0708011F Industrial Preparedness

(U) A. Mission Description and Budget Item Justification: This is in Budget Activity 7 - Operational System Development, Research Category 6.6, because it provides support to systems in production and/or in operational use. The Manufacturing Technology (MANTECH) program establishes and demonstrates advancements in manufacturing process technologies, manufacturing engineering systems, and industrial practices and transitions these pervasive advancements into all design, development, acquisition, and/or sustainment programs. The program provides cost reduction processes and practices and new manufacturing capabilities applicable to existing and new programs. The program strives to make superior mission enabling technologies an affordable life cycle reality by expanding access to a capable, responsive, multi-use industrial base with efficiencies comparable to world-class enterprises. Program efforts accelerate shop floor manufacturing process maturation at every stage of development through increased emphasis on cost, time, and quality risks in transition. Best processes are evaluated and adapted for application. Where mature processes are not available, laboratory-developed initial process capabilities are matured and inserted into all programs. The MANTECH program goes beyond the factory floor manufacturing/repair processes to encompass every activity within an industrial enterprise, ranging from above the shop floor activities (including tools for integrating product process development (IPPD)) to supplier base interactions and performance. The strategies and best practices of world-class enterprises are analyzed and the performance of defense suppliers benchmarked. The world's best industrial practices are adapted and validated in multiple pilot projects and deployed in defense applications. Project efforts address and target all industry levels, from large prime contractors to small material and parts vendors. Program efforts also enhance the organic repair/remanufacture capability to affordably sustain the aging weapon systems inventory. Note: Congress added $7.6 million for the Computer-Assisted Technology Transfer (CATT) effort in FY 1996 and $3.0 million for a general program increase in FY 1997 which explains the perceived decrease in FY 1997 and out.

(U) FY 1996 ($ in Thousands):

- (U) $15,355	Demonstrated integrated product/process development tools capable of affecting reduced cost and accelerated cycle time in the design and manufacture of defense systems. Established and demonstrated electronic data exchange concepts and tools and their applications in affecting networked enterprise relationships, product producibility, manufacturing systems interoperability, and technology affordability. - (U) Continued effort to establish and demonstrate the methodologies and tools for the capture of tester-independent test requirements to reduce the warfighter's systems life cycle cost burden. - (U) Continued effort to demonstrate a product definition management system which spans bills of material in multiple production environment.
- (U) $8,469	Facilitated process maturation and standardization for military unique modules, sensors, arrays, solar cells, automatic test systems, and devices to enable the low-risk, affordable utilization of mission enabling technologies. Established and demonstrated process modeling and statistical process control metrics for electronics systems components, materials, test, and inspection techniques. - (U) Continued effort to establish a manufacturing process to produce affordable tactical grade fiber optic gyroscopes. - (U) Demonstrated electronic manufacturing process improvements for low-cost ferrite circulators and for maintenance-free batteries. - (U) Initiated manufacturing efforts on multi-bandgap solar cells for spacecraft to complement Phillips Laboratory development effort.
- (U) $7,793	Established and demonstrated advanced processes for metal material manufacturing. Facilitated process maturation to accelerate affordable, low-risk exploitation of mission enabling technologies. Established process control and improvement aimed at reducing product variability with special emphasis laced on process considerations in the design phase. Achieved industrial base risk reduction by promulgating critical process technologies. - (U) Established manufacturing capacity for large welded titanium assemblies for fighter aircraft. - (U) Demonstrated thin-wall casting manufacturing process for turbine engines leading to product validation.
- (U) $8,590	Established integrated process/product capabilities for the design and manufacture of mission enabling, low-cost composite structures. Facilitated process maturation to accelerate expanded composites utilization. Demonstrated in situ process control and closed-loop improvement capabilities. Achieved industrial base risk reduction by facilitating enhanced composites affordability. - (U) Demonstrated rapid manufacture of thermoplastic ramose spare parts for special purpose aircraft. - (U) Validated reproducible and affordable processes for the manufacture of multi-functional structures for fighter aircraft.
- (U) $16,833	Benchmarked world-class enterprise processes and practices aimed at identifying capabilities and/or approached for reducing cycle time and at eliminating waste and inefficiencies. Conducted pathfinder and pilot efforts in high-payoff endeavors aimed at validating potential benefits accrued from flexible manufacturing, commercial military integration, quality processing, supplier improvements, and integrated product/process development. - (U) Continued pilot efforts to demonstrate manufacture of military electronics components on a commercial line. - (U) Continued effort to implement Lean Aircraft Initiative findings in support of fighter and tactical missile Air Force needs.
- (U) $57,040	Total

(U) FY 1997 ($ in Thousands):

(U) $37,301	Esta Establish and demonstrate cost-effective and efficient manufacturing technologies for critical, high quality, reliable structural, propulsion, and electronic components and assemblies required for existing and next generation aircraft. Conduct pilot efforts in high-payoff endeavors aimed at validating potential benefits accrued from flexible manufacturing, commercial military integration, qual quality processing, and supplier improvements. Conduct long-term projects focused on integrated product process development (IPPD) tools. - (U) Initiate effort to validate revolutionary concepts for manufacture of Òall compositeÓ vehicles at cost of 50% of alternate structures. (U) - (U) Continue effort to reduce investment casting manufacturing costs by 50%, focusing on the gas turbine engine supplier base. - (U) Complete effort for affordable production of multifunctional radomes for fighters, achieving a 30% manufacturing cost reduction. - (U) Establish the capability to reproducibly fabricate affordable, high performance rugate coatings for optical components.
(U) $6,130	Esta Establish and demonstrate cost-effective repair and remanufacturing technologies to affordably sustain existing weapon systems and to enhance mission readiness. Reduce repair and maintenance cycle time for aging systems and establish remanufacturing capabilities able to rapidly generate standardized replacement parts on demand. - (U) Complete effort to provide Air Logistics Centers (ALCs) with the tools needed to prepare spare parts procurement packages. - (U) Establish metal forming simulation remanufacturing processes for logistics centers to generate standardized replacement structures. - (U) Continue lean sustainment effort to transform the aerospace depot maintenance support infrastructure into a world class enterprise. - (U) Complete effort to enable the ALCs to efficiently design and develop a composite secondary structure by providing an automated drafting and analysis capability.
(U) $4,385	Esta Establish and demonstrate efficient and cost-effective manufacturing methods for high performance, high reliability electronics, lightweight structures, and efficient propulsion methods for advanced tactical missiles. Establish manufacturing improvements required to transition precision guided munitions subsystems into production. Conduct pilot efforts in high-payoff endeavors aimed at validating potential benefits accrued from inserting best practices in production of weapon systems. - (U) Complete effort manufacturing processes capable of producing affordable tactical grade fiber optic gyroscopes in support of missiles. - (U) Initiate effort to enable the affordable manufacture of ballistic wind sensors for use in munitions targeting and/or wind shear dete detection systems. - (U) Continue programs to implement lean benchmark findings by demonstrating a modular factory approach to the manufacture of missile components.
(U) $2,816	Esta Establish and demonstrate affordable, flexible manufacturing processes to reduce the cost and lead time of higher performance spac spacecraft and launch vehicles. Establish effective and efficient manufacturing technology for critical high quality, reliable elec electronic components and assemblies required for surveillance, tracking communications links, and data/signal processing. Conduct pilot pilot efforts in high-payoff endeavors aimed at providing an efficient, low-cost capability to produce components and weapon systems in the space, launch, and command, control, communications, and integration (C3I) industrial base sectors. - (U) Continue process refinement phase of effort to establish manufacturing processes for affordable power-efficient, space-qualified multi- bandgap solar cells. - (U) Initiate activity defining benchmarking approach for applying lean principles to space and launch industry sector.
- (U) $50,632	Total

(U) FY 1998 ($ in Thousands):

(U) $34,589	Establish and demonstrate cost-effective manufacturing technologies for critical, high quality, reliable structural, propulsion, and electronic components and assemblies required for existing and next generation aircraft. Conduct pilot efforts in high-payoff endeavors aimed at validating potential benefits accrued from flexible manufacturing, commercial military integration, quality processing, and supplier improvements. Conduct long-term projects focused on integrated product and process development (IPPD) tools. - (U) Complete pilot effort to demonstrate manufacture of military electronics components on a commercial line. - (U) Initiate pilot effort to demonstrate manufacturing development and management of supplier processes, and to implement lean technologies in producing critical defense products. - (U) Complete methodology effort that will establish functional electronic specifications critical to expanded product life.
(U) $8,596	Establish and demonstrate cost-effective repair and remanufacturing technologies to affordability sustain existing weapon systems and to enhance mission readiness. Reduce repair and maintenance cycle time for aging systems and establish remanufacturing capabilities able to rapidly generate standardized replacement parts on demand. - (U) Complete effort to establish and demonstrate the capability to capture electronic device test requirements independent of specific test equipment, thereby, reducing the warfighter's systems life cycle burden. - (U) Initiate efforts such as large area structural repair to establish process improvements for repair/remanufacture of aging aircraft. - (U) Initiate effort to address the issue of electronics parts obsolesence.
(U) $2,575	Establish and demonstrate cost-effective repair and remanufacturing technologies to affordably sustain existing weapon systems and to enhance mission readiness. Reduce repair and maintenance cycle time for aging systems and establish remanufacturing caspabilities able to rapidly generate standardized replacements parts on demand. - (U) Continue effort to establish large area structural repair capability for aging aircraft and to address the issue of electronics parts obsolesence. - (U) Continue effort on lean implementation of turbine engine blade tip repair to cut repair costs and reduce scrap by 30%.
(U) $2,669	Establish and demonstrate affordable, flexible manufacturing processes to reduce the cost and lead time of higher performance spacecraft and launch vehicles. Establish effective and efficient manufacturing technology for critical high quality, reliable electronic components and assemblies required for surveillance, tracking communications links, and data/signal processing. Conduct pilot efforts in high-payoff endeavors aimed at providing an efficient, low-cost capability to produce components and weapon systems in the space, launch, and command, control, communications, and integration (C3I) industrial base sectors. - (U) Initiate process validation phase of effort to establish manufacturing processes for affordable power efficient, space-qualified multi-bandgap solar cells. - (U) Continue effort to infuse lean principles into the defense space industry and initiate pilot efforts on lean concepts in the space and launch industry sector.
(U) $48,429	Total

(U) FY 1999 ($ in Thousands):

(U) $26,377	Establish and demonstrate cost-effective and efficient manufacturing technologies for critical, high quality, reliable structural, propulsion, and electronic components and assemblies required for existing and next generation aircraft. Conduct pilot efforts in high-payoff endeavors aimed at validating potential benefits accrued from flexible manufacturing, commercial military integration, quality processing, and supplier improvements. Conduct long-term projects an integrated product and process development (IPPD) tools. - (U) Continue effort to reduce investment casting manufacturing costs by 50%, focusing on the gas turbine engine supplier base. - (U) Continue effort to validate revolutionary approaches for manufacture of Òall compositeÓ air vehicles at costs of 50% alternative structures. - (U) Initiate effort to improve manufacturing process understanding and reduce process variability. - (U) Complete Phase II of the Lean Aircraft Initiative
(U) $10,504	Establish and demonstrate cost-effective repair and remanufacturing technologies to affordably sustain existing weapon systems and to enhance mission readiness. Reduce repair and maintenance cycle time for aging systems and establish remanufacturing capabilities able to rapidly generate standardized replacements parts on demand. - (U) Continue effort to establish large composite patch repair capability for aging aircraft. - (U) Initiate effort to address the issue of electronics parts obsolescence. - (U) Continue effort on lean implementation of turbine engine blade tip repair to cut repair costs and reduce scrap by 30%. - (U) Initiate manufacturing processing effort to improve the high cycle fatigue performance of turbine engine components.
(U) $3,051	Establish and demonstrate efficient and cost-effective manufacturing methods for high performance, high reliability electronics, lightweight structures, and efficient propulsion methods for advanced tactical missiles. Establish manufacturing improvements required to transition precision guided munitions subsystems into production. Conduct pilot efforts in high-payoff endeavors aimed at validating potential benefits accrued from flexible manufacturing, commercial military integration, quality processing, and supplier improvements. - (U) Continue effort to enable the affordable manufacture of ballistic wind sensor for use in munitions targeting and/or wind shear detection systems
(U) $5,991	Establish and demonstrate affordable, flexible manufacturing processes to reduce the cost and lead time of higher performance spacecraft and launch vehicles. Establish effective and efficient manufacturing technology for critical high quality, reliable electronic components and assemblies required for surveillance, tracking communications links, and data/signal processing. Conduct pilot efforts in high-payoff endeavors aimed at providing an efficient, low-cost capability to produce components and weapon systems in the space, launch, and command, control, communications, and integration (C3I) industrial base sectors. - (U) Complete effort to establish manufacturing processes for affordable power-efficient, space-qualified multi-bandgap solar cells. - (U) Continue Lean Space Initiative. - (U) Initiate Lean Space implementation pilots.
(U) $45,923	Total

(U) B. Program Change Summary ($ in Thousands):

	FY 1996	FY 1997	FY 1998	FY 1999	Total Cost
(U) Previous President's Budget	57,945	49,969	51,851	51,811	Cont
(U) Appropriated Value	60,932	52,969
(U) Adjustments to Appropriated Value
a. Congressional/General Reductions	-1,181	-1,145
b. SBIR	-1,150	-1,143
c. Omnibus/Other Above Threshold Reprogrammings	-1,617	-49
d. Below Threshold Reprogrammings	+56
(U) Adjustments to Budget Years			-3,422	-5,888
(U) Current Budget Submit/FY 1998 PB	57,040	50,632	48,429	45,923	Cont

(U) Change Summary Explanation:

Funding: Changes since the previous President's Budget are due to budget constraints and Air Force priorities.

Schedule: Not Applicable.

Technical: Not Applicable.

(U) C. Other Program Funding Summary: Not Applicable.

(U) D. Schedule Profile: Not Applicable.