Technology Driven ·  Warfighter Focused

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Efficient Power Take-Off Manufacturing (EPTO)

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OBJECTIVE / SOLUTION

Develop an improved manufacturing process with the goal of reducing production cost and increasing throughput for an efficient, affordable and reliable EPTO with a multispeed fan drive system and electronic controls for the Bradley Fighting Vehicle (BFV) and other Army Ground Vehicles.

Achievements

• Increased reliability and production rates while decreasing cost for BFV EPTO
• Updated Make/Buy Analysis to identify additional opportunities for reducing cost
• Implemented Parallel Line Assembly Flow Process in order to achieve higher productivity and better overall assembly performance
• Linked and balanced manufacturing processes into parallel flow lines to reduce factor floor space by 20%
• Developed Product Verification Plan to capture all physical test/ demonstration activities to verify multispeed fan drive functions as intended prior to assembly with EPTO.
• Leveraged TARDEC’s PTO Simulator equipment to execute performance and durability testing to validate EPTO manufacturing process
• Developed Quality Management System and reduced 100% item inspection to 10% item inspection

Benefits

• Improved assembly line process increasing efficiency & productivity resulting in output of two EPTOs per day, which is over 100% increase in operator productivity from the original method
• Improved efficiency of manufacturing engineers and production costs by implementing process plan improvements that allow the definition of plant- specific processes with alternate/parallel sequences of operations to decreased cost from $150k per unit to $10k per unit
• Reduced cost of manufacturing changes by identifying design changes earlier in the design for cost effective, and consistent manufacturing process
• Improved productivity by optimizing manufacturing processes to establish a production ready coplanar gear and polycone clutch manufacturing process resulting in a direct replacement PTO assembly ready for transition to platform

Transition and Weapon Systems / Secondary Items Impacted

• Target transition: Bradley Fighting Vehicle (BFV) (Technology Transition Agreement in place)
• Impacts future AGV (Army Ground Vehicle) projects that are improving mobility of the Warfighter through efficient systems
• Applicable to all systems that require PTO variable fan drive. Including AMPV (Armored Multi-Purpose Vehicle), PIM (Paladin Integrated Management) and ABRAMS

POC: Army ManTech Manager, U.S. Army Research, Development and Engineering Command (RDECOM), Army Research Laboratory (ARL), ATTN: RDRL-WMM-D, Aberdeen Proving Ground, MD 21005

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