Team Members & Role:
- Alexa Attleson – Team Lead
- Tyler Millay – Design Lead
- Hunter Williams – Fabrication Lead
- Andrew Ruggiero – Evaluation Lead
- Henry Lanza – Analysis Lead
Abstract:
General Dynamics Missions Systems is a military contractor who provides products and technology to several nations’ Military and Naval sectors. They are an original equipment manufacturer and technology integrator with expertise in land, sea, air, space, and cyber security. Among other components, General Dynamics produces Missile and Tube Interface Boxes that house the weapon systems and subsystems on the second and third Columbia Class submarines for the US Navy and Dreadnought Class submarines for the UK Navy. The boxes are bolted together during assembly and then pinned in 16 locations in order to pass the standard vibration test that simulates real-time conditions aboard a submarine. General Dynamics has a 20-year contract with the US Navy and UK Navy to produce these components. Through 2023, the US and UK Navy covers the cost of materials and labor to produce the components and then will pay a flat rate for each enclosure for the remainder of the contract. Team 9707 has been tasked with reducing the time of the drilling and pinning process by 50% in order to minimize production costs before the fixed price per unit takes effect. General Dynamicswas awarded the contract in July 2022, and it currently takes a single operator 22+ hours to set up, drill, clean, and pin one box due to the size and precision required. The General Dynamics Mission Systems facility in Pittsfield, MA has tasked each newly hired entry-level engineer since the contract began with improving the process, to no success thus far. The operators have made small changes themselves with the addition of drilling jigs, alignment aids, and multi-use paint protection. Team 9707’s solution is to change the current drilling and pinning process by implementing various improvements and fixture changes. The first process adjustment eliminates multiple changes to the cabinet’s orientation (currently performed via crane) by implementing a work positioner. A work positioner allows access to all locations needed to be drilled and pinned with the cabinet in one position. Additionally, the team has designed a drilling jig. The jig allows each hole to be drilled with a hand drill which improves mobility while also maintaining the benefits of a drill press. The team is also implementing a commercial blind hole cleaner to ensure each hole is free of chips and coolant before the pin is inserted. The culmination of each of these process adjustments will drastically reduce the time required for drilling and pinning in order to maximize the production cost reduction.
