1. Shaping the Future Tobyhanna Army Depot’s Successful Partnership with Commercial Technologies for Maintenance Activities Rick Foley Electronics Engineer New Technology R&D Div 25 July 2007

2. ISO 9001:2000/14001:2004 Facility Shingo Award Winner Completed Projects ✔ e-Collaborative Maintenance for Depot Repairs and Manufacturing ✔ Rapid Response Computer Aided Manufacture of Printed Wiring Boards ✔ Embedded Decoupling Capacitance (EDC)—Phase I ✔ Workflow Process Automation with Automatic Status Reporting II ✔ Enhanced Wiring Integrity Systems (EWIS) ✔ Affordable High-Density Chip On Board ✔ Isotropically Conductive Adhesives

3. ISO 9001:2000/14001:2004 Facility Shingo Award Winner Completed Projects Embedded Decoupling Capacitance Test Vehicle 2 Top

4. ISO 9001:2000/14001:2004 Facility Shingo Award Winner Completed Projects Eclypse EWIS Operational Tools

5. ISO 9001:2000/14001:2004 Facility Shingo Award Winner Current Projects ✔ Automatic Test Equipment (ATE) Test Program Set (TPS) Migration System ✔ OptiCAM Phase III/IV ✔ Static Event Detector Initiative (SED) ✔ ATE Synthetic Instrumentation Insertion

6. ISO 9001:2000/14001:2004 Facility Shingo Award Winner ATE TPS Migration System ✔ Objective: ●Minimize recurring costs when migrating TPS to new ATE platforms ●Develop automated methods for extracting test requirements from legacy ATE/TPS ●Develop “Middleware” to generate new TPS on modern systems ●Enable data collection for trend analysis and knowledge base ✔ Benefits: ●An integrated set of tools running on Microsoft Windows –Perform test program screening –Represent original source code in a neutral format –Automatically allocate resources with operator selection capability –Output new source code ✔ Status: Green ●TPS 2 and 3 integration completed ●TPS 1 ran successfully on WR-ALC hardware ✔ Future : ●Completion of onsite effort at WR-ALC ● Finial Report

7. ISO 9001:2000/14001:2004 Facility Shingo Award Winner ATE TPS Migration System

8. ISO 9001:2000/14001:2004 Facility Shingo Award Winner ATE TPS Migration System Legacy ATE Technology New ATE Technology

9. ISO 9001:2000/14001:2004 Facility Shingo Award Winner OptiCAM Phase III/IV ✔ Objective: ●To develop and deploy an improved, more accurate method of creating 3D models ●Employ advanced 3D imaging and capturing technology ●Create the initial steps in a new Reverse Engineering process ✔ Benefits: ●Scan time reduced by 50% over Laser or Coordinate Measuring Machine (CMM) ●Processing time for a good surface model reduced 50% versus manual registration ●Measurement of Productivity impacts ✔ Status: Green ●Teamcenter TM in place at Spatial Integrated Systems (SIS) ●VZX imaging system updated ●VZX and UGS imaging software enhanced ●Accuracy approaching 0.005 inches ✔ Future : ●Determination of data storage methodology ●Enhancement of point data processing ●Performance metrics data collection ●Finial Report

10. ISO 9001:2000/14001:2004 Facility Shingo Award Winner OptiCAM Phase III/IV

11. ISO 9001:2000/14001:2004 Facility Shingo Award Winner OptiCAM Phase III/IV Process Flow

12. ISO 9001:2000/14001:2004 Facility Shingo Award Winner OptiCAM Phase III/IV

13. ISO 9001:2000/14001:2004 Facility Shingo Award Winner SEDSED ✔ Objective: ●Develop a Static Event Detector Health Monitoring system –Alerts personnel of a Electro Static Discharge (ESD) event ●Fabricate a Magneto-Optic Static Event Detector (MOSED) –Capable of being interrogated by an optical reader ✔ Benefits: ●Confirmation of a ESD event ●Activation of special tests to ensure operational reliability ✔ Status: Green ●MOSED devices and prototype optical reader successfully demonstrated ✔ Future : ●Completion of improvements to –Reader auto focus –Optical recognition software –MOSED packaging –Demonstration and testing on site at Tobyhanna Army Depot (TYAD)

14. ISO 9001:2000/14001:2004 Facility Shingo Award Winner SEDSED

15. ISO 9001:2000/14001:2004 Facility Shingo Award Winner SEDSED Figure 1.MOSED device Showing Tripped Condition Indicating A Static Discharge Event Occurred (squiggly lines in left side square) Figure 2.The Static Sensitive Test Circuit. The MOSEDs are mounted in three component packages. The test circuits were used to demonstrate confirmation of a static discharge event. Figure 3. Pictures (a) and (b) of the Prototype Reader Showing Top and Side Views (a) (b)

16. ISO 9001:2000/14001:2004 Facility Shingo Award Winner ATE Synthetic Instrumentation Insertion ✔ Objective: ●Utilize advances in Commercial Off The Self (COTS) ATE ●Reduce the costs of acquisition, operation, maintenance, support and obsolescence for DoD ATE ✔ Benefits: ●Reduced burden for storage, documentation, mobilization and training ●Increased performance ●60 day User Trial ✔ Status: Green ●Technical effort completed ●User Trial completed –Extended to 5months –End to End performance 5 times faster –Mean Time To Repair (MTTR) 4 times faster ✔ Future : ●Expand the Synthetic instrument suite ●Increase the family of Units Under Test (UUT) ●Allow for testing up to a frequency of 12.4 GHz ●60 day User Trial

17. ISO 9001:2000/14001:2004 Facility Shingo Award Winner ATE Synthetic Instrumentation Insertion

18. ISO 9001:2000/14001:2004 Facility Shingo Award Winner ATE Synthetic Instrumentation Insertion CTMA SI Suite

19. ISO 9001:2000/14001:2004 Facility Shingo Award Winner Future Projects ✔ Rapid Manufacturing & Rapid Repair (RM&R) ✔ Laser Projection of Camouflage Patterns

20. ISO 9001:2000/14001:2004 Facility Shingo Award Winner RM&RRM&R DoD Sites and Platforms: US Navy: TRF Kings Bay, NUWC Keyport, NFPC Philadelphia Detachment, NAVAIR China Lake, Portsmouth & Pearl Harbor Naval Shipyards US Army: Anniston & Tobyhanna Army Depots US Air Force: OC-ALC, Other Government: DOE, NNSA – Honeywell FM&T NASA – Marshall Space Flight Center Technology Transfer: Inserted 12 pieces of ADF-RP equipment into DoD Maintenance facilities and 12 pieces of ADF-RP equipment for initial piloting at industrial partners - conducted >68 case studies to date Problem: Military depot facilities need fabrication processes and engineered materials to build or repair hard-to-replace legacy parts Need to reduce long-lead-times for cast parts with unavailable data packages through use of rapid molds and patterns Need to reduce long-lead-times for other parts with unavailable data packages through use of ADF-RP processes Technology Application: ADF-RP processes include laser sintering (LS), electron beam melting (EBM), stereo-lithography (SLA), fused deposition modeling (FDM), direct metal deposition (DMD), and ultrasonic consolidation. Objective is to install rapid tooling capability in at least one maintenance facility Industry/government Team pilots the building of net-shape and near-net-shape parts, directly or indirectly using ADF-RP, in parent alloys and engineered materials, evaluating materials and process performance parameters Readiness Benefits: Cycle Time: >280 weeks of cycle time savings* Cost: >$4.5 MM in cost avoidance* Reliability: Parts verified by CAD, RP models, metallurgical & performance testing to spec Availability: Continuous improvement - key enabler to system maintenance turn around improvements *See Case Studies for part & weapon system information

21. ISO 9001:2000/14001:2004 Facility Shingo Award Winner Laser Projection of Camouflage Patterns ✔ Problem: ●Every system repaired or fabricated at Tobyhanna AD is painted by the Paint Shop in the Mobile Equipment Refinishing Branch, a historical bottleneck to system flow. ●Chalking of the Camouflage and stencil patterns is a manual method dependent on the skill of the technician. ●Cycle time reduction is required to make the painting operation more efficient and to reduce the disruption of the product flow while increasing quality. ●A method to reduce dependence on the skill of the technician and to reduce the time required to manually chalk a system and to change to another system is required. ✔ Technical Approach: ●Demonstrate a system and techniques of Laser Projection Technology from Assembly Guidance. ●Full setup by a trained shop person (30 minutes training) is less than 2 minutes, each dimension thereafter is available in less than 4 seconds, and low accuracy coverage of five sides of large structures can be accomplished with two projectors, each covering 2 1/2 sides. Subject application was a shelter. ●The system can also rapidly change between product systems like shelters, trailers and vans. (Would require building models and digital data package for each model.) ●Development tasks in bringing the commercial technology to a production level for maintenance activities include: data creation, process configuration and new reference targeting methods. ✔ Projected Benefits: ●Delivery of multiple Laser Projection heads and a Lap Top Computer plus control software. The hardware will also include any electro-mechanical devices necessary to facilitate the rapid change between systems. ●$35k savings for one shelter application ●a Laser Projection System can reduce the time to chalk the camouflage pattern by.5 hours. This does not include the stencil package where the Laser projector would eliminate time required to measure for the location of the stencil. Therefore the payback on 80 items would be one week. Extrapolate that to a year at 80 items

22. ISO 9001:2000/14001:2004 Facility Shingo Award Winner Laser Projection of Camouflage Patterns Laser will project around edges Chalking of projected shape Technology Demonstration