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Ground Systems Industrial Enterprise

Leadership Teaming Communication Employee Support Strategic Thinking Organizational Climate Ground Systems Industrial Enterprise Transforming the Industrial Base T ank-automotive & A rmaments COM mand Outline GSIE overview, capabilities, and intent

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Ground Systems Industrial Enterprise

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  1. Leadership Teaming Communication Employee Support Strategic Thinking Organizational Climate Ground Systems Industrial Enterprise Transforming the Industrial Base Tank-automotive & Armaments COMmand

  2. Outline • GSIE overview, capabilities, and intent • Initiatives to date • Legislative reform • Financial reform • Lean initiatives • Workforce revitalization • Infrastructure reduction • Summary

  3. GSIE Overview • Combines the capabilities of Anniston, Red River, and Sierra Army Depots, Rock Island and Watervliet Arsenals, and the Lima Army Tank Plant into a single Enterprise • Designed to leverage the capabilities of the ground systems industrial base • Goal is to continuously improve support to soldiers while reducing the cost of products and services to a level comparable with industry without the need for subsidies

  4. GSIE Capabilities • Engineering and Prototyping • Manufacturing • Maintenance and Overhaul • Field Services

  5. Engineering and Prototyping • Product Design and Development • Rapid Prototyping • System/Component Simulation • CAD/CAM/CIM (Unigraphics/ProE/Autocad) • Dynamic/Stress Analysis • Material Testing • Chemical Analysis • Oil and Lubrication • Metallurgical/Rubber • Manufacturing Support • Product Redesign/Improvement • Lean/Six Sigma/ABC

  6. Manufacturing • Precision Machining • 7-axis Machining Centers • CNC/Automated Cellular/Flexible Machining • Fabrication/Assembly • Welding (Robotic, Submerged, Orbital, etc.) • Ferrous, Non-Ferrous, Composites, Rubber, and Titanium • Casting/Forging • Cannon Tubes • Ferrous, Non-Ferrous, and Titanium • Heat Treatment/Plating/Finishes • Cylinder/Cannon Tube Chrome Plating • Chemical Agent Resistive Coating (CARC) Painting • Tool, Die, and Gage

  7. Maintenance and Overhaul • Systems/Subsystems Support • Wheeled and Tracked Vehicles • Self-Propelled and Towed Artillery • Small Arms and Mortars • Major Subsystems (engines, transmissions, etc.) • Optics/Electronics • Night Vision • Radiological • Circuit Cards • Unique Processes • Robotic Metal Spray • Rubber Denuding • Testing • Gymnastication/Live-Fire/Test Track • Engine/Transmission/Hydraulic Component Test Facilities

  8. Field Support • Forward Repair Facilities/Teams • Modifications/Upgrades • Failure Analysis • Testing (laboratory and simulation) • Spare/Repair Parts • Reverse Engineering • Rapid Prototyping • Receipt, Storage, and Issue of Equipment • Manual and Automated Storage/Retrieval Systems • Open-air and Enclosed Facilities • Environmentally Controlled and High Desert Storage

  9. Capabilities Summary • Cradle to grave capability • Full range of processes and materials • Current, interim, and future systems • Leading edge of new technologies • Partnerships to meet the Warfighter’s needs • Private industry • Win-win for government and industry • Flexible infrastructure • Ability to meet any requirement

  10. GSIE Intent • To grow the workload at each installation, not rearrange existing workload • To clarify and simplify the rules under which we operate • To make the rules applicable to all • To advance public/private partnerships • To increase efficiency • To reduce capital expenditures

  11. Initiatives to Date • Established organization 7 October 2002 • Formed Corporate Board of Directors and Leadership Council • Approved as Business Initiatives Council (BIC) initiative (legislative and financial reform) • Implementing lean and other efficiencies • Revitalizing the workforce • Focusing on quality • Integrating engineering and production • Pursuing additional workload • Looking at footprint reductions

  12. Legislative Reform • 11 statutes currently affect business, 3 prominently • Introduced by different Congressmen for different reasons • All offer benefits for some installations, but not all • Variance causes confusion, uncertainty, and program delays • New legislation being offered that combines the best of each into a single statute • Clarifies the rules and applies them to everyone • Intended to facilitate more public/private partnerships • Firm fixed prices, multi-year contracts, variable costing

  13. Financial Reform 14 Army Working Capital Fund (AWCF) Business Initiatives Council (BIC) reforms • Examples • Return of financial gain • Capital investment authority • Depreciation rules • Capacity measurement • Removal of material costs from rates • Metrics

  14. Sample of Lean Projects SIAD CLASS VIII MEDICAL SUPPLIES (COSIS) ANAD AVDS 1790 RECIPROCATING ENGINE PROCESS • Eliminating excess handling and eliminating non-value added movement of materials • Cost avoidance: $4.2M • Turn-around Time: 62 days down to 36 days • Labor efficiency: 33% Improvement • Now, AVDS 1790 is part of entire reciprocating engine process, exporting gains to 6V53, M903, 8V71, and APU. RIA FORWARD REPAIR SYSTEM • Travel distance reduced by 35% • Labor efficiency: 14% Improvement WVA RRAD LEAN PROJECTS SEE VEHICLE RECAP PROCESS • Cost avoidance: T-53 and 81mm Mortar with a savings of $330K. • Weapon System Lead Time process will use 120mm M256 Cannon as pilot project to reduce weapon system lead times • Cost avoidance: $4.3M • Monthly output up 30% • Labor hours per engine: 34% reduction

  15. Staffing Initiatives andWorkforce Revitalization Efforts • LEAN staffing process • Reviewing each vacancy at command level • Reallocating or reengineering as required • Targeting 2 for 3 direct replacements and 1 for 3 indirect • Workforce revitalization • Apprentice program • Co-op program • Student employment program • Worker trainees • Temporary hires and terms employees to enhance flexibility • Efforts and results • Working toward 75/25 percent direct/indirect ratio • Reducing average age of employees • Reducing average length of service • Trends going in right direction

  16. Average Age

  17. Examples of Infrastructure Reductions • Watervliet Arsenal • 290,000 square feet of floor space • 525 pieces of industrial plant equipment • Potential for more • Rock Island Arsenal • 700,000 square feet of floor space • 683 pieces of industrial plant equipment

  18. Summary • Leverages the government-owned industrial capability • Grows the workload at each installation • Reduces unit prices to customer • Eliminates the need for any subsidy • Revitalizes the workforce • Fosters more public/private partnerships

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