Dr. Ronald M. SegaDr. Ronald M. SegaDirector, Defense Research & EngineeringDirector, Defense Research & Engineering

Technology for the Warfighter

Defense Manufacturing ConferenceNovember 27, 2001

Technology for the Warfighter

Defense Manufacturing ConferenceNovember 27, 2001 November 27, 2001

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1. AGENCY USE ONLY (Leaveblank)

2. REPORT DATE11/27/2001

3. REPORT TYPE AND DATES COVEREDBriefing 11/27/2001

4. TITLE AND SUBTITLETechnology for the Warfighter: Defense ManufacturingConference

5. FUNDING NUMBERS

6. AUTHOR(S)Sega, Dr. Ronald M.

7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES) 8. PERFORMING ORGANIZATION REPORT NUMBER

Department of Defense

9. SPONSORING / MONITORING AGENCY NAME(S) AND ADDRESS(ES) 10. SPONSORING / MONITORING AGENCY REPORT NUMBER

11. SUPPLEMENTARY NOTES

12a. DISTRIBUTION / AVAILABILITY STATEMENTApproved for public release; Distribution unlimited

12b. DISTRIBUTION CODE

A

13. ABSTRACT (Maximum 200 Words)

Briefing given by Dr. Ronald Sega about the direction for Defense research and engineering.

14. SUBJECT TERMSIATAC Collection, warfighter, DoD, technology, readiness

15. NUMBER OF PAGES

19

16. PRICE CODE

17. SECURITY CLASSIFICATION OF REPORT

UNCLASSIFIED

18. SECURITY CLASSIFICATION OF THIS PAGE

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20. LIMITATION OF ABSTRACT

UNLIMITED

NSN 7540-01-280-5500 Standard Form 298 (Rev. 2-89)Prescribed by ANSI Std. Z39-18298-102

Quadrennial Defense Review (QDR)September 30, 2001

• Move From “Threat-Based” to “Capabilities-Based” Planning

• Key Military-Technical Trends of Adversaries

• Exploit R&D to Maintain Decisive lead in Technologies

• Develop & Exploit Technologies

• Reduce Cycle Time

““Protecting the American Homeland From Attack is the Protecting the American Homeland From Attack is the Foremost Responsibility Foremost Responsibility of the U.S. Armed Forcesof the U.S. Armed Forces…”…”

Under Secretary of Defense (Acquisition, Technology & Logistics)

• Achieve credibility and effectiveness in the acquisition and logistics support process

• Revitalize the quality and morale of the DoD Acquisition, Technology, and Logistics workforce

• Improve the health of the defense industrial base

• Rationalize the weapon systems and infrastructure with the defense strategy

• Initiate high leverage technologies to create the warfighting capabilities, systems, and strategies of the future

GoalsGoals

Direction for Defense Research and Engineering

• Enable future DoD capabilities through an integrated technology program

• Accelerate technology transition to the warfighter

• Enhance near term technical support• Revitalize the DoD laboratories• Develop, attract and retain a quality

national security technical workforce

Global US InterestsPolitical - Economic - Humanitarian

Globalization of Technology

Asymmetric ThreatsIn any domain - Air, Land, Sea, Space or Information

Year

EstimatedTotal

Bill

ions

of 8

7 $

0

10

20

30

40

50

60

70

80

90

100

1975 1980 1985 1990 1995 20001970196519601955

U.S. Gov. – DoD

U.S. Commercial

DoD

E.U. and Japan

Projected

Source: Report of the Defense Science Board Task Force on the Technology Capabilities of Non-DoD Providers; June 2000; Data provided by the Organizationfor Economic Cooperation and Development & National Science Foundation

0

4

8

12

16

20

24

28

32

36

40

6.5 Engineering andManufacturingDevelopment ($10.3B)

6.4 Demonstration andValidation ($11.4B)

6.3 Advanced TechnologyDevelopment ($3.8B)

6.2 Applied Research ($3.7B)

6.1 Basic Research ($1.3B)

Technology Base(6.1 + 6.2 = $4.9B)

Science and Technology(6.1 + 6.2 + 6.3 = $8.8B)

FY02 RDT&E = $47.2Brequested

(6.1 thru 6.7)

19% of RDT&E

6.6 RDT&E ManagementSupport ($2.5B)

6.7 Operational SystemsDevelopment ($14.2B)

Development(6.4 + 6.5 = $21.6B)

(6.6 + 6.7 = $16.7B)

($B)

.0

.5

1.0

1.5

2.0

2.5

Army Navy Air Force DARPA OSD Other DefAgencies

Basic Research (6.1) Applied Research (6.2) Adv Tech Dev (6.3)

Total FY02S&T= $8.8B

requested

$ B

illio

ns

Technical• Basic Research• JV 2020 Capabilities

– Chemical & Biological Defense– Information Assurance– Hardened & Deeply Buried Targets– Smart Sensor Web– Cognitive Readiness

• Revolutionary Capabilities– High Energy Laser– Electric Drive– Autonomous Systems

• Enabling Capabilities– Propulsion– Software Intensive Systems– High Performance Computing– Modeling & Simulation

Non-Technical• Funding Stability• S&T Workforce• Technology Transition

– Technology Readiness Assessments

– Technology Readiness Levels

S&T Role in Evolutionary Acquisition• DoDD 5000.1

– Rapid Transition From S&T to Products

– Emphasis on Affordability

• DoDI 5000.2– Focus on S&T

Solutions in Pre-Acquisition

– Use Mechanisms with User & Acquisition Customer to Ensure Transition

• DoD 5000.2-R– Conduct Technology

Readiness Assessment for Critical Technologies

Documents Available Athttp://www.acq.osd.mil/ara/Documents Available At

http://www.acq.osd.mil/ara/

Technology Opportunities& User Needs

IOCConcept &

TechnologyDevelopment

SystemDevelopment

& Demonstration

Production &Deployment

Pre-SystemsAcquisition

Systems Acquisition(Engineering Development,

Demonstration, LRIP & Production)

Support

C

Sustainment &Maintenance

� Process entry at MilestonesA, B, or C (or within phases)

� Program outyear fundingwhen it makes sense, but nolater than Milestone B

A B

Defense Acquisition Management FrameworkDefense Acquisition Management Framework

Actual system “flight proven” through successful mission operations

Actual system completed and “flight qualified” through test and demonstration

System prototype demonstration in a operational environment

System/subsystem model or prototype demonstration in a relevant environment

Component and/or breadboard validation in relevant environment

Component and/or breadboard validation in laboratory environment

Analytical and experimental critical function and/or characteristic proof-of-concept

Technology concept and/or application formulated

Basic principles observed and reported

System Test & Operations

System/Subsystem Development

Technology Demonstration

Technology Development

Research to Prove Feasibility

Basic Technology Research

TRL 9

TRL 8

TRL 7

TRL 6TRL 6

TRL 5TRL 5

TRL 4

TRL 3

TRL 2

TRL 1

Assess Technology Maturity

• Technology Readiness Assessments (TRAs) for Critical Technologies– Use Technology Readiness Levels (TRLs), or Some Equivalent

• TRAs Conducted by the Services & Agencies (Except Joint Programs)• Assessments Evaluated by the Dep Under Sec of Defense (S&T)

• Findings Forwarded to the Overarching IPT and Defense Acq. BoardTechnology Readiness Levels (TRLs)

Technology Readiness Assessment (TRA) Example: Joint Strike Fighter (JSF)

FLIGHT SYSTEMSFLIGHT SYSTEMS

STOVL IFPCSTOVL IFPC

MANUFACTURING/MANUFACTURING/PRODUCIBILITYPRODUCIBILITY

INTEGRATED INTEGRATED SUPPORTSUPPORT

MISSION SYSTEMSMISSION SYSTEMS

PROGNOSTICS &PROGNOSTICS &HEALTH MGMTHEALTH MGMT

STRUCTURES &STRUCTURES &MATERIALSMATERIALS

� FADEC SW� VMS SW� IFPC GND TESTS� STOVL FLT CONTROL

FLIGHT DEMONSTRATION

�� LEAN & COMMON TOOLINGLEAN & COMMON TOOLING�� FLOW TIME EFFICIENCESFLOW TIME EFFICIENCES�� 33--D MODELING DESIGN TO FABRICATIOND MODELING DESIGN TO FABRICATION

� AUTONOMIC LOGISTICS� SUPPORTABLE LO

� INTEGRATED RF SYSTEMS� CORE PROCESSING

(ICP) & SOFTWARE� MISSION SYTEMS

INTEGRATION

� UNITIZED COMPOSITES / METALLIC STRUCTURE

� REDUCED MAINTENANCE MANPOWER� INCREASED SORTIE GENERATION RATE� ENABLES AUTONOMIC LOGISTICS

� INTEGRATED SUBSYSTEMS (J/IST)

JSF Digitally Driven Product Design & Manufacture

•• Solid Model DataSolid Model Data– NC Ready Models– Reduced Span

Time

•• Data ReData Re--UseUse– Eliminates

Interpretation Error

– Reduce Task Span Times

•• Digital Product/ Digital Product/ Process Process VerificationVerification

– Form, Fit, & Producibility Verified Prior to Assembly

– Improved Quality– Reduced Cost and

Reduced Risk

Common Digital Data Flow

Digital Fab(NC Driven)

Digital Inspection

Digital Assy (NC Auto Drill)

Lean Assy Planning

Creation Integration Data Re-useSolid Model

Part

Electronic Mock-up

Digital Process Verification

Factory Simulation

RM&S Simulation

Digital Verification Digital Hardware ApplicationsForm Fit Producibility

•Rapid Product Development

• Integrated Product & Process Development (Concurrent Engineering)

• Improved Communications

• Improved Quality•Concurrent Engineering

•Reduction in Changes

• Improved Communications

• Improved Quality•Learning for Reduced T1

•Tooling Reduction

•Reduction in Changes

•Process Flexibility

• Improved Quality•Automated, Repeatable Processes

265D0333-101

265D0421-101 L/H265D0420-101 R/H

EL4202EN6-4EN1182ND68 PLCS NS

Solid Model Tool

Digital Data Data Re-use Eliminates Errors, Drives Down Cost

Air Force Manufacturing Technology (ManTech) Program: F-22 Impact

T/R Modules• Reduced Cost 90%

Comm/Nav Modules• Potential $120M

Cost Avoidance

Multi-Function Radome• $50M Cost Avoidance• Reduced Cycle Time 50%

Integrally Bladed Rotors (IBR)• Reduced Part Count From 87 to 1• Reduced Weight 54lbs

Other ManTech Initiatives• Lean Manufacturing • Digital Product Models• Ultra-thin Castings

Welded Titanium Structure• Potential $100M Cost Avoidance

Subarray Interconnects• $80M Cost Avoidance

Laser Shock Peening• Reduced Cost $10K / Blade• Increased Throughput 6X

Army ManTechEnhanced Manufacturing Processes

for Body Armor Materials

•• Objective:Objective: Develop & Implement Economical Production of Ceramic / Composite Small Arms Protective Plates for Personnel Protection

•• Participants:Participants:– Army Natick Soldier Center– PM, Soldier Systems– Marine Corps– Simula Safety Systems Inc.– CERCOM Inc.

Winner: 2001

Defense ManTech

Achievement Award

Interceptor Body Interceptor Body Armor JacketArmor Jacket

Plate Forming: Plate Forming: Boron CarbideBoron Carbide

Plate Forming: Plate Forming: Siliconized Silicon CarbideSiliconized Silicon Carbide

•• Benefits:Benefits:– Stops Rifle / Machine Gun Fire– 55% Lighter, 60% Lower Cost

Compared to Armor Plates – Cost Avoidance (NPV): $193M

•• Implementation:Implementation:– Over 50K Plates Delivered &

Fielded; 140K Plates on Contract

– Supports “Operation Enduring Freedom”

Bottom Line: Warfighter CapabilityBottom Line: Warfighter Capability

Right Materiel, Right Place, Right Time, at the Right Cost -

All The Time

Director, Defense Research & EngineeringDr. Ronald M. Sega

DDR&E Organization

DUSD, Science & TechnologyDr. Charles J. Holland

Director, Plans & ProgramsMr. Alan R. Shaffer

DUSD, Laboratories and Basic Sciences

Dr. John Hopps

Dir, Defense AdvancedResearch Projects Agency

Dr. Anthony Tether

Dir, Defense ThreatReduction Agency

Dr. Stephen M. Younger

DUSD, AdvancedSystems & Concepts

Ms. Sue Payton

CTO

TechnologyAreas

Capabilities& Budget

Projects and Systems• Efficient Technology Transition• Synergy and Integration of S&T Efforts• Mutual Support for Programs within DoD (and outside of DoD as appropriate)

• Planning• Oversight• Review Programs across

Services and Agencies• Technology “Push”

• DoD Needs Focus (QDR)• Resources• Technology “Pull”

Integrated Approach to Technology in DoD

DATSD, ChemBio Defense Programs

Dr. Anna Johnson-Winegar

DATSD, NuclearMatters

Mr. Frederick Celec

ASD C3IDr. John Stenbit

BMDOLt Gen. Ron Kadish

ATSD, Nuclear, Chemical &Biological Defense Programs

Dr. Dale Klein (Nom)S&TS

Dr. George Schneiter

ARMY

NAVY

AIR FORCE

Impact on V-22

Payoff• Weight Reduction• Increased Maintenance Cycle Time• Improved Performance

LifeLife--Cycle Cost Avoidance Cycle Cost Avoidance Exceeds $45MExceeds $45M

ManTech Project BenefitHeat Treatment for High-Performance Transmissions

Increased Power Density and Loss ofLube Tolerance

Thermoplastic Bearing Cages Reduced Weight by 60%

T406 Engine Vane ActuatorsPowder Injection Molding

Life-cycle Cost Avoidance up to $1.5M

Resin ImpregnatedHoneycomb Core Structures

Excellent Impact Resistance andLighter Structure

Fiber Steering for LightweightComposites

Improved Structural Efficiency

Gear Metrology & PerformancePrediction

Reduced Vibration and Gear Wear

Hi-Speed Gear Inspection Reduced Gear Inspection Time

Non-Contact Work PiecePositioning

Enhanced Precision Machining

Powder Metal Processing ofT406 Turbine Disks

Life-cycle Cost Avoidance up to $19M

In-Situ Composites FiberPlacement

20% Reduction in Fabrication Costs

Smart Sensors/Actuators Increased Operational Capabilities

Ausform Finished Gears Increased Gear Durability

Superalloy CastingTechnology:

Reduced Manufacturing Costs