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Mine-Resistant Ambush Protected Case Study

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Mine-Resistant Ambush Protected Case Study MINE-RESISTANT AMBUSH PROTECTED CASE STUDY: NAVISTAR DEFENSE’S PLANT IN WEST POINT, MISSISSIPPI • MARCH 2017 POINT, IN WEST DEFENSE’S PLANT NAVISTAR AMBUSH PROTECTED CASE STUDY: MINE-RESISTANT Mine-Resistant AmbushAmbush ProtectedProtected Case Case Study: Study: Navistar Defense’sDefense’s PlantPlant inin West West Point, Point, Mississippi Mississippi GlennDewel Dennis,Brasher, ClayClay Glenn Walden,Walden, Dennis, SteveSteve Clay Puryear, Puryear,Walden, Travis LarryTravis Dalton,Hill, Hill, Larry Larry FebruaryFebruaryMarch 2017 2017 Dalton,Steve Puryear, Dewel Brasher, Brasher,TravisMine-Resistant Hill SimonSimon Simon R.R. R. Goerger Goerger Goerger Ambush Protected Case Study: Navistar Defense’s Plant in West Point, Mississippi Glenn Dennis, Clay Walden, Steve Puryear, Travis Hill, Larry February 2017 Dalton, Dewel Brasher, Simon R. Goerger MRAP IntroducedMRAP Introduced MRAP Introduced Mississippi State University Center for Advanced Vehicular Systems Extension Mississippi State University Center for Advanced Vehicular Systems Extension Mississippi State University Center for Advanced Vehicular Systems Extension Mine-Resistant Ambush Protected Case Study: Navistar Defense’s Plant in West Point, Mississippi Glenn Dennis, Clay Walden, Steve Puryear, and Travis Hill Mississippi State University Center for Advanced Vehicular Systems - Extension 153 Mississippi Parkway Canton, MS 39046. Larry Dalton Mississippi State University Institute for Systems Engineering Research 3909 Halls Ferry Road Vicksburg, MS 39180-6199 Dewel Brasher Navistar Defense 901 E Half Mile St West Point, MS 39773 Simon R. Goerger U.S. Army Engineer Research and Development Center (ERDC) Information Technology Laboratory 3909 Halls Ferry Road Vicksburg, MS 39180-6199 1 Abstract During Operation Iraqi Freedom and Operation Enduring Freedom, the need for better protection of personnel and equipment traveling in military wheeled vehicles became critically apparent. In order to meet this need, the Department of Defense (DoD) authorized the expedited acquisition of the Mine Resistant Ambush Protected (MRAP) wheeled vehicle from multiple contractors. The acquisition program ultimately proved to be very successful in meeting mission requirements; however, the program costs were excessively high in relation to other typical, non- expedited DoD acquisition programs for a wheeled vehicle. This case study, related to the “manufacturability” of one version of the MRAP vehicle, the Navistar MaxxPro®, was initially published by the Mississippi State University Center for Advanced Vehicular Systems Extension in 2014. It thoroughly documents the history of this specific MRAP program and provides a list of lessons learned from the various experiences that occurred during program execution that may prove conducive for facilitating future DoD acquisition programs. 1 Contents Abstract ............................................................................................................................................................. 1 Illustrations ........................................................................................................................................................ 5 Preface ............................................................................................................................................................... 6 Acronyms ........................................................................................................................................................... 7 1 Introduction .............................................................................................................................................. 10 2 Background .............................................................................................................................................. 11 3 The Problem .............................................................................................................................................12 4 After Kellogg, Brown, and Root (KBR) came MaxxPro® ...............................................................................13 5 Navistar Design Process ............................................................................................................................18 6 Facility and Production System Design Issues ............................................................................................ 20 7 Key Enablers to Production ....................................................................................................................... 22 7.1 Centralized purchasing authority ........................................................................................ 22 7.2 Local empowerment .......................................................................................................... 22 7.3 Defense Priorities and Allocations System (DPAS) ................................................................ 22 8 Workforce Development ............................................................................................................................ 24 8.1 Industry partnerships ........................................................................................................ 24 8.2 Labor pool ........................................................................................................................ 25 8.3 Skill set development ........................................................................................................ 25 9 Supply Chain ............................................................................................................................................ 28 9.1 Garland Assembly Plant (GAP) ............................................................................................ 28 9.2 West Point assembly plant ................................................................................................. 29 9.2.1 Tier 1 supplier quality .................................................................................................................. 29 9.2.2 DX-Procurement authority ........................................................................................................... 29 9.2.3 Supply chain flexibility ................................................................................................................ 30 9.2.4 Supply chain management .......................................................................................................... 30 9.2.5 Electronic payment system .......................................................................................................... 31 10 Development of the West Point Assembly Plant .......................................................................................... 32 10.1 Establishment of the Brownfield site ................................................................................... 32 10.2 Site development for the MaxxPro® .................................................................................... 35 10.2.1 Vehicle staging area ................................................................................................................... 36 10.2.2 Chassis-prep building ................................................................................................................. 37 10.2.3 Test and Tune (T&T) building ........................................................................................................ 37 10.2.4 Chassis paint facility ................................................................................................................... 38 2 10.2.5 Truck docks................................................................................................................................ 39 10.2.6 Security upgrades ....................................................................................................................... 40 10.2.1 Administrative workplace upgrades .............................................................................................. 41 10.3 Development of the MaxxPro® assembly line ....................................................................... 43 10.3.1 Assembly line design .................................................................................................................. 43 10.3.2 Bay 1 assembly line .................................................................................................................... 44 10.3.3 Bay 2 assembly line .................................................................................................................... 45 10.3.4 Bay 3 assembly line .................................................................................................................... 48 11 Simulation - Analysis Tool for Facility Design; MRAP Traffic Flow and Dock Analysis ..................................... 50 12 Design for Manufacturability ..................................................................................................................... 53 12.1 The Navistar defense business plan .................................................................................... 53 12.2 Impact of bolt and bond design on manufacturability ........................................................... 54 12.3 Implementing the plan ...................................................................................................... 56 13 Development of the Workforce .................................................................................................................
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