Munitions Manufacturing -- Copyright -- Preface -- Acknowledgments -- Contents -- Executive Summary -- STATEMENT OF TASK -- MAIN FINDINGS -- MAIN CONCLUSIONS -- MAIN RECOMMENDATIONS -- Budgetary and Management Issues -- Technical and Program Approaches -- Special Recommendation -- 1 Munitions Manufacturing in the United States -- HISTORY AND CURRENT STATUS -- THE TOTALLY INTEGRATED MUNITIONS ENTERPRISE PROGRAM -- Background -- Vision, Goals, and Objectives -- Program Description -- Program Elements -- Metrics for Judging Success -- Deliverables -- Program Funding -- STUDY OBJECTIVES AND APPROACH -- Charge to the Committee -- Frame of Reference for the Committee -- Committee Analysis -- 2 Enterprise Integration -- INTRODUCTION -- TECHNOLOGIES ENABLING AGILE MANUFACTURING -- Background -- Methodology -- Demonstration Projects -- Difficulties of Enterprise Integration -- NETWORKING AND CONNECTIVITY -- ASSESSMENT OF ENTERPRISE INTEGRATION -- Supply Chain Management -- Problem Definition -- Details of Enterprise Integration -- Concluding Discussion -- 3 The Approach to Munitions Replenishment -- INTRODUCTION -- MUNITIONS REPLENISHMENT POLICY -- TOTALLY INTEGRATED MUNITIONS ENTERPRISE REPLENISHMENT STRATEGY -- CONCERNS REGARDING REPLENISHMENT -- Commercial Manufacturing Environment in the Year 2000 -- Remote Operation of Equipment -- Agile, Lean Manufacturing -- Replenishment as a Technology Transfer Problem -- Labor Force for Replenishment -- State of the Art -- Organizational Learning -- Needs Assessment Tools -- Theoretical Approaches for Organizational Learning -- Theoretical Approaches for Representing Organizational Learning -- Managing Workforce Maintenance and Development -- Maintenance of Replenishment Manufacturing Capability -- 4 Product Realization -- APPROACH TO PRODUCT REALIZATION -- Vision -- Case Study: Product Realization -- Background.

Modeling and Simulation Tools -- Mechanical Piece Parts -- Product Realization Model -- Concept Optimization -- Design Optimization -- Execution -- Conceptual Design Cockpit -- COMMITTEE ASSESSMENT -- Computer Aided Design and Manufacturing -- Modeling and Simulation -- Importance of First Prototype -- Realization -- Multidisciplinary Design -- Rapid Prototyping -- Knowledge, Expertise, and Reasoning -- Realization Speed -- 5 Controllers -- INTRODUCTION -- INDUSTRIAL NEEDS AND DESIRES -- COMMERCIAL OFF-THE-SHELF CONTROLLERS -- Difficult Domain-to-Domain Integration -- Large-Packet Delivery Latencies -- Large Timeouts Due to Packet Failure -- EFFORTS TO DEVELOP OPEN MODULAR ARCHITECTURE CONTROLLERS -- Concept of Open Architecture -- History of Open Architecture -- International Efforts -- Department of Energy Involvement in OMAC -- Approach to the Needs of Commercial and Munitions Industries -- Math-Based Manufacturing -- Reduction of Control System Development and Integration Time -- Incremental Upgrades of Control Systems -- Munitions Industry Needs and Commercial Controller Capabilities -- COMMITTEE ASSESSMENT OF CONTROLLERS -- Needs Versus Wants in the Munitions Industry -- Commercial off-the Shelf Controls Versus Industry Needs -- 6 Demonstration and Validation -- INTRODUCTION -- DEMONSTRATION PROJECTS -- Project Selection -- Concept Validation -- Miniaturized GPS -- Scranton/GMPT Product Data Exchange -- M42 Grenade -- Explosively Formed Penetrator -- Twin-Screw Extruder -- Summary of the Demonstration Projects -- VALIDATION -- Validation of Product Designs and Manufacturing Processes -- Validation Details -- Controller Validation -- Assessment of Validation Plan -- 7 Benchmarks and Metrics -- INTRODUCTION -- VISIONARY MANUFACTURING CHALLENGES FOR 2020 -- Grand Challenge 1: Concurrent Manufacturing.

Grand Challenge 2: Integration of Human and Technical Resources -- Grand Challenge 3: Conversion of Information to Knowledge -- Grand Challenge 4: Environmental Compatibility -- Grand Challenge 5: Reconfigurable Enterprises -- Grand Challenge 6: Innovative Processes -- Summary -- DEFENSE MANUFACTURING IN 2010 AND BEYOND -- Required Manufacturing Capabilities -- Composites Processing and Repair -- Electronics Processes -- Information Technology Systems -- Sustainment -- Design, Modeling, and Simulation -- Production Processes -- Advances in Commercial Manufacturing -- Summary and Recommendations -- A WORD OF CAUTION -- 8 Conclusions and Recommendations -- MUNITIONS MANUFACTURING POLICY -- MUNITIONS INDUSTRY CAPABILITIES -- Modernization of Munitions Industrial Base -- Private Sector Production -- TECHNICAL AND PROGRAM APPROACHES -- PROGRAM PLAN AND SCHEDULE -- References -- A Totally Integrated Munitions Enterprise ManTech Project -- SCOPE -- BACKGROUND -- B Machine Controllers -- INTRODUCTION -- HISTORY OF COMPUTER NUMERICAL CONTROL AND PROGRAMMABLE LOGIC CONTROL -- COMPUTER NUMERICAL CONTROL FUNCTIONS -- User Interface -- Programmable Logic Control -- Machine Executive -- The Rationale for Open Architecture Controls -- PREVIOUS PROGRAMS RELATED TO OPEN ARCHITECTURE CONTROLS -- COMMERCIAL APPLICATIONS FOR OPEN ARCHITECTURE CONTROLLERS -- C Open Modular Architecture Controller -- INTRODUCTION -- MELT POUR OPERATION -- Overview -- OPERATIONAL SCENARIOS -- Projectile Component Pre-Heat -- Melt Kettle -- Pour Machine -- Cooling Bay -- Probe Machine -- Integrated Projectile Handling System -- TWIN SCREW OPERATION -- Overview -- Operational Scenarios -- Material Feed -- Extruder -- Die and Takeaway Area -- CONTROL REQUIREMENTS -- Melt-Pour Program -- Twin Screw Program -- TIME Project Controller Requirements Summary.

Need for a Single Development Environment -- Portability of Logic -- STATE OF COMMERCIAL CONTROLLERS -- Division of PLC and Complex Motion -- Lack of Integration Between Vendors -- DCOM Sets Integration standard -- Difficult Domain-to-Domain Integration -- Possible Large Packet Delivery Latencies -- Large Timeouts on Packet Failure -- COMMERCIAL CONTROLLER SHORTFALLS -- D Biographical Sketches of Committee Members -- E Glossary -- F Acronyms.