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