columns (13-25+ months) vary no more than +2 -.percentage points from reporting period to reporting period.

There are two problems that affect accurate project slippage report-ing. One problem is delinquent status reports. During the current report-ing period, there were 26 delinquent reports. This delinquency results ina larger number of active projects because final status reports are notsubmitted for those delinquent projects that have in actuality been closedout. These "completed" projects then increase in months of slippage whichcould account for a larger than actual percentage of projects in the "25+Mo" columns. With decreased delinquency over the past 3 periods (18Z to5Z), the current slippage profile must be considered more accurate thanthat to which it is being compared. A further decrease in delinquency of .9project status reports will improve the accuracy of the project slippageprofile.

Another problem that affects accurate project slippage reporting is thebasis on which final status reports are submitted. Some organizationswait financial close-out before submitting final status reports. By doingthis, several months might be added to the apparent duration of the proj-ect. The general policy has been that final status reports should besubmitted when the technical work has been physically completed. If out-standing financial action does not hinder project Implementation, then thetime required for financial close-out is not meant to be added to an indi-cator which measures engineering achievement. Continued emphasis on usinga consistent basis for project close-out, namely technical completion, willprovide a more accurate accounting of the technical life of MlT projects.

162

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P ROJ E CT S LI PP A GE S TUD Y

PROJECT SLIPPAGE DISTRIBUTION_ _ _ _ - -(PERCENT)_

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AMETA 1 57 14 29

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* TSARCOM 2 100---- --------

SUMMARY 452 7 35 12 13 9 10 16(DARCOM WIDE)

1S 15CY82 555 9 38 10 8 11 8 15SUMMARY

*FJIURES REFLECT DATA ON THlE ACTIVE PROGRAM AS OF 7 NOV 83.o\

FIGURE 1-SLIPPAGE PROFILE 6

163

APPENDIX III: USER'S GUIDE

165

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APPEIIDIX IV: hew 191 PRoGmm REPREsENTATivES

169

17 7:' -

AR.MY MHT PROGRAM REPRESENTATIVES

HQ, DAR-O

US Army Materiel Development and Readiness Command* ATTN: DRCMT, Mr. F. Michel

5001 Eisenhower Avenue C: 202 274-8284/8298 A...Alexandria, VA 22333 AV: 284-8284/8298

AVSCOMUS Army Aviation System CommandATTN: DRSAV-EGX, Mr. Dan Haugan4300 Goodfellow Blvd. C: 314 263-1625St. Louis, MO 63120 AV: 693-1625

CECOI4US Army Communications Electronics Command C: 201 535-4926ATTN: DRSEL-POD-P-G, Messr Feddeler/Esposito/Resnic AV: 995-4926

ATTN: DRSEL-PC-I-IP, Mr. Leon Field C: 201 532-4035Fort Monmouth, NJ 07703 AV: 992-4995 . 4

ERADCOM .-

US Army Electronics R&D CommandATTN: DELET-R, Mr. Joseph Key C: 201 544-4258Fort Monmouth, NJ 07703 AV: 995-4258

ATTN: DRDEL-PO-SP, Mr. Harold Garson2800 Powder Kill Road C: 202 394-3812Adelphi, MD 20983 AV: 290-3812

MICONUS Army Missile CommandATTNl: DD.SMI-RST, Mr. Bobby Park C: 205'876-2065Redstone Arsenal, AL 35898 AV: 746-2065

TACCIIFSTIruy Tank-Automotive CommandATTN: DRSTA-RCDI, Mr. Donald Cargo C: 313 574-6065Warren, MI 48090 AV: 786-6065

AMCCONUS Army Armament, Munitions & Chemical CommandATTN: DS.SMC-IRI-A (R), Ms. Geri Kopp (Ammo)ATTN: DRSMC-IRW (R), Mr. Joseph Pohlmmn (Wpns)Rock Island Arsenal C: 309 794-3666/3166Rock Island, IL 61299 AV: 793-3666/3166

ATTN: DUNGC-PHI-P (D), Mr. Donald J. Fischer C: 201 724-6092Dover, NJ 07801 AV: 880-6092

TUARM01F Arm Troop Support and Aviation Materiel Readiness CommandATTN: DILTS-PLE, Mr. Don G. Doll4300 Goodfellow Blvd. C: 314 263-2218Ste Louis, MD 63120 AV: 693-2218

1711

BRDCUS Army Belvoir R&D CenterATTN: STRID-HE, Mr. K. K. Harris C: 703 664-5433Fort Belvoir, VA 22060 AV: 354-5433

NRDCUS Army Natick R&D CenterATTN: DRDNA-EHL, Mr. Frank Civilikas C: 617 651-4883/4882Natick, MA 01760 AV: 256-4883/4882 7

TECOKUS Army Test & Evaluation CommandATTN: DRSTE-AD-M, Mr. John Gehrig C: 301 278-3677Aberdeen Proving Ground, MD 21005 AV: 283-3677

AMMRCUS Army Materials & Mechanics Research CenterATTN: DRXKR-PP, Mr. John Gassner C: 617 923-5521Watertown, MA 02172 AV: 955-5521

HDLHarry Diamond LaboratoriesATTN: DELHD-PO-P, Mr. Julius Hoke2800 Powder Mill Road C: 202 394-1551Adelphi, MD 20783 AV: 290-1551 -

RIARock Island ArsenalATTN: SMCRI-ENM, Mr. J. W. McGarvey C: 309 794-4142Rock Island, IL 61299 AV: 793-4142 .

WVAWatervliet ArsenalATTN: SMCWV-PPI, Mr. Charles Hall C: 518 266-5319Watervliet, NY 12189 AV: 974-5319

MPBMAUS Army Munitions Production Base Modernization AgencyATTN: SMCPM-PBM-DP, Mr. Joseph Taglairino C: 201 724-6708Dover, NJ 07801 AV: 880-6708

MRDLUS Army Applied Technology LaboratoryUS Army Research Technology Lab (AVRADCOM)AT'TN: DAVDL-ATL-ATS, J. Waller C: 804 878-2771/3073Fort Eustis, VA 23604 AV: 927-2771/3073

DESCOMUS Army Depot System ComndATTN: DRSDS-RM-EIT, Mr. Mike Ahearn C: 717 263-6591Cbembersburg, PA 17201 AV: 238-6591

'MAUS Army Industrial Base Engineering ActivityAM!: DUXIB-41T, Mr. James Carstens C: 309 794-5113lock Island, IL 61299 AV: 793-5113

172

.4 Department of the ArmZ2 ODCSRDA

ATTN: DAMA-PPM-P, LTC S. MarshRoom 3C400, The Pentagon C: 202 695-0507Washington, DC 20310 AV: 225-0506

AMITAUS Army Management Engineering Training ActivityATTN: DRXOM-SE, Mr. Paul Wagner C: 309 794-4041Rock Island, IL 61299 AV: 793-4041

DARCOM Intern Training CenterATTN: DRXMC-ITC-E, Mr. Mickey CarterRed liver Army Depot C: 214 838-2001Texarkana, TX 75507 AV: 829-2001

TMDEUS Army TMDE Support Group -

ATTN: DRXTM-S, Mr. Ken Magmarat C: 205 876-1132Redstone Arsenal, AL 35898 AV: 746-1132

SI.

173

- -. * -. . - .. -. -. : - - - . - . - ~~I -i-n ~rr.r - -- . * . ..~

DISTRIaJmM

4

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175

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*4* %(,~%~4 * .- ~S. *...S.*....*. *. -. .- -. *5 .* *5 .. SS,,*.*.. ---- S..-. S -

~~~~~~1 .. . . . .. . . . .. . . .

PROJECT EXECUTION REPORT

DRXIB-MT LDISTRIBUTION:

Department of Defense:OUSDRE (R&AT), The Pentagon, Attn: Dr. Lloyd L. Lehn (2 cys)Defense Technical Information Center, Attn: DDR-1 (12 cys)

* Department of the Army:HQDA, OASARDA, The Pentagon, Attn: Manufacturing Technology RepresentativeHQDA, DCSRDA, Attn: DAMA-WSW, LTC Fischer

HQ DARCOM:Cdr, DARCOM, Attn: DRCCG ~Cdr, DARCOM, Attn: DRCDE 4Cdr, DARCOM, Attn: DRCDMDCdr, DARCOM, Attn: !DRCDMRCdr, DARCOM, Attn: DRCMT, Mr. Fred Michel (20 cys)Cdr, DARCOM, Attn: DRCPPCdr, DARCOM, Attn: DRCPP-I/DRCPP-I, Mary BrittainTechnical Library, Attn: DRXAM-TL

* Aberdeen Proving Ground: A.,

Cdr, Attn: STEAP-MT-M, Mr. T.R. Giroux

hI4CCOM:Cdr, Attn: DRSMC (D)CdAtn RMCA R

Cdr, Attn: DRSMC-ASA (R)Cdr, Attn: DRSMC-ASA (R)

Cdr, Attn: DRSMC-IRI-A (R), Ms. Geri Kopp (5 cys)Cdr, Attn: DRSMC-IRW (R), Mr. Joseph Pohlman (2 cys)

*Cdr, Attn: DRSMC-IRW-T (R), Mr. John KohrellCdr, Attn: DRSMC-LEP (R) (5 cys)Cdr, Attn: DRSMC-QAR-I (D), Mr. Mark WeinbergCdr, Attn: DRSMC-PMP-P (D), Mr. Donald J. Fischer (7 cys)Cdr, Benet Wpns Lab, MAn: DRSMC-LCB-S (D), Dr. F. Heiser

*Cdr, Benet Wpns Lab, Attn: DRSMC-LCB-TL, Tech Library*PM, Cannon Artillery Weapons Systems, Attn: DRCPM-CAWS

Cdr, Chemical Systems Lab, Technical Library, Attn: DRSMC-CLY-T (A)Technical Library, Attn: DRSMC-LEP-L (R) (2 cys)

AMHRC:*Dir, Attn: DRXMR, DRXMR-M, DRXMR-PL (1 cy ea)

Dir, Attn: DRXMR-EO, Dr. Morton KlimanDir, Attn: DRXMR-PP, Mr. John Gassner

'1Dir, Attn: DRXMR-STQ, Mr. H. Campbell

177

7 7 74

DRXIB-MTDISTRIBUTION (Cont'd):

AVSCOM:Cdr, Attn: DRSAVCdr, Attn: DRSAV-EGX, Mr. Dan HauganTechnical Library, St. Louis, MO

f BRDC:Cdr, Attn: STRBDCdr, Attn: STRBD-HE, Mr. K. K. Harris

*PM, Mobile Electric Power, Attn: DRCPM-MEP (Springfield, VA)Technical Library, Ft. Belvoir, VA

* CECOM:Cdr, Attn: DRSELCdr, Attn: DRSEL-PC-I-IP, Mr. Leon FieldCdr, Attn: DRSEL-POD-P-G, Messrs. Feddeler, Esposito, Resnic (1 cy ea)RD&E Technical Documents Ctr, Ft. Monmouth, NJ

DESCOM:Cdr, Attn: DRSDS-RM-EIT, Mr. Mike Ahearn

ERADCOM:Cdr, Attn: DELET-R, Mr. J. Key

J Cdr, Attn: DRDELCdr, Attn: DRDEL-PO-SP, Mr. Harold Garson

PM, Stand-off Target Acquisition Systems, Attn: DRCPM-STA

-. MCdr, Attn: DRSMICdr, Att'i: DRSMI-Q, Mr. Gil HutchinsCdr, Attn: DRSMI-RST, Messrs. Park, Austin (1 cy ea)PM, HAWK, Attn: DRCPM-HAMagazine Room, Attn: RSIC

* NRDC: ~Cdr, Attn: DRDNA

* TACOM:Cdr, Attn: DRSTA-RCKM, Mr. Don Cargo A"Cdr, Attn: DRSTA-FX

* Technical Library, Warren, MI

TECOM:Cdr, Attn: DRSTECdr, Attn: DRSTE-AD-M, Mr. John Gehrig S

TSARCOM:Cdr, Attn: DRSTSCdr, Attn: DRSTS-PLE, Mr. Don G. Doll

TMDECdr, Army ThDE Support Group, Attn: DRXTMCdr, Army ThDE Support Group, Attn: DRXTM-S, Mr. Ken Magmant

178

** .t ~* C.'A C -, . . . -

_77.

DRXIB-MTDISTRIBUTION (Cont'd):

Arsenals:Cdr, Pine Bluff Arsenal (PBA), Attn: SMCPB-COCdr, Rock Island Arsenal (RIA), Attn: SMCRI-COCdr, Rock Island Arsenal (RIA), Attn: SMCRI-ENM, Mr. J. W. McGarveyCdr, Watervliet Arsenal (WVA), Attn: SMCWV-PPI, Mr. Charles Hall

Munitions Production Base Modernization Agency:Cdr, MPBMA, Attn: SHCPM-PBM-DP, Mr. Joseph TaglairinoCdr, MPBMA, Attn: SMCPM-PBM-PC, Mr. William Donnelly (5 cys)

* Army Ammo Plants: *~. %

Cdr, Crane AAA, Attn: SMCCN-EDCdr, Crane AAA, Attn: SMCCN-QAM-C, Mr. S. R. CaswellCdr, Hawthorne AAP, Attn: SMCHW-ADFCdr, Holston AP, Attn: SMCHO-COCdr, Iowa AAP, Attn: SMCIO-EN

*Cdr, Lone Star AAP, Attn: SMCLS-COCdr, Milan AAP, Attn: SMCMI-ENCdr, Mississippi AAP, Attn: SMCMS

Depots:Cdr, Anniston Army Depot, Attn: SDSAN-PPM, Mr. Shelly Sewell

*Cdr, Corpus Christi Army Depot, Attn: SDSCC-MPI, Mr. Mike AdhernCdr, Letterkenny Army Depot, Attn: SDSLE-MMS, Mr. Gerald ClineCdr, New Cumberland Army Depot, Attn: SDSNC-ME

*Cdr, Red River Army Depot, Attn: SDSRR-MO, SDSRR-ME, Mr. Walt Oosterveen*Cdr, Sacramento krmy Depot, Attn: SDSSA-RPM-1, SDSSA-R, Mr. Bernard Grindle*Cdr, Tobyhanna Army Depot, Attn: SDSTO-ME, SDSTO-ME-E, Mr. Frank Estock*Cdr, Tooele Army Depot, Attn: SDSTE-MAE, SDSTE-MAE-E, Mr. Douglas Deem

*Army Organizations:* Dir, Army Management Engineering Training Acty (AMETA), Attn: DRXOM-SE,

Dr. Shallman (3 cys)Dir, Army Signals Warfare Lab, Attn: DELSW-MPDir, DARCOM Intern Training Center, Attn: DRXMC-ITC-E, Mr. CarterCdr, Foreign Science and Technology Ctr (FSTC), Attn: DRXST-MT1, .

Mr. James WamsleyCdr, Harry Diamond Laboratories, Attn: DELHD-PO-P, Mr. Julius HokeDir, Installations and Services Activity (I&SA), Attn: DRCIS-RI

* Cdr, Night Vision and Electro-Optics Lab, Attn: DELNV-SE, Mr. Manuel PabloMetals & Ceramics Info Center, Attn: Mr. Del Spaisbury, hattelle-Columbus

Labs, Columbus, OH

*Navy Organizations:Cdr, Naval Material Command, Attn: Mr. J. W. Mclnnis, Code 064

*Dir, Naval Mat Comd Ind Resources Detachment, Officer-In-Charge, Bldg 75-2*Cdr, Naval Oceans Systems Ctr, Attn: Code 926, Dr. Wil Watson

Cdr, Naval Sea Systems Command, Attn: Mr. T. Draschil, Code SEA-05R23Cdr, Naval Weapons Ctr, Attn: Code 36404

1.79 4

"4 DRXIB-MT

DISTRIBUTION (Cont'd):

Air Force:Cdr, Air Farce Logistics Command, Attn: AFLC/MAXCdr, Air Force Wright Aeronautical Lab, Attn: AFWAL/LT, AFWAL/MLTE,

AFWAL/M~LS, AFWAL/MLTN (1 cy ea)Cdr, Hanscom AFB, Attn: AFGL-STJLL, R. Bergmann

Cdr, San Antonio Air Logistics Ctr, Attn: B. Boisvert, MMEI, Kelly AFB

-'44

4180

4' \*,4%

FILMED

1 8

DTIC