Improving Industrial Base Manufacturing Processes (formerly Material Availability)
Abstract
The Improving Industrial Base Manufacturing Processes Strategic Focus Area (SFA) is an R&D effort undertaken with DLA’s suppliers to reduce material costs, reduce the length and variability of production lead-times, assure DLA managed products meet performance requirements, and continuously improve quality and reliability. Benefits of this SFA include lower material costs, lower inventory levels and more predictable customer wait times, fewer quality deficiencies, and lower customer support costs. This SFA includes within its scope the Subsistence Network, the Battery Network, the Castings/Forging programs and Additive Manufacturing programs. The Subsistence Network (SUBNET) program is the successor to the Combat Rations Network R&D program. SUBNET focuses on solutions to develop and promote manufacturing improvements in the subsistence supply chain. The program's expanded areas of interest include: combat rations, food equipment, field feeding solutions, food footprint, food innovations, food safety and defense developments, garrison feeding, nutrition and health, storage and packing solutions, surge and sustainment support, and water security. SUBNET forms a community of practice with Military Services, U.S. Department of Agriculture, Natick Soldier Research Development, and Engineering Center; Academia, and Industry to research and promote manufacturing improvements in the Subsistence Supply Chain with the goals of maximizing capability and capacity to produce, and to encourage innovation and modernization needed to leverage the latest technologies. Desired outcomes include: reduced cost, increased efficiencies, improved processes, enhanced quality, and improved surge demand capabilities. The Casting program works to ensure a stable, reliable, and competitive domestic casting industrial base supporting the weapon system needs of the Department of Defense (DoD) and the Defense Logistics Agency (DLA). The casting program works with industry, universities, and the Casting Industry Associations to identify projects that improve the materials, processes and business practices of the nation’s foundry industry. The program aligns projects with strategic issues and identified focus areas within the DLA and DoD. Guidance for these projects comes from the DLA Strategic Plan and input from the casting industry. Weapon system spare parts managed by DLA that contain castings are responsible for a disproportionate share of DLA’s backorders or unfilled orders (UFOs). Cast parts are ~2% of National Stock Numbered Class IX parts but represent ~5% of all backorders, and when only the oldest backorders are considered, up to 10% are castings. This program includes tasks that focus on developing new capabilities in the areas of inspection, materials, processes, modeling, and design. Once developed, these capabilities will support the foundry industry, where the technologies will be tested and implemented, most often in conjunction with the casting industry associations. These advancements improve the metal casting supply chains for the DoD and the DLA to better support the warfighter. We will invest in projects aimed at reducing lead-time, reducing cost, and improving quality of castings critical to DoD weapon systems. The Forging program works to ensure a stable, reliable, and competitive domestic forging industrial base for the weapon system needs of the Department of Defense (DoD) and the Defense Logistics Agency (DLA). Working with industry, universities, and the Forging Industry Associations to identify projects that improve the materials, processes and business practices of the nation’s forging industry. The program aligns its projects with strategic issues and focus areas identified within the DLA and DoD. Guidance for these projects comes from the DLA Strategic Plan and input from the forging industry. Weapon system spare parts managed by DLA that contain Forgings are responsible for a disproportionate share of DLA’s backorders or unfilled orders (UFOs). Forged parts are ~2% of National Stock Number (NSN) Class IX parts but represent ~5% of all backorders, and when only the oldest backorders are considered, up to 10% are forgings. This program includes tasks to develop new capabilities in the areas of inspection, materials, processes, modeling, and design. Once developed these capabilities will support the forging industry, where these technologies will be tested and implemented in conjunction with the forging industry associations. These advancements improve the forging supply chains for the DoD and the DLA to better support the warfighter. We will invest in projects aimed at reducing lead-time, reducing cost, and improving quality of forgings critical to DoD weapon systems. The Battery Network (BATTNET) program objective is to develop the next generation of battery manufacturing technologies for cost and price efficiency, longer shelf life, and lighter batteries with higher energy. BATTNET conducts R&D initiatives to address sustainment gaps and bridge technical solutions into higher a Manufacturing Readiness Level (MRL) for specific groups of batteries. BATTNET also focuses on projects to develop the production capability for advanced lithium-based non-rechargeable and rechargeable batteries to ensure the prompt and sustained availability, quality, and affordability of Service approved batteries. Desired outcomes include: streamlined inventory and associated cost reductions through standardization and improved distribution practices; resolved obsolescence issues; addressed surge and sustainment issues; enhanced security of supply chain; increased competition and manufacturing base; reduced per unit battery cost; and leveraged Service-level (Army, Navy, Air Force) and other governmental (DOE, DOT, NASA) R&D efforts to insert new technology and practices into the existing DLA battery inventory. The Additive Manufacturing (AM) program objective is to establish AM as an effective alternative to conventional manufacturing and document the process for AM benefits. DLA is pursing all AM technology as a lead-time and inventory reduction enabler. The AM effort pursues alternate means of supply for products that are otherwise non-procurable or susceptible to procurement issues due to an unresponsive manufacturing vendor base. The AM effort includes the identification of AM candidates among the population of products that are needed but hard to obtain, costly or have long manufacturing lead times. The AM effort requires management of 3D digital technical and manufacturing data. In addition, the AM effort includes the development of the processes that will tie the designers, engineers, maintainers, logisticians, procurement managers and the vendor base into a seamless AM procurement stream. Potential benefits include products that can address an unfulfilled Warfighter readiness need by reducing production lead times, production costs, storage costs, transportation costs and in some cases fuel consumption due to lighter design and material options. DLA R&D will leverage these efforts with Industry, Academia and ongoing Military Service-level agreements (Army, Navy, Marine Corps, Air Force), Oak Ridge National Laboratory (ORNL) and the Department of Energy.
Document Details
- Document Type
- Project
- Publication Date
- Oct 01, 2020
- Source ID
- IBMP_0603680S_3_0400_PB_2020