implementing a strategy to deliver weapon …...thermal batteries are used to power mda weapons...

ManTechImplementing A Strategy

to Deliver Weapon Systems

Affordability

director of DEFENSE RESEARCH AND ENGINEERING3030 defense pentagon

washington, dc 20301-3030

Zachary J. Lemnios

October 29, 2010

The future of our Nation’s defense depends on our ability to respond to military challenges with innovation, speed, and agility. The Manufacturing Technology (ManTech)Program meets this challenge with its focus on affordable, timely, and low-risk development, production and sustainment of defense systems. ManTech helps strengthen our technology and industrial bases to maintain our technological edge in a dynamic, diverse, and evolving threat environment.

This brochure highlights the Warfighter impact of products implemented by the ManTech projects of the Office of the Secretary of Defense, Army, Navy, Air Force, Missile Defense Agency, and Defense Logistics Agency. The pages of the brochure show the ongoing benefits of the ManTech Program to provide cost savings, improve technology implementation with an early focus on manufacturing, reduce manufacturing lead time, provide faster surge capabilities, improve manufacturing processes for greater reliability, and rapidly respond to Warfighter requirements. The centerfold of the brochure highlights the Joint Defense Manufacturing Technology Panel’s Advanced Manufacturing Enterprise (AME) Subpanel that was established in 2010 to respond to the thrusts identified in the 2009 DoD ManTech Strategic Plan.

ManTech works closely with Warfighters, PEOs, PMs, and sustainment and logistics experts who support and endorse the products implemented by the ManTech program. The products identified throughout this brochure include helicopter health monitoring, affordable shipbuilding processes, faster surge capabilities for critical parts, tagging, tracking, and locating, efficient batteries and space solar cells, lighter aircraft parts and soldier weaponry, improved aircraft maintenance, deployable force protection, and manufacturing workforce training.

ManTech’s combination of top notch people and compelling ideas will continue to help drive our Department’s innovative engine and ensure our Nation maintains its competitive edge on the battlefield. I am pleased that the ManTech team’s approach is consistent with the DDR&E goals to accelerate delivery of technology capabilities to win the current fight, to build strategic relationships to prepare for an uncertain future, and to reduce cost, acquisition time and risk of major defense acquisition programs.

MISSION STATEMENT

The DoD Manufacturing Technology (ManTech) Program anticipates and closes gaps in manufacturing capabilities for affordable, timely, and low-risk development, production

and sustainment of defense systems.

FOCUS

An important focus of ManTech is on the technologies, processes, and enabling manufacturingcapabilitiesthatreducetheacquisitionandsustainmentcostofweaponsystems,andprovidedirectbenefit to theWarfighter. Measures of effectiveness include improved mission capability, improvedreadiness, and reduced total ownership costs. Timely transition of the technology consistent withacquisitionandoperationalrequirementsisessential.

STRATEGY

TheDoDManufacturingTechnologyProgramStrategicPlanpreparedin2009bytheOfficeoftheSecretaryofDefenseinclosecollaborationwiththeJDMTPcontainsfourstrategicthrusts:

•Thrust1:Effectivemanagementanddeliveryofprocessingandfabricationtechnology solutions

•Thrust2:Activesupportforahighlyconnectedandcollaborativedefensemanufacturing enterprise

•Thrust3:Activesupportforastronginstitutionalfocusonmanufacturabilityandmanufacturing processmaturity

•Thrust4:Activesupportforahealthy,sufficientandeffectivedefensemanufacturing infrastructureandworkforce

TheManTechProgramstrategyistobalanceitstraditionalemphasisonprocessingandfabricationtechnologysolutionswithactivesupporttomeetbroaderdefensemanufacturingneeds.21stcenturydefensemanufacturingreliesonanetworked,collaborative,andincreasinglyglobalsupplybase,withcapabilitiesthatcanbelinkedbetweenandamongallstakeholders–fromdevelopertousertosustainer–torespondrapidlytodynamicallychangingdefenseneeds.

TheManTechsuccessesdocumentedhereinarecategorizedbytheappropriatestrategicthrust.ThemajorityofManTechprojectsareinThrust1.ThecentertwopagesofthisdocumenthighlighttherecentlyformedAdvancedManufacturingEnterprise(AME)SubpaneloftheJDMTPfocusedonThrusts2,3,and4.

VISION

Insummary,theDoDManTechProgramvisionis:“Aresponsiveworld-classmanufacturingcapabilitytoaffordablyandrapidlymeetWarfighterneedsthroughoutthedefensesystemlifecycle.”

ARMY

light graduation to page edge - dark toward center

THRUST ONEPROCESSING & FABRICATION

The Challenge:AircraftsuchastheAH-64Apachehavebeeninservicefor20+years,yettheairframeshavelimitedsensinganddiagnostictechnologytoreliablyassessthestructuralhealthoftheairframe.Pilotsneedtodetectandassessstructuraldamage in real-timewhenaircraftarehitbygroundfire. Additionally,asnewcompositematerialsareintegratedintoaircraftstructuralcomponents,airframehealthmonitoringismorecriticalthanever.Currentmanufacturingandinstallationprocessesforlightweightsensorsarecostlyandlackmilitary-gradereliability.

ManTech Response:• AnArmyManufacturingTechnologyprojectidentifiedandintegratedasensornetwork tocollectinformationontheeffectsofvibration,temperature,strain,andballisticdamageonthe airframe

• Improvedthemanufacturingprocessofthesensorusingdirectprintforsensorgridproduction

• Developedprocessesandselectedoptimummaterialsforsensorinstallationinsidethecomposite skinoftheaircraft

• ArmyManTechinvestmentof$4.9MwithApacheprogramfundingof$3.6M

Impact:• Reducedunitcostofsensorsheetby>65%(from~$2000persheetto<$700persheet)

• Increasedperformanceandreliabilityofsensorsystembyreducingmanufacturingvariability

• ReducesdirectoperatingcostsforApacheairframesthroughsensorcapabilityforstructuralhealth monitoringthatenablesincreasedtimebetweenoverhaul

• ProvidestheWarfighterwithaffordable,real-timeaircraftballisticdamageindicationcapability

Enables lightweight sensor production for aircraft structural assessment

Army ManTech, The Boeing Company, Dynetics,Radiance Technologies, and PM Apache

ManTech Reduces Cost of Embedded Sensors for Aviation Composite Structures

Page 2

Flexible Sensor Sheets

Composite Vertical

Stabilizer

Apache AH-64

NAVY

The Challenge:ButtweldingexteriorshippanelsproducesaweldprotrusionthatexceedstheDDG1000exteriorsurfacefairnessrequirements.Asaresult,approximately23,000feetofweldreinforcementmustbehandgroundflushat3feet/hourcausingincreasedshipbuildingcosts,frequentinjuries,andcostlymedicalexpenses.

ManTech Response:• Withaninvestmentof$1.3M,aNavyManTechteamdevelopedamechanizedtoolthatremoves80% oftheweldreinforcementatratesexceeding20feet/hour

• Thetooloperatescontinuouslyinaruggedshipyardenvironmentinallorientations(flat,vertical, horizontalandoverhead)

• BathIronWorksimplementedthetechnologyonDDG51inJune2009andonDDG1000inAugust 2009

Impact:• Increasedremovalspeedover500%from3feet/hourto20feet/hour

• Reduceddirectlaborbyasmuchas75%• Costreductionof$924KperhullfromreducedlaboranddecreasedinjuryclaimsonDDG1000alone

• Lightweight,portableTrackWeldShaverisnowcommerciallyavailable

• ApplicabletoothershipsincludingLandingHelicopterAssault,AmphibiousTransportDockandthe NationalSecurityCutteraswellasforcommercialvesselandwindmillconstruction

ManTech Reduces Labor Costs While Improving Safety for Weld Reinforcement Removal

Total cost reduction of $2.77M on DDG 1000

Navy ManTech, Navy Metalworking Center, Bath Iron Works (BIW), Northrop Grumman Shipbuilding - Gulf Coast,

PushCorp, and Naval Surface Warfare Center - Carderock Division

The commercially available track weld shaver (TWS91) increases removal speed by over 500%

Page 3Page 3



AIR FORCE

The Challenge:F-35aircraftinletductsmustbemanuallydrilledfromtheinsideinordertoattachframesaroundtheduct.Thisprocessisergonomicallydifficultandrequiresexcessivetooling,laborcosts,andlongcycletime(approximately50hoursofdrillingperduct).

ManTech Response:• AirForceManTechdemonstratedautomatedholedrillingwithaPhase-IICriticalSmallBusiness InnovationResearch(SBIR)programteamofprimes,smallbusinesses,systemintegrators,andthe F-35JointStrikeFighterJointProgramOffice(JPO)

• Improvedmaturityofproduction-readyautomatedholedrillingprocesstomanufacturingreadiness level(MRL)8,pilotlinedemonstration

• TransitionedthreeproductioninletductroboticdrillingcellstoproductionlineinPalmdale,CA

• AirForceManTech,SBIRandF-35JPOinvested$6.2M

Impact:• Reducedtooling,floorspace,andmanpowercost

• Reduceddrillingcycletimeby75%(from50to12hoursperduct)

• RoboticallydrillsF-35inletductstonowmeetfullrateproductiontargetsof1aircraftperday

• Eliminatedergonomicwork-relatedinjuries

Saves $40M in JSF production cost

Air Force ManTech and Variation Reduction Solutions

ManTech Develops Revolutionary F-35 Inlet Duct Robotic Drilling (IDRD)

Page 4



DEFENSE LOGISTICS AGENCY Page 5

The Challenge:Theindustrialbasenolongersupplieshighperformance,highreliabilitymicrocircuitsrequiredbyDoD.Militarysystem readiness and costs are adversely impacted by microcircuit obsolescence. The DLA MicrocircuitEmulationProgram(MEP)assuresaccurateandeffectivetestingtoqualifyemulatedmicrocircuitsformilitaryplatformsandassuresacontinuingsourceofadvanceddigitalmicrocircuits.

ManTech Response:• TheDLAMicrocircuitEmulationProgram(MEP)providedForm,Fit,FunctionandInterface(F3I) integratedcircuitreplacementsformilitaryvehiclessuchasF-15,C-17,B-52,A-10,JointSTARS, Phalanx,Harier,Apache,andtheBradleyFightingVehicle

• Providesadvancednon-procurablemicrocircuitsforproduction,supportandNationalStock RequirementsforF-18,MLRS,andApache

• Improvedthecurrentemulationmanufacturingtestcapabilitybyreducingtestcycle-timeand extendingthecapabilitytoaddressmorecomplexmicrocircuits

• DLAManTechpartneredwiththeIndustrialBaseInnovationFund(IBIF)toinvest$0.79M

Impact:• Supportsgreaterthan350registeredweaponsystems

• Reducesleadtimesby20weeks

• Increasedbenchmarkdeviceyieldfrom50%to80%

• IncreasedtestcapacityforcomplexICs

• Over100,000military-quality-emulateddeviceshavebeenshipped

ManTech Improves Test Capability for Integrated Circuit Emulation

Total cost avoidance of $680M to include $40M for F-15 Program

DLA ManTech, DLA IBIF, DLA Land and Maritime, SPAWAR Systems Center, and Sarnoff Corporation



DEFENSE-WIDE MANUFACTURING SCIENCE AND TECHNOLOGY (DMS&T)MISSILE DEFENSE AGENCYPage 6

The Challenge:ThermalbatteriesareusedtopowerMDAweaponsin-flightbutoftenmustbedesignedmuchlargerandheavierthan necessary because the current production method is incapable of “right size” fabrication. Use of theselarger,heavierthannecessary,mission-criticalbatteriesdegradesmissileperformanceandcapability.

ManTech Response:• TheMDAProducibilityandManufacturingProgramworkedwithENSER,thesecondlargestUS thermalbatterymanufacturertodevelopatapecastmanufacturingprocesscapableofproducing verythincells• ENSERleveragedMDAManTechandSBIRfunding,priordevelopmentworkandacquiredcost- sharefundingfromaprimecontractortoadapttapecast“thin-film”manufacturingforthermal batteriestoimplementintheExtendedAreaProtectionSystem• Technologytransitionagreementsforprogramofficesandprimecontractorsencompassedmultiple DoDplatformsforwidestpossibleinitialadoptioninfuture:GroundBasedInterceptor,PATRIOT PAC-3MissileSegmentEnhancement,STANDARDMissile3,THAAD,NextGenerationAegis MissileSystems• ManTechinvested$1.9Mwithindustrycostshareof$350K

Impact:• Reducedvolumeofhighpowerthermalbatteriesby20to40%dependingondesign• Reducedweightofthermalbatteriesby15to25%dependingondesign• EnablesMDAandotherDoDapplicationsthatareseverelysizeandweightconstrained

Reduces cell manufacturing costs by 70 – 80%

MDA Producibility and Manufacturing, and ENSER Corp.

ManTech Develops New Production Method for Lighter Mission-Critical Batteries



DEFENSE-WIDE MANUFACTURING SCIENCE AND TECHNOLOGY (DMS&T)Page 7

The Challenge:Engineshavehundredsofairfoilsthataremadefromorganicmatrixcomposites,ceramicmatrixcomposites,orcastalloys.Thecurrentprocessesforinspectingcomplexairfoildesignsforturbineenginesaretooslow,takinganaverageof1hourperairfoil,andcannotmeetfullrate/surgeproductionorefficientmaintenanceoperationsofadvancedturbineengines.

ManTech Response:• AnIntegratedProjectTeam(IPT)wasformedofengineersfromtheAirForceResearchLaboratory (AFRL),ArmyAviationandMissileResearch,Development,andEngineeringCenter(AMRDEC), airfoilcastingsuppliers,sensorsuppliers,andthreeturbineengineOriginalEquipmentManufacturers• A“ThreeDimensionalAirfoilInspection”(3DAI)systemwasprototypedin17monthsthatprovides analternatedimensionalinspectionmethodologyforcomplexturbineengineairfoils• Theteamdemonstratedamethodforhighspeeddatacollectionandanalysisofairfoilgeometry, whichleadstoasignificantreductionincycletime

Impact:• Reducedairfoildimensionalinspectiontimesfrom1hourto2-4minutes• Reducedcostandman-hoursofinspection• ImplementedonT700platformaswellaslegacyengines

ManTech Decreases Inspection Time of 3-D Airfoils for Advanced Turbine Engines

Cost avoidance of $26M for 1500 engines

Air Force, DMS&T, General Electric Aviation, Accurex Measurement Systems,Breuckmann (Germany), PCC, Howmet, and General Electric CCP

ConceptMRL 3

RealityMRL 6



ARMYPage 8

The Challenge:Soldier-portabledesignatorsandmarkersprovideaccuratetargetingforlaserguidedmunitions.Currentlaserdesignatorsuselegacylasermodulesandelectronics,resultinginlargesize,power,weight,andcost.Areductionin laserdesignatorandmarkerweightandcost is required todecreaseSoldierweightburden, increase theavailabilityofthesedevicesinthebattlefield,andenablesmallUASwithdesignation/markingcapability.

ManTech Response:• ArmyManTechreducedtheweightandcostoflaserdesignatormodulesbysimplifyinglaser construction,andreducingtheweightofdiodestackdriversthroughdesignoptimizationanduseof lowcostcommercialoff-the-shelf(COTS)electrolyticcapacitors

• Lasermodulecostandweightwasminimizedbydirectlybondinglasercomponentsontoalight- weightcomposite-metalbasetoenableintegrationofthelaserontoaClassIUAS

• Developedcompacthand-heldorrifle-mountedlasermarker/designatorforSoldiertotransitiontoPM Soldiers,SensorsandLasers(SS&L),Marines,SpecialOperationForces(SOF),andAirForce(infield)

• WorkingwithJointEffectsTargetingSystemsandLaserTargetLocatorModuleProgramstotransition technologyin2012and2011respectively

• $4MArmyManTechInvestmentand$1.5MfromPM-SS&L

Impact:• Reducedweight(<0.5lb)oflasermodulesforrifle-mounteddesignator

• Reducedsoldierweightby>10poundsvs.currentdiodepumpedSpecialOperationForcesLaser AcquisitionMarker(SOFLAM)

• Ultra-low-weight(1.6oz/40mJ)lasermoduleandlaserdiodestackdriver(2.5oz)forUAS

2x cost reduction of laser designators/markers from $100K to $50K

Army ManTech, FLIR SMC, BAE, L3 Insight Technologies, and OptiSwitch Technology Corp.

ManTech Reduces Weight and Cost of Laser Designator Modules for Soldiers



2.5 oz diodestack driver

1.6 oz laser module

AIR FORCE

Class I Unmanned Air System (UAS)

AIR FORCE Page 9

The Challenge:U.S.manufacturersofmulti-junctionspacesolarcellsarefacinginternationalcompetition,aswellasgrowingpower,mass,andvolumerequirementsforWarfighter-specificpayloads.Duetoshrinkingbudgets,spacecraftdesignersneedtomanufacturespacecraftsubsystemswithlowercost,weight,andvolume.

ManTech Response:• AirForceManTechandtheSpaceandMissileCenter(SMC)collaboratedwithsolarcell manufacturerstomaturemanufacturingprocessesandaccelerateinsertionofspace-qualifiedhigh efficiencymulti-junctionsolarcells• AFRLSpaceVehiclesDirectoratedevelopedmaterialsandprocessingusedforsolarcells• Teamimprovedpower,mass,andvolumeandreducedmanufacturingcostsofsolarcellstoretrofit intoWarfighter-specificsatellites• AFManTechinvested$2.4M

Impact:• Increasedpowerlevelfrom<15kWsystemto30kWsystem• Significantlyreducedsolararraycostperwattby15-20%• Reducedsolararraysizeandmassby15-17%• Benefitsnumeroussatellites:AdvancedExtremelyHighFrequency,WidebandGlobalSATCOM, SpaceBasedInfraredSystems,SpaceTrackingandSurveillanceSystem,andNextGeneration GlobalPositioningSystem

ManTech Reduces Cost and Improves Efficiency of Multi-Junction Space Solar Cells

Reduces production costs by 20%

Air Force ManTech, AFRL Space Vehicles Directorate (RV), AF Space and Missile Center (SMC), Spectrolab, and Emcore




Joint Defense ManTech Panel(JDMTP)

Summary

TheJointDefenseManufacturingTechnologyPanel’sAMESubpanelwasestablishedin2010inresponsetoneedsidentifiedinthe2009DoDManTechProgramStrategicPlan.AMEinvestmentsaddress“abovetheshopfloor”technologiesandintelligentbusinesspracticesenablingnewwaysofdoingbusinessacrossanincreasinglycomplexandnetworkedmanufacturinglandscape.AMEvisualizesahighlyconnectedandcollaborativemanufacturingenvironmentamongthemultipleplayersinsystemdevelopment,production,andsustainment.Formoreinformation,gotohttps://www.dodmantech.com.

AME Subpanel Scope

TheSubpanel’sinvestmentactivityencompassesthetechnologies,processes,andpracticesthatfosterrapid,superiorexecutionofmanufacturingenterprisesacrossthelifecycleofmanufacturedproductsandsystems.Thisincludes:

• Model-based tools and approachesthatoptimizeproducibility duringearlydesignandsupportstandarddataenvironments

• Network centric manufacturing capabilitiestofacilitate resilientandadaptablesupplychains

• Intelligent manufacturing planning and factory execution

• Modeling and simulationcapabilitiesadvancingtheabove businesspractices

• Technologiesandpracticestofullyrealizegovernmentand industry-wideuseofmanufacturing readiness tools and processes

• Actionstoassistinimprovingdefense manufacturing Infrastructure and workforce

JDMTP JDMTP

Metals

Composites

Electronics

DoD ManTech Program

Defense Manufacturing Enterprise

Defense Industrial BaseCOST EFFECTIVE SUFFICIENTRELIABLE

Strategic Thrust 2Active Support for

A Highly Connected and Collaborative

Defense Manufacturing

Enterprise


A Strong Institutional Focus on

Manufacturability and Manufacturing

Process Maturity


A Healthy, Sufficient, and Effective Defense

Manufacturing Infrastructure and

Workforce

Strategic Thrust 1Effective Management

and Delivery of Processing & Fabrication

Technology Solutions

AME

Strong,Traditional

JDMTP Focus onMaterial

Transformation

JDMTP Subpanel Structure

Improved Program

Focus on New Strategic

Thrusts 2, 3, & 4

Advanced Manufacturing Enterprise (AME) Subpanel

Page 10

NewSubpanel!


Joint Defense ManTech Panel(JDMTP)

JDMTP JDMTP

AME Investment Focus Areas

Model Based Enterprise: “Building the Digital Thread”

The Challenge: Driveacontinuousflowofintegrateddesign,analysis,andmanufacturinginformationthroughouttheproduct/systemlifecycle.

The AME Response:• AdvancedModelingandSimulation• DesignOptimizationTools• VirtualPrototyping• DataStandardsEfforts

BAE

NGC

MNP

LAP

CLK

DRP

NPP

PIN

MDS

MRDKFP

MAR

FWT

Warning!! The financial health of “X - CO” is still weak!

Weak/Toxic

Vulnerable Average Good Strong/Optimal

Financial Risk

Manufacturing Networks: “Connecting the Enterprise”

The Challenge:Enableseamlessinteroperabilityofdataandprocessesacrossorganizationalboundaries.

The AME Response:• AdvancedSupplyChainManagementPractices• EnterpriseIntegrationTechnologies• ToolstoEnableSeamlessCollaboration

Intelligent Manufacturing Planning and Execution

The Challenge: Createagileandadaptivemanufacturingcapabilitiesthatintegratefactoryfloorresourcestorapidlydeliveradvancedsystemstothewarfighter.

The AME Response:• FactoryIntegrationforAutonomousOperations• AdvancedProductionPlanningandScheduling

Industrial Base Infrastructure and Readiness

The Challenge:ActivelysupportinitiativesandpoliciestoensuremanufacturinginfrastructurehealthandU.S.globalmanufacturingsuperiority.

The AME Response:• ManufacturingReadinessBodyofKnowledgeDevelopment• Activecollaborationtoenableeffectiveimplementationand sustainmentofmanufacturingtechnologies

Page 11

4thSubpanel

DEFENSE-WIDE MANUFACTURING SCIENCE AND TECHNOLOGY (DMS&T)Page 12

The Challenge:Ceramic Matrix Composite (CMC)parts made with silicon carbide (SiC) are lighter than metal and provideimprovedacceleration,speed,andfuelefficiencyinaircraft.However,thecurrentmachinesusedtomanufactureCMCsrequirelongstart-up,cool-down,andmaintenancecyclesforeachcoatingrunwhichaddstotheoverallaircraftcostandreducescapacity.

ManTech Response:• AirForceManTech,ArmyAviationandMissileResearch,DevelopmentandEngineeringCenter (AMRDEC),andtheDefense-WideManufacturingScienceandTechnologyProgramsteamed withGeneralElectricAviation(GEA)toreducethemanufacturingstepsforSiCtowcoatingandto providegreaterthroughputwithsubstantiallylowercosts

• TheCMCmulti-stepbatchprocesswasconvertedintoasinglestepprocess

• Manufacturingcostsandengineweightarereducedtoimproveacceleration,speed,andfuel efficiency

• CompositematerialswerevalidatedduringCMCpanelfabricationandmechanicalpropertytesting

Impact:• Increasedcoatingrunlengthby100%from137metersto275metersoffiber

• Reducedlaborcostforcoatingprocessby70%

Lighter CMC parts enable fuel savings of 1 million gallons/year

Air Force, Army AMRDEC, DMS&T, and General Electric Aviation

ManTech Improves Silicon Carbide Tow Coating Process



Page 12 NAVY

NAVY Page 13

The Challenge:ReducingtheacquisitioncostofcurrentandfutureplatformsiscriticaltotheNavywiththespecificgoaltobuildeachVIRGINIAClassSubmarine(VCS)forunder$2B.

ManTech Response:• NavyManTechanditsCentersofExcellence(COEs)workedcloselywithPEOSubs,theVCS ProgramOffice,GeneralDynamicsElectricBoat,andNorthropGrummanShipbuilding–Newport NewstofocusManTechresourcesonidentifyinganddevelopingneededmanufacturingtechnology

• AfocusedVIRGINIAClasssubmarineaffordabilityinitiativewasestablishedtodevelopandtransition cost-reducingmanufacturingtechnologiesforimplementationonthefactoryfloor

• ThecurrentNavyManTechVCSaffordabilityportfolioincludesapproximately60projectswithatotal expended/plannedinvestmentof$62Mtoaddressaffordabilityimprovementsinmanufacturing

Impact:• Todate,technologyfrom18of60NavyManTechVCSaffordabilityprojectshavebeenimplemented onthefactoryfloor

• Theresultisrealacquisitioncostsavingsofover$20Mperhulltodate

• NegotiatedintotheBlockIIIVIRGINIAClasssubmarineprocurement

• FutureimplementationsfromtheNavyManTechVCSaffordabilityportfolioareprojectedtoresultinat leastanadditional$12M/hullcostsavings

• NowaddressingBlockIVandtotalownershipcostreduction

ManTech Enables Significant Cost Reduction for VIRGINIA Class Submarine Construction

Total cost savings estimated at over $32M per VCS hull

Navy ManTech, Navy ManTech Centers of Excellence (COEs), General Dynamics Electric Boat, Northrop Grumman Shipbuilding – Newport News, PEO (Subs), and the VCS Program Office


THRUST ONE & TWOMFG. PROCESSING & MFG. ENTERPRISE

ManTech project implementations are resulting in significant cost savings for VCS

DEFENSE LOGISTICS AGENCYPage 14

The Challenge:Soldiersareatriskif theyuseprotectiveclothingthat ispasttheexpirationdateorequipmentthathasbeenrecalledforqualityproblems.Trackingindividualitemssuchashelmetsandchemicalprotectivegeariscriticalintheeventofshelflifeexpirationorrecall.

ManTech Response:• ImplementedcosteffectiveRadioFrequencyIdentification(RFID)itemleveltaggingtechnology solutionsatmilitaryapparelmanufacturers

• Improvedsupplychainprocessmeetsmilitaryneedsforassetvisibility,accountability,disposaland shelf-lifemanagementofmilitaryclothingandequipmentitems

• AsDefenseSupplyCenterPhiladelphia(DSCP)continuestoexpandRFIDrequirements, manufacturerswillcontractdirectlywithcommercialRFIDserviceproviderstoimplementthe newcosteffectivetechnologysolutionsattheirfactories

• DLAManTechandIBIFinvested$1.4M

Impact:• Reducedclothingissuetimetosoldiersfrom165minutesto45minutes

• Inventorysavingsof$148Katonelocation

• Reducedtime/laborforreceivingincomingshipmentsfrom4hoursto30minutes

46% improvement in inventory discrepancies

DLA ManTech, DLA IBIF, DLA Troop Support Clothing and Textiles, AdvanTech, Logistics Management Institute, Modulant,

Military Apparel Vendors, Lackland AFB, and Travis Third Party Logistics

ManTech Implements Supply Chain Process Improvements for RFID Item Level Tagging for Apparel


THRUST TWOMANUFACTURING ENTERPRISE

NAVY

NAVY Page 15

The Challenge:Outfitting activities consume 1.5M man-hours and over 30% of the totalVIRGINIA Class Submarine (VCS)manufacturingtime.Oneofthegreatestopportunitiesforcostsavingsandcycletimereductionlieswithintheoutfittingprocess.

ManTech Response:• NavyManTechinvested$1.7Minaprojecttoimproveoutfittingschedulingandworksequencing,improvematerialhandling/controlconcepts,andoptimizeshopforemantime

• GeneralDynamicsElectricBoat(GDEB)implementationoftheseprocess/toolimprovementsbegan inDecember2008inaphasedapproachconsidering: • themostsignificantopportunity • thetimerequiredforimplementation,and • thecost/benefit

• Resultsofthisprojectshouldbefullyimplementedduring2010

Impact:• Theprocess/toolimprovementsfromthisefforthave:

• reducedmanufacturingactivitiesintheOutfittingWorkCell

• increasedefficiencyinhand-offsofmaterial,information,andwork

• improvedtrade/foremanproductivity

• Resultedinacostsavingstodateof$2.0MperVCShullandanexpectedcostsavingsof$5Mper hullwhenfullyimplemented

ManTech Improves Outfitting Processes for the VIRGINIA Class Submarine

Total cost reduction across VA Class of $90M

Navy ManTech, PEO Subs, General Dynamics Electric Boat, Center for Naval Shipbuilding Technologies, and the Institute for Manufacturing and Sustainment Technologies


THRUST TWOMANUFACTURING ENTERPRISE

Accounting for over 30% of new construction costs, outfitting is fertile ground for cost and cycle time reductions

INDUSTRIAL BASE INNOVATION FUNDPage 16

Background:TheIndustrialBaseInnovationFund(IBIF)ensuresthat investmentsaremadetoaddressdefense industrialbaseshortfallsespeciallyrelatedtosurgeproductionrequirementsanddiminishingsourcesofdefensematerial.

The Challenge:Since2005,theBattleJacket™fuelcontainmentsystemhasbeenusedwithgreatsuccesstoprotectgasolinefuel tanksandfuel tanker trucksoperating in IraqandAfghanistan. BattleJacket™isaself-sealing,externalpolyurethane elastomer that minimizes fuel leakage on fuel tankers due to penetration by bullets or otherprojectiles.Currentlyitisappliedmanuallytotheoutsidesurfaceoftankersandtypicallyrequires21man-hourstocompleteonthe25,000galloncapacityHeavyExpandedMobilityTacticalTruck(HEMTTM-978).

ManTech Response:• Developedanautomatedsprayapplicationprocessutilizingcommerciallyavailablerobotictechnology

• FanucM-16iB/10LTrobotwithaR-30iAcontrollerusedtoapplythethreelayersofcoating

• Automatedcoatingprocessincreasesproductivity,ensuresquality,andreducescost

Impact:• 86%reductioninapplicationtime(from21hoursto3hours)

• ImplementationontheentirefleetofHEMMTM-978truckscurrentlyinproductionisexpectedto save$2Minlaborcosts

• Improvedhealthandsafetythroughdecreasedoperatorexposuretohazardouschemicals

IBIF/ManTech Investment - $.3M

DLA IBIF, Office of Naval Research (ONR), SCRA Composite Manufacturing Technology Center, and Composites Research and Material Development, LLC

ManTech Provides Ballistic Protection for Fuel Tanks


THRUST FOURMFG. INFRASTRUCTURE

INDUSTRIAL BASE INNOVATION FUND

INDUSTRIAL BASE INNOVATION FUND Page 17

The Challenge:PowerrequirementsoftheF-35JointStrikeFighter(JSF)demandmorereliablepowerfromthe270Vemergencybattery.

ManTech Response:• TheDefenseLogisticsAgency’sIndustrialBaseInnovationFund(DLAIBIF)implementedultra-high power(UHP)Li-iontechnologyintheF-35270Vsystemtosustainlargecurrentsandimprovelow temperaturepowerandlifecyclecosts

• IndustrializedtheVL5Ucellmanufacturingprocessandassociatedcelldesign

• ArmyManTechimplementedlowercost(50%lessatcelllevel),75%improvedpowerdensityLi-Ion batteriesintheImprovedTargetedAcquisitionSystem(ITAS),JointLightTacticalVehicles, SEALDeliveryVehicle,F-35,HybridElectricHMMWVXM1124Vehicle,AutonomousPlatform Demonstrator

Impact:• 25%reductionincomponentsandprocessingsteps

• Newhardwaredesignresultedina10%weightreductionofthecell

• Increaseintotalbatterylifefrom2yearsto4years,withhigherperformancerequirements

ManTech Improves Ultra High Power Li-ion Technology for the F-35 Joint Strike Fighter Aircraft

DLA IBIF/ManTech Investment of $1.4M

DLA IBIF, OSD ManTech, U.S Air Force Research Laboratory, Army ManTech and SAFT America, Inc.


THRUST FOURMFG. INFRASTRUCTURE

NAVYPage 18

The Challenge:ThetrainingofskilledweldersiscriticaltotheaffordableconstructionofNavyships.Anapproachwasneededthatincreasedtrainingeffectiveness,improvedworkmanshipforfewerdefects,andreducedmaterialandacquisitioncosts.

ManTech Response:• ANavyManTechprojectteamconsistingoftheNavyJoiningCenter,GeneralDynamicsElectricBoat (GDEB)andvirtualrealitydeveloperVRSim,Inc.,developedanddemonstratedaprototypevirtual- realityweldertrainingsystemthatsimulatesthegasmetalarcweldingprocess

• The3Dhead-mounteddisplayprovidesreal-timefeedbackshowingthewelderhowtoaccurately positionthetorchandthepropertravelspeed

• NavyManTechinvestmentof$670Kwithindustrycostshareof$625K

Impact:• Virtualrealitytrainingresultsinmorehighlyskilledweldersproducinghigherqualityweldswithfewer workmanshipdefects

• Thevirtualrealityapproachtoweldertrainingincreaseseffectiveness,reducesarctimerequiredfor training,andsignificantlyreducesmaterialpreparationandacquisitioncostsassociatedwithtraining

• TheweldingtrainerisnowcommerciallyavailableasVRTEX™360fromLincolnElectricCompany, Cleveland,Ohio

• PurchasershaveincludedArmyAberdeenProvingGrounds,SouthDakotaSchoolofMinesand Technology,CaliforniaStatePenitentiary,ElectricPowerResearchInstitute,TrainingSystems Australia,WellingtonInstituteofTechnology,andtheShawGroup

Navy ManTech Investment: $670,000

Navy ManTech, Navy Joining Center, General Dynamics Electric Boat, and VRSim

ManTech Improves Welder Training with Virtual Reality


THRUST FOURMFG. WORKFORCE

Virtual reality approach to welding training increases effectiveness

DoD ManTech - Did You Know?

• DoDManTechdevelopedtheoriginalnumericallycontrolledmachine toolandtheassociatedprogramminglanguage,APT,inthe1950’s toadvancemilitaryaircraftmanufacturing.Nowusedgloballyin countlessmanufacturingapplications.

• TheDoDManTechprogramdevelopedthetechnologythatbecamethe foundationforthecurrentmicroelectronicsindustryinthe1960’s.

• Inthe1970’s,DoDManTechdevelopedprocessesfortheproductionof theforerunnersofprecisionlaserguidedmissilesandmunitions.

• Inthe1980’s,DoDManTechdevelopedaprocessforreverse engineeringthousandsofobsoletemicrocircuitsthatsupportweapon systemsstillinservice.Useandmissionbenefitscontinuetoexpand today.

• Inthe1990’s,theDoDManTechprogramdevelopedmagneto- rheologicalfinishingforadvancedmilitaryoptics.Theprocessisnow alsousedbyallmanufacturersofphotolithographicoptics.

• Inthecurrentdecade,DoDManTech:

–ProvidedrevolutionaryelectronicssuchasMicroElectro-Mechanical Systems(MEMS)forfieldartillerysystemsandFocalPlaneArrays (FPAs)forsensorsystems

–Enabledmanufacturingofinterceptorbodyarmorcurrentlyusedby ourforces

–Manufacturednextgenerationofenhancedcombathelmetsto replace30-yearoldtechnology

–Developedautomatedprocessesforlighter,durableandmore comfortablecompositeprosthetics

–Providedimprovedcombatrationswithhighquality,safer,and surge-capableproduction

–Implementedhigherpower,longerdurationbatteriesacrossweapon systems

– Appliedmodel-basedmanufacturingandCADinaeronauticaland maritimeconstructionforgreateraffordability

2010 Defense ManTech Achievement Award Nominations

Project Title Service

3D“Official”ESADataEnvironment, NationalMEPNetworkPilotChainDemonstration Army

AffordableWeaponsDatalinksInsertion(AWDI) AirForce

*HighPower,HighEnergyDensityLithium-IonBatteries Army

StrentheningEconomicandTechnological CompetitivenessoftheU.S.DefenseIndustrialBasefor TravelingWaveTubeAmplifiersforSpaceApplications AirForce

ThreeDimensionalAirfoilInspection(3DAI) AirForce

*LowObservableMaintainability-SealExtrusion DevelopmentandDemonstration(SEDD) AirForce

HSLA-115EvaluationandImplementationforCVN78 Navy

PredictingthePerformanceofCriticalCastParts onWeaponsSystems DLA

CollaborationProcurementSupportfor ProblematicMetalcastingSustainmentParts DLA

*WeldSeamFacingandBackGouging Navy

BallisticProtectionforGasolineTankerTrucks Navy

DoDPowerSourcesTechnologyRoadmap Army

*Finalist

Therewere12nominationssubmittedthroughJDMTPSubpanelsforthe2010DefenseManTechAchievementAward.TheawardeeswereannouncedattheDefenseManufacturingConference.

TheJDMTPPrincipalswouldliketorecognizethesenomineesfortheirefforts.

The Joint Defense Manufacturing Technology Panel (JDMTP) seeks to recognize and honor those individuals most responsible for

outstanding technical accomplishments in achieving the vision of the Department of Defense (DoD) ManTech Program.

That vision is to realize a:

“Responsive world-class manufacturing capability to affordably meet the Warfighter’s needs throughout the defense system life cycle.”

To this end, the Defense Manufacturing Technology Achievement Award was established in the Fall of 1999.

AWARDEES

2009 – F-35 Inlet Duct Robotic Drilling

2009 – Low Cost Manufacturing of Materials for Improved Warfighter Protection

2008 – Laser-Welded Corrugated-Core (LASCOR) Panel Evaluation

2008 – Low Observable Paints for Aircraft

2007 – Lean Battery Initiative

2007 – Low Cost SiC-N Ceramic Tile

2007 – Translational Friction Stir Welding

2006 – Uncooled Focal Plane Array Producibility

2006 – Engine Rotor Life Extension

2005 – Large Aircraft Infrared Countermeasures

2005 – Large Marine Composite-to-Steel Adhesive Joints

2004 – Lean Depot Repair

2004 – Uniform Cannon Tube Reshaping

2003 – Laser Additive Manufacturing

2003 – Laser Shock Peening

2002 – Composites Affordability Initiative

2002 – Apparel Research Network

2001 – Enhanced Mfg. Processes for Body Armor

2000 – Advanced Optics Manufacturing

2000 – Flexible Manufacturing of Microwave Vacuum Devices

1999 – Advanced Fiber Placement

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For Further Informationwww.dodmantech.com

November 2010

implementing a strategy to deliver weapon …...thermal batteries are used to power mda weapons...

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