Materials and Manufacturing Capabilities for Sustaining Defense Systems Summary of a Workshop (2013) / Chapter Skim
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community to work together to enhance DOD S&T programs, eliminate unwarranted duplication, and strengthen cooperation among the military services and other DOD agencies. The DMMI appointed a workshop planning group to develop the workshop agenda and decide on invited guests and presenters, in accordance with the statement of task approved by the Governing Board of the NRC (Appendix A)
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Policy Obstacles to and Enablers for Meeting System Sustainment Challenges These themes were also described in the open discussion before the close of the workshop, when discussion leader Steven Wax asked the participants for comments, in light of all the presentations and discussions, on unmet needs and unresolved big issues in the areas of sustainment, replication/obsolescence, and counterfeits. The discussion resulted in the following outline of needs and issues suggested by one or more participants.
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• Which data should be captured to have a digital data thread adequate for life-cycle sustainment? • What policy and implementation can be considered for DOD purchase of data rights?
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. • Trusted production -- for example, the Trusted Supplier Program of the D efense Microelectronics Activity (DMEA)
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of potential use. Similarly, materials and parts/components need requalification or recertification when the raw materials used in them or their manufacturing processes change.
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Air Force, made the case for proactively managing diminishing manufacturing sources and materials shortages rather than reactively addressing shortages after they occur. He described how the Air Force is using the Advanced Component Obsolescence Management (AVCOM)
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Neither commercial users nor DOD agencies were routinely reporting instances of counterfeiting found by their independent testers. In all four cases of counterfeit microprocessor chips described by Scott Fish (Army chief scientist)
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. An initial risk management capability for supply chain issues includes increased attention on the government side and increased diligence on the part of prime contractors and their suppliers in testing parts for performance compliance.
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Temporary material shortages can also occur when production capability is transferred from one supplier to another, either because the original supplier sells a product line to another company or because the customer initiates a change in supplier. To address this cause of temporary shortages, one participant suggested that a best practice would be for any supplier to notify customers when it was initiating any disruption in supply capability.
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Stevens used data from that study showing that O&M costs for the Air Force fleet have nearly doubled in the past 14 years, even though total aircraft inventory has continued to decline. The study also argued for use of key sustainment effectiveness metrics other than cost alone, such as aircraft avail ability divided by cost (AA/$)
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THEME 5 ENABLING THE CRADLE-TO-GRAVE DIGITAL THREAD FOR MATERIALS, PARTS, AND COMPONENTS OF SYSTEMS As noted under Theme 4, the digital data collection portion of AFRL's integrated life-cycle approach to sustainment is called the "cradle-to-grave digital thread." But beyond this particular AFRL initiative, a number of workshop participants were interested in and commented on both the challenges of and the potential approaches for implementing a digital data environment that would capture relevant data throughout the system life cycle and make it available for sustainment activities. Several participants noted the challenge of capturing adequate design and manufacturing data and documentation from the OEMs during system development and acquisition so that they will remain available even after a part or component goes out of production.
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Several participants also noted a number of current efforts, such as the ManTech programs in OSD and the Army, to overcome or at least ameliorate some of these problems for implementing the digital data thread vision. THEME 6 TRANSITIONING TO CONDITION-BASED MAINTENANCE Condition-based maintenance is maintenance where the traditional form of scheduled maintenance at regular intervals is replaced by maintenance when needed.
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Other participants suggested that the SDW concept could be expanded to include more of DOD, defense prime contractors, or even the wider aerospace industrial community. Bringing government and industry together in partnerships such as the new Army Cooperative Research Alliances for multiscale and microstructured materials was suggested as a way to attack sustainment problems.
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THEME 9 POLICY OBSTACLES TO AND ENABLERS FOR MEETING SYSTEM SUSTAINMENT CHALLENGES The participants discussed whether S&T solutions for the system sustainment challenges highlighted above could be separated from changes in current policy and DOD and military service culture. Many of them expressed skepticism that purely S&T approaches could in and of themselves effectively meet the challenge.
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Throughout the workshop, and particularly in the question and discussion periods, various participants commented on linkages between potential technology approaches and policy or culture issues that would have to be addressed to make the technology approach effective. Several participants described how de facto responsibility for key decisions that affect downstream (after system acquisition)
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