Materials and Manufacturing Capabilities for Sustaining Defense Systems Summary of a Workshop (2013) / Chapter Skim
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Workshop Presentations and Discussions
Workshop Presentations and Discussions
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community to work together to enhance Defense S&T programs, eliminate unwarranted duplication, and strengthen cooperation among the military services and other DOD agencies. As its name indicates, the focus of DMMI is on issues relevant to materials, manufacturing, and the infrastructure that sustains the materials and manufacturing enterprises essential to national defense.
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Critical materials substitution and demand reduction were addressed at a previous DMMI meeting and remain a focus of DOD planning. Two weeks before this workshop, the Institute for Defense Analyses (IDA)
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He cited as an example the close interactions among Joint Staff, requirements developers in the services, acquisi tion managers, and industrial base policy staff within the Pentagon. He also sees some good examples of teaming in large integrated programs such as the F-35 Joint Strike Fighter and in some of the integrated teams at the Defense Advanced Research Projects Agency (DARPA)
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As context for the Air Force's problem of aging aircraft, Dr. Stevens showed a chart of the systems that had been introduced in each decade since the 1950s, with those still in the inventory shown in red, those out of the inventory in black, and systems in development shown in blue (Figure 1)
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This pervasive qualification process demonstrates the challenge of ensuring system safety when common materials or components are not properly tracked. With respect to improving fleet health management, Dr.
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and a digital data collection and archiving com ponent called the "cradle-to-grave digital thread." While the objective of the former is to enable earlier development of game-changing products and manufacturing process technologies, the cradle-to-grave digital thread aims to develop and em ploy digital environments and tools that increase efficiencies in all stages of the life cycle. Participants noted that one of the challenges for the cradle-to-grave digital thread is capturing computer-aided design/computer-aided manufacturing (CAD/ CAM)
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Digital thread activities include generating, capturing, organizing, and utilizing relevant data and information. SOURCE: Katherine Stevens, AFRL, "AFRL and materials issues," presentation to the committee on July 23, 2012, Slide no.
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Another question was how willing potential competitors might be to share approaches and practices that in some cases they might see as part of their competitive advantage. On the problem of different OEM part numbers for the same physical part in different systems or in different subsystems or components of the same system, Royce Smith of the Air Force Diminishing Manufacturing Sources and Materiel Shortages (DMSMS)
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Stevens. He first described Army S&T activities in materials and proceeded on to the issues of counterfeit parts, parts obsolescence, and materials shortages.
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• ASAALT is continuing to work with the Office of the Secretary of Defense (OSD) to develop a Trusted Supplier standard.
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Fish said that reliance on a sole (domestic) source for a critical material must be paired with a program to stockpile sufficient reserves to carry through an interim supply shortage, as happened for strong nitric acid.
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McGrath suggested that this discussion session should focus on how the prior presentations relate to the following five critical issues, which were called out in the prologue of the workshop's announcement-agenda document, and whether any additional critical issues have emerged: • Are there ways to rapidly qualify materials or components when the raw materials or their manufacturing process has been changed? • How does one economically replicate the production of a part that is no longer made?
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so that DOD is not facing the same problems 30 years from now that it faces today? Does this mainly involve making policy changes that facilitate the government's forming long-term relationships with suppliers as opposed to putting sup 2 EEE-488 is a specification for a short-range digital communications bus and was created in the I late 1960s for use with automated test equipment.
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• Are there industry best practices in supplier management and manufac turing data capture that could be adopted or adapted by DOD as better ways to do business? A first step would be to benchmark what companies do as best practices in supplier management -- for instance, in building and maintaining a network of trusted suppliers.
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Potential solutions for ensuring parts quality include building trusted supplier relationhips, having appropriate policies, and applying appropriate test proce s dures. The second category, which appears harder to address, concerns attempts, for any number of reasons, to hide some new functionality in the counterfeit part without altering the part's properties as measured by the quality standards.
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Dr. Schafrik described the risk assessment process that GE has adopted to be proactive in introducing technical risk reduction programs for materials with high criticality for the company.
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In addition, designs for engines and other highly complex systems and subsystems are now taking materials availability into account in design decisions. This materials sustainability risk management process is also used for nonmetal materials such as polymers and fibers.
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In response to a question on recent shortages of particular forms of titanium, Dr. Schafrik said the materials sustainability risk assessment he was describing ap plied only to the material and not to the availability of the end product.
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Eckbreth chaired the study team that authored the Air Force Scientific Advisory Board (AFSAB) report Sustaining Air Force Aging Aircraft into the 21st Century (AFSAB, 2011)
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3 and how sustainment issues are making it unlikely that the aircraft availability goals set by combatant commanders can be achieved. Of particular relevance to this DMMI workshop, parts supply issues grow as a system ages: • Diminishing manufacturing sources and materiel shortages (DMSMS)
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The report also discusses specific maintenance technologies that the study team considered to have cross cutting benefits for improving fleet maintenance and sustainment. In closing, Dr.
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. THE AIR FORCE DIMINISHING MANUFACTURING SOURCES AND MATERIALS SHORTAGES PROGRAM OFFICE Royce Smith, Lead Program Manager 448th Supply Chain Management Wing, Tinker Air Force Base Mr.
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A joint overnment–contractor team works on resolving the obsolescence issues g for subsystems, in priority order, typically several years before the inventory for AVCOM Automated Solutions the obsolete part is forecast to be exhausted. A final solution may involve a formal Technical Order change to allow use of a replacement part or a redesign package with complete specifications for recreating the part.
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To summarize his argument for the value of proactive DMSMS management by systems like AVCOM and SDW rather than reactive management of obsolescence issues, Mr. Smith characterized the two approaches as follows: • Reactive DMSMS Management -- vent driven -- already behind the curve when notified that a part is not E available for a repair; -- ncreased risk of impact on mission readiness; and I
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During preacquisition planning, if the government is not going to buy all the technical data needed to remanufacture, then performance based logistics contracts -- for example, on contractor logistics support (CLS) -- are needed to motivate OEMs to commit to maintaining the system throughout its life cycle.
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A relevant policy question is whether DOD should attempt to buy the technical data sufficient to maintain a digital data thread and store the data in an engineering data repository or instead look to OEMs to maintain the data and buy the information as a service. Would a DOD data repository be as complete and accurate and updated as the data OEMs would maintain?
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has extensive planning for critical materials in the energy sector, similar to the approaches Dr. Schafrik described.
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SENATE ARMED SERVICES COMMITTEE REPORT ON COUNTERFEIT ELECTRONIC PARTS IN THE DOD SUPPLY CHAIN Joseph M Bryan, Professional Staff Member Senate Armed Services Committee Mr.
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As part of the investigation, the Armed Services committee asked GAO to set up a shell company to search the Internet for certain hard-to-find electronic parts, as well as parts marked with incorrect production dates (beyond the date of last actual production) and parts with bogus part numbers.
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had supplied. The National Defense Act Authorization for FY 2012 requires, among other things, that counterfeits be reported, that contractors use trusted suppliers, and that a tighter inspection regime for imported electronic parts be implemented.
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Figure 7 lists the approaches that are used in the DMSMS manage ment strategy, while Figure 8 illustrates the steps in one of these approaches, the DMSMS Management Process.
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most of these tools and associated testing technique development are intended for structural materials certification. Boeing has problems with parts and materials obsolescence because, even within its supply chain, it may be a relatively small customer for some suppliers, as Mr.
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SOURCE: Dianne Chong, Assembly, Factory, and Support Technologies; Engineering, Operations and Technology, Boeing, "Counterfeit parts and parts obsolescence," presentation to the committee July 24, 2012, slide 14.
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• Boeing uses warranty-servicing data and other field-servicing data as a source for lessons learned in its DMSMS management process. • For the resolution to a DMSMS problem (see Figure 8)
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The DARPA TRUST and IRIS programs are aimed at protecting the national critical infrastructure. As defenses against attacks on software systems and networks improve, Dr.
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The option for DOD trusted fabrication within the United States by a vertically integrated supplier remains, but the military market increasingly relies on COTS parts, including some that are foreign designed, for both mission-critical and non-mission-critical applications. Furthermore, DOD has decreasing control over the electronics supply chain as one moves further back in the chain from the major systems integrators to the suppliers of subsystems, then to board assemblers, and ultimately to the parts and materials suppliers.
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IRIS has the following specific goals: • Technical Area 1. Determine the full functionality of a silicon digital IC when only a functional specification and limited test vectors for the IC's operation are given.
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Determine the full functionality of a silicon mixed-signal or analog IC when only a functional specification and limited test vectors for the IC's operation are given. Use reverse engineering of mixed-signal ICs to derive their functionality by either nondestructive or destructive methods.
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54 M at e r i a l s and M a n u fac t u r i n g C a pa b i l i t i e s for S u s ta i n i n g D e f e n s e S y s t e m s OPEN DISCUSSION RELATED TO COUNTERFEIT PROBLEMS, SUBSTANDARD PARTS, AND SUBSTANDARD MATERIALS Discussion Leaders: Denise F Swink and Robert Latiff In response to questions from other workshop participants, Dr.
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Two major challenges for defense microelectronics are that (1) weapons systems have extended life cycles, from 20 to 40 years, and (2)
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• As the accreditation authority for the Trusted Foundry Initiative, DMEA evaluates security parameters, process controls, and the like for design houses, aggregation facilities, mask-making facilities, fabrication facilities, and test facilities throughout the supply chain to ensure they are abiding by security requirements. Every company in the program must renew its accreditation every 2 years, and DMEA audits the fabrication and mask-making facilities.
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can have the fabrication done by a Trusted Foundry participant. Workshop participants discussed the potential for expanding the relationship between DMEA and participants in the Trusted Foundry Initiative.
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FDA is working with the World Health Organization, which is adding counterfeit medical devices to its long-standing concern with counterfeit drugs. It also works with the Office on Intellectual Property in the Executive Office of the President, which has issued several white papers on counterfeit pharmaceuticals.
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However, FDA does have a regulation requiring a Unique Device Identifier on authentic medical devices, similar to the universal product code barcode used on retail sale items. Because FDA will have a database of the authentic identifiers from two trusted suppliers of the codes, counterfeiting should become more difficult.
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• With respect to the drug side, the new FDASIA gives FDA more legal au thority to establish a Trusted Supplier program, such as registering facili ties and knowing the source of the active ingredients, to make it harder to introduce counterfeit drugs into the supply chain. Those provisions make it harder for an entity in the supply chain to change the source of supply from one facility to another.
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2011. United States Air Force Scientific Advisory Board eport R on Sustaining Air Force Aging Aircraft into the 21st Century.
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Appendixes
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Key Terms
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