Casting and Forging Program Assistance

1
Casting and Forging Program Assistance

• Christopher D. Brust
• DSCR-VEA Value Engineering
• DSCR Casting Forging Program Manager
• June 7-8, 2005

2
Agenda

• DSCR Casting Forging Program
• American Metalcasting Consortium Program (AMC)
• Defense Tooling Locator (Castings)
• Forging Defense Manufacturing Consortium (FDMC)
• National Forging Tooling Database
• Q A
• Summary

3
Two Programs-A Common Plan

• DLA has implemented two industry cost shared,
  manufacturing technology programs, to address
  business enterprise technical needs and key
  industries of DoD
• PRO-ACT - supported by the American Metalcasting
  Consortium (AMC), managed by Advanced Technology
  Institute (ATI).
• PRO-FAST - supported by the Forging Defense
  Manufacturing Consortium (FDMC), managed by ATI.
• Three Parts to the Programs
• NSN Part Problem Resolution
• Training for Government Personnel
• Research Development
• Potential Population of NSNs Impacted is 300K

4
Castings and Forgings are a Backorder Problem

• DSCR estimates 5 of NSNs contain cast or forged
  (C/F) content
• C/F NSNs comprise 10 of all backorders
• C/F NSNs comprise 15 of the oldest backorders
• Why?
• No C/F suppliers
• No tooling
• Obsolete drawings and specifications
• No response to solicitation

5
NSN Part Problem Resolution

• SCOPE The NSN has a casting/forging that is
  causing readiness problems for an aircraft
  supported by DSCR
• GOAL Reduce Back Orders, ALT PLT via Internal
  Process Improvement, Resolve Technical Data
  Issues, and Assist Contractors with C/F Issues
• PRO-ACTIVE EFFORTS Changing the Way We Do
  Business for These Complex Parts via Additional
  Information in the Solicitation
• PARTNERING
• The X-IT Team is the combination of DSCR Value
  Engineering, AMC Engineers and FDMC Engineers.
• Through established relationships with their
  industry associations and member companies,
  second tier commercial metalcasting/forging
  supply chain capability is deployed.
• The Team collaboratively resolves the problem
  with the ICP, ESA, OEM, Prime Contractor, and
  Foundry/Forge as required

6
How X-IT Can Help

• Sourcing - Inability to Manufacture due to
  unresponsive C/F supply chain
• Tooling - Inability to Manufacture due to
  unavailable tooling
• Technical Field Support to Foundry/Forge
• Update TDP with current specifications,
  processes, etc
• Assist Engineering Support Activity in expediting
  required Engineering Analysis/Response

7
Research Development

• Collaborative RD Effort Among Government,
  Industry Academia
• Rapid Tooling
• National Tooling Databases
• Part Quality Simulation Tools

8
An OEMs View of Castings RD

• Castings can provide formidable benefits in
  aerospace structural applications.
• The OEM recognizes the cost and time savings
  that castings can provide.
• Despite the benefits achievable with castings,
  we have not fully realized their
  potentialcastings are the worst performing
  commodity in terms of delivery and quality this
  type of industry performance has resulted in a
  lack of confidence in castings.
• What we need are optimally designed castings,
  reliable in quality, and delivered on time.
• Your work at UAB with computer simulations and
  non-destructive testing techniques resonates with
  our aerospace casting development expectations.
• It is my hope that UAB will continue to work
  with our company and our casting suppliers in
  advancing casting technology Thank you for your
  efforts in promoting this research.

9
View of FDMCfrom DLA and Industry

• The UH-60M program would not have a forging
  improvement program if it werent for PRO-FORGE.
• Our training efforts continue to expose the
  complexities of the forging process to DSCR
  personnelgiving them the ability to better
  interact with customers and suppliers. The way
  that DLA conducts its business is changing and
  the forging effort supports that change.
• The RSP Tooling process will revolutionize the
  forging industry when the machine capability can
  be increased to produce larger tools and molds.
• JSLEAN works! PFAST works! The savings we are
  experiencing from the implementations is a
  definite proof that Lean works.
• The National Forging Tooling Database holds
  promise for the future here at DSCC in terms of
  locating sources, both old and new, for forgings.
  Knowing the location of tooling can help
  re-connect an old supply chain or create a new
  supply chain for a hard-to-find part.
• 2004 has been a year of exceptional effort and
  inroads on the part of the forging teams effort
  much has been done to improve supply
  availability.

10
AMC PRO-ACT

• Michael Bess
• PRO-ACT Cast-It Application Engineer
• June 7-8, 2005

11
Complex Metal Shapes

• Structural, mechanical, engineered applications
• Formed from liquid metal
• Produced in a mold (sand, refractory, metal)
• Made from iron, steel, aluminum, magnesium,
  copper, titanium
• Often are components of an assembly

12
Casting Flow Chart
Technical requirements assessed (AQP)
Process and solidification modeling
New order received
Tooling constructed
First article cast, inspected, approved by
customer
Production castings poured
Secondary processing (gate removal, heat
treatment, machining)
NDE and final inspection
Assemble with system components
Packaging
Shipment
13
DLAs Needs

• Procure high-quality, cost-effective cast parts
  for legacy weapon systems to meet readiness
  requirements
• Problems
• Identifying cast parts / components at the NSN
  level
• Root cause analysis on backordered deliveries
• Diminishing manufacturing sources
• Design and specification deviations
• Tooling availability

14
AMCs Strategic Direction

• Ensure a casting supply chain for DLAs aging
  weapon systems
• Apply new casting technologies to reduce
  administrative and production lead times
• Utilize casting experience and knowledge to solve
  supply chain backorders
• Strengthen the casting supply chain to ensure a
  dependable US manufacturing base for the future
• Incorporate AMC information into DLAs
  procurement processes (BSM) to improve readiness

15
Casting Program Foci

• NSN leadtime/backorder problems
• One-by-one attack on current backordered NSNs
• Reduce potential procurement process delays
• Developing new casting technologies
• Reduce overall lead times
• Improving part quality
• Integrating new technologies into the foundry
  industry to ensure future sources

16
Supplying Parts for Legacy Weapon Systems Like
the A-10
17
Benchmarking Site Visits

• Instructional seminar
• casting fundamentals
• concepts and processes
• Five seminars to date 123 attendees
• Next event for DSCR Fall 2005

As a procurement person, I now see why it is not
always best to go with the lowest cost offer.
Stepheny Finnie, Contract Specialist, BSM
Organization
18
NSN Part Problem Resolution

• F-5 Crossbleed Valve Body (2995-01-088-7021)
• Problem DLA Backorder - Foundry Technical Issue
• Resolution
• The cast design was improved by AMC and approved
  by the ESA
• The metal feed system on the cast part tooling
  was modified
• Result
• The new foundry tried several times to make good
  castings with no success. I got a call from
  American Metalcasting Consortium and they told me
  that they work for the Government AMC and the
  new foundry solved the problems with the castings
  and got them to pass x-ray. The castings are now
  being machined. The problem area for porosity has
  been machined and there have been no defects or
  rejections.
• John Stallbaumer, Triumph Accessory Services

19
NSN Part Problem Resolution

• KC-135 Rudder Bracket (1560-00-592-5957)
• Problem No bids due to conflicting quality
  requirements
• Resolution
• Eliminate Specification Creep
• Worked with ESA to resolve issue
• Result PID modified to INSPECT CASTING PER
  SAE AMS 2175 CLASS 2 GRADE C I/L/O MIL-C-6021
  CLASS 1B. RADIOGRAPHIC INSPECT PER MIL-STD-453

20
Short Run Tooling Advisor

• Technical Description
• Web-based software for selection of best rapid
  tooling technology for short run castings
• Available to DoD and commercial engineering /
  procurement personnel
• Intuitive, Windows-style user interface
• Estimates lead-times and tooling costs
• Benefits
• Improve supply-chain management process of
  short-run tooling and cast parts

Process considerations from various types of
casting
Tooling Process Capability
Needs/ Constraints for type
Intelligent Tooling and Geometry Advisor
Needs/ Constraints of Geometry
Needs/ Constraints for quality, cost, material
quality
Designer and/or Procurement
21
Rapid Tooling for Metal Mold Processes
Objectives Develop rapid, cost effective
methods for fabricating metal tooling for low
volume casting needs Approach Evaluate and
optimize die/mold material selection and
fabrication method for prototype quantities of
castings

• Deliverables
• On-line database of guidelines for selection of
  materials and fabrication methods for rapid metal
  tooling that will promote
• Shorter lead times Lower cost
• Tighter tolerances
• More metal molded castings
• for DLA low volume, high specification casting
  procurements

22
Industry Major Trends

• Foundries Are Merging/Closing
• Foundries Are Redefining Their Business Model
• Foundries Pursuing Value Added Products
• Foundries keeping complex shapes while letting go
  of simple shapes to overseas competitors

23
Industry Major Trends (continued)

• Foundries Slowly Adopting EDI/EC
• Foundries Slowly Adopting New Technology
• Work Force is Aging and is Not Rapidly Being
  Replaced by Young Engineers or Technicians
• Loss of Market Share to Simpler Designs,
  Alternate Materials or Processes
• Foundries Slowly Becoming ISO or QS Compliant or
  Certified

24
Identifying the Proper Foundry Source

• In general look for a foundry that has production
  experience with
• The alloy
• The geometry
• The quality
• The quantity
• The process
• First Article Test requirements
• Understand the importance of tooling
• Significantly influences lead-time
• A significant cost factor

25
Other Considerations

• The importance of a casting drawing in the TDP
• Specifies permissible weld repair
• Details extent of casting defects
• Solid model vs. 2D drawing
• Heres what to watch out for if you dont have
  one
• Datum Targets Machining stock Tolerances
  Surface finish (cast/machined) Inspection
  requirements/QA
• Collaboration is a success factor - talk to your
  foundry early and often, and visit in person if
  possible

26
If You Are Uncertain That a NSN Includes a
Casting

• Look at the notes section on the drawing for a
  casting process (i.e. sand investment permanent
  mold)
• Look at the detail listings (bill of materials)
  or separate parts list where it calls out alloys
  and processes
• Check on-line specs and standards for reference
• Defense Standards
• http//assist2.daps.dla.mil/quicksearch
• SAE Website for AMS standards http//www.sae.org/t
  echnicalcommittees/index.htm

27
When to Call for X-IT/AMC Assistance?

• When a NSN involves a casting
• To identify a casting process (this may be buried
  in a OEM specification and not be apparent)
• As-cast tolerances
• Surface Finish Requirements
• For assistance with interpreting a specification
• To find potential tooling sources
• To find potential casting sources
• To identify the material or alloy (this may be
  buried in an OEM specification and not be
  apparent)
• For assistance in understanding a casting process

28
Additional Resources

• Metalcasting source identification search
  capabilities
• Metalcasting application tutorials
• Metalcasting abstract literature search
• http//www.sfsa.org
• http//www.afsinc.org
• http//www.diecasting.org
• http//www.nffs.org

29
Remember.

• Using AMC does not change your contractual
  responsibility
• AMC is not part of your contract
• AMC won't charge you, AMC won't pay you
• AMC is available to consult and assist
• AMC is an industrial organization, not government
• AMC cannot approve any tech data changes
• AMCs input does not change anything in the Terms
  and Conditions of the contract

30
Defense Tooling Locatorhttp//www.defensetooling.
net

• .an online searchable database of
  defense-related patterns
• Provides a resource for DLA to reduce production
  costs lead-time associated with backorder parts
• Strengthens supply chain management
• Free online resource for contractors to locate
  tooling/suppliers
• Provides additional business opportunities
• Contact
• Ryan Moore, Program Manager
• [phone] ryanm_at_nffs.org

31
http//www.defensetooling.net
32
(No Transcript)
33
(No Transcript)
34
(No Transcript)
35
(No Transcript)
36
(No Transcript)
37
Acknowledgement
The PRO-ACT program is sponsored by the Defense
Logistics Agency, Industrial Capabilities
Division, DLA-J339, Ft. Belvoir, VA.
38
Aviation Supply Chain Business ConferenceJune
7-8, 2005
Jon Tirpak, FASM PRO FAST Program Manager FDMC
Executive Director Engineering Director
ATI [phone] tirpak_at_aticorp.org
39
Objectives

• Provide an overview of
• Forging Defense Manufacturing Consortium
• Current projects
• Additional information

40
Organization


41
Inside FDMC

• BEI - business enterprise research projects
• FORGE-IT Team problem solvers
• RD technical research projects

42
Inside FDMC
The projects...providing solutions for
government and the forging industry...
43
National Forging Tooling Database

• Bridges gap between existing tooling and
  government procurement
• Saves cost and lead-time of new tooling
• Part order quantities typically low
• Utilizes existing tooling at forge shops
• Helps forged parts remain forgings

44
Production Flow Analysis

• Lean manufacturing for high volume, low mix
  operations (forge shops, machine shops, etc.)
• Develops improvement scenarios for
• Existing layout
• Slightly modified layouts
• Highly modified layouts
• Reduced lead-time
• Reduced work in process (WIP)
• Increased production capacity

45
FORGE-IT Team

• Technical Solutions
• TDP (drawing, process, material, engineering
  quality requirements)
• Tooling
• Performance
• Quality
• Coordinate with ESA

• Enterprise Solutions
• Quote
• Price
• Lead time
• Sourcing (requires ESA approval)

Combination of Solutions Involve elements of
both enterprise and technical solutions
46
FORGE-IT Interaction

• DLA/DoD
• Identifying problem forged parts
• Addressing backordered parts
• Verifying supply chain capabilities
• Forging education
• Industry
• Provide training to forgers and OEMs
• Selling to the Government
• Forging education
• Identify government procurement of forgings

47
NSN 1620-01-252-3344F-16 MLG Inner Piston
Problem

• No known forging source

Actions

• Identified two sources for the forging
• Both forging sources have existing tooling
• Provided forging source POC and quote information

48
A-10 Fitting, StructuralHog-up Aft Wing Fitting

• Problem
• Part has one approved forging source
• OEM owns tooling rights
• Initial DLA contract award made to supplier that
  had not received permission to utilize forging
  tooling
• Contract cancelled
• Parts backordered
• FORGE-IT Actions
• Worked with previous supplier to provide
  
  additional quote for the 58 pieces, and
  
  subsequent 200 piece order
• Worked with DSCR and approved forge
  shop to
  ensure quotes are valid
• Procurement documentation now includes
  written
  quoting requirements to verify
  bidder
  has access to approved forgings

49
NSN 1560-00-966-6796 F-4 Bell Crank
Problem

• No forging source available

Actions

• Identified source for the forging
• Forging source has existing tooling
• Provided forging source POC and quote information

50
Relationship Map

• All three must work together to improve the
  supply chain!

51
Rapid Tooling

• Rapid tooling manufacturing method can reduce
  lead-time and cost
• RSP Tooling (Rapid Solidification Process)
• From CAD to tool in one week
• Many spare part orders...
• ...are low quantity
• ...have no existing tooling

52
Forging Simulation

• Improve part quality
• Increase die life
• Decrease cycle time
• Minimize development time on production equipment
• Analyze production operations
• Part quality deficiencies
• Tooling failures

53
PRO FORGEOEM Partnership

• PRO FORGE Team
• Forging Design and Acquisition
• Collaborate with suppliers
• Lean manufacturing
• Supply chain responsiveness
• Utilize DSCR X-IT Team processes
• Respond to DLA needs

54
PRO FORGEProcess Flow
Revision original 6/24/04
55
Metrics UH60M
Equivalent to 8 aircraft
Present value
56
National Forging Tooling Database(NFTD)
57
NFTD Summary(As of May 12, 2005)

• Database of forging tooling!
• 122,832 part numbers
• 62,004 dies correlated with NSNs
• Access is through IHS Haystack www.ihs.com
• Search by
• NSN
• NIIN
• Part Number
• Weapon System

58
NFTD Example NSN 2520-00-796-3997

• Flange, Companion, Universal Joint
• M109 Self Propelled Howitzer (155mm)
• NFTD provided existing tooling location
• Supplier ordered forgings from existing source
• Leadtime Savings 100 to 150 days
• Cost Savings 15,000

59
Example Search
60
Forging Industry Association RFQ Website
61
www.forging.org
62
Request for Quote Button
Click on it!
63
Request for QuoteIntroduction Page
Click on it!
64
Request for Quote Button
65
Request for Quote Button
66
Request for Quote Button
Attach a file! (sketch, drawing, etc)
67
Request for QuoteSubmit Button
Click on Submit button and your RFQ is e-mailed
to over 100 forgers!
68
Request for QuoteCompleted

• What happens after RFQ is submitted?
• A confirmation screen will appear
• You will receive an e-mail confirmation,
  including a copy of your RFQ info
• Forge shops will evaluate the RFQ and respond
  accordingly

69
Forging Industry

• Most forge shops are small/medium sized
  businesses
• Forging business is increasing
• Top five concerns for forgers
• Energy costs
• Medical insurance costs
• Raw material costs
• Raw material leadtimes
• Foreign competition
• Forging supply base is consolidating
• 22 of forgers use forging simulation
• 60 of forgers plan to buy new equipment this year

70
http//fdmc.aticorp.org/
71
Acknowledgements

• The PRO-FAST Program is enabled by the dedicated
  team of professionals representing the Department
  of Defense and industry. We are determined to
  ensure the Nations forging industry is
  positioned for the challenges of the 21st
  Century.
• Key team members include
• RD Enterprise Team (DLA J339), Logistics
  Research and Development Branch (DLA DSCP), and
  the Forging Industry Association.

72
Questions Answers

73
Take Aways

• X-IT is a Pre-positioned Resource to Solve
  Casting Forging Issues
• Charter with Aviation Engines Airframes
  Division PID with Table A1202
• Searchable Web Based National Tooling Databases
• Define Cast/Forged Requirement to Preclude Issues
  on Future Procurements
• BSM Working towards adding more data to the
  solicitation
• Government Training Benchmarking Site Visits,
  Seminars
• Engagement DSCR-VE Booth

74
For More Information Visit our WebsitesFor AMC
 http//amc.aticorp.org/For FDMC
http//fdmc.aticorp.org/

• Contact Us
• Christopher Brust [phone]
• Christopher.Brust_at_dla.mil
• CASTINGS
• Michael Bess [phone]
• bess_at_aticorp.org
• FORGINGS
• Russell Beard [phone]
• beard_at_aticorp.org