MOFA Battery ATK Ordnance and Ground Systems, LLC
Power Sources Center
Automation of the Multi-Option Fuze for
Artillery (MOFA) Post-launch Battery
Presented by
48th Annual NDIA Fuze Conference
Charlotte, NC
April 28, 2004
by
John C. Bostwick
Program Manager for Reserve Batteries
215-773-5428
Automation of MOFA Battery_ 4_28_2004.ppt
Slide 1
MOFA Battery ATK Ordnance and Ground Systems, LLC
Power Sources Center
Presentation Outline
Facility Highlights
Description
Equipment History
Process Control and DFSS/6-Sigma Lean
Material Identification and Handling
Video Clips of Equipment
Summary
Automation of MOFA Battery_ 4_28_2004.ppt
Slide 2
MOFA Battery ATK Ordnance and Ground Systems, LLC
Power Sources Center
Features:
• Single story, 52,000 ft2 facility.
• 40,000 ft2 available for manufacturing.
• 6,000 ft2 of humidity controlled
dryrooms (RH maintained at < 5%)
• Computer modeling and analysis
capability.
• Extensive laser welding capacity.
• In-house machining and tool room.
Power Sources Center
• Multiple production lines.
Horsham, Pennsylvania • Specialized battery manufacturing and
Power Sources Center has all of the processing equipment.
physical assets and facilities required • Quality Assurance ISO 9001:2000
to: design, develop, manufacture, test, Certified
and analyze lithium batteries. • Extensive battery testing equipment
and expertise.
Automation of MOFA Battery_ 4_28_2004.ppt
Slide 3
MOFA Battery ATK Ordnance and Ground Systems, LLC
Power Sources Center
Description
• The MOFA Post-launch Battery is a state-of-the-art reserve lithium oxyhalide
power supply.
• It utilizes a moderate rate formulation of the lithium / thionyl chloride.
• It can be stored in the dormant state for in excess of 20 years and then
be activated by the conditions of ballistic launch.
• Supplies post-launch power to the MOFA Fuze -- Army’s next-generation,
NATO standard all-purpose artillery fuze for bursting munitions.
• Power needed for electro-mechanical operation during four fuze modes:
Proximity, Time, Point Detonate, and Delay
• Automation needed to assemble large quantities of this small, hermetic
vessel (current orders and future domestic/foreign forecasts include over 1
million units)
Automation of MOFA Battery_ 4_28_2004.ppt
Slide 4
MOFA Battery ATK Ordnance and Ground Systems, LLC
Power Sources Center
Equipment’s History
• ATK initiated design, development and procurement of automated
equipment 1999.
• Installation of equipment at Horsham, PA facility was completed in
November 2001.
• Average monthly production is 25K units, with surge capacity to 35K
units
• To date, the line has produced nearly 400K batteries
• The four major pieces of automated equipment are:
• Battery Assembly Machine (BAM)
• Closure/Terminal Plate Welder (automatic laser)
• Reservoir Welder (semi-automatic laser)
• Electrolyte Fill and Seal Machine
• We have since installed another semi-automated work-cell in 2003 for
inspection as part of our DFSS/Lean Six Sigma Initiatives
Automation of MOFA Battery_ 4_28_2004.ppt
Slide 5
MOFA Battery ATK Ordnance and Ground Systems, LLC
Power Sources Center
Process Control and DFSS/Lean 6 Sigma
• In-process/statistical process control (SPC) data collection capability:
• The equipment automatically monitors 14 parameters and will shut
itself down if parts become out-of-tolerance
• The program team performs weekly data review of key
characteristics to review data trends and proactively respond to
conditions prior to defect creation
• All equipment yields are greater than 98% with over 90% availability
• DFSS/Lean 6-sigma philosophy and tools have become instrumental to
the facility to develop a culture of Continuous Improvement
• 100% percent of manufacturing/quality engineers trained as green-
belts
• 2 engineers are currently in training for black-belt certification
• 7 projects completed and/or underway…significant improvements
seen in quality, cost, and lower risk for battery
Automation of MOFA Battery_ 4_28_2004.ppt
Slide 6
MOFA Battery ATK Ordnance and Ground Systems, LLC
Power Sources Center
Example: Results from Poka-Yoke
• Installed semi-
automatic work-
cell for final
inspection
• Integrated ball-
height and
voltage &
resistance
inspection
• Eliminated risk of
escapes
• Improved
throughput by
20%
• Reduced labor
costs by 35%
Automation of MOFA Battery_ 4_28_2004.ppt
Slide 7
MOFA Battery ATK Ordnance and Ground Systems, LLC
Power Sources Center
1999 2001 2003 2004
• Hand assembly • Automated • DFSS/Lean Six • DFSS/Lean Six
assembly Sigma initiated Sigma throughout
the organization
• Limited rate • Greatly Increased • Increased • Increased
throughput 10x throughput 1.5x throughput
capabilities
• Operator dependent • Operator • Poka Yoke • Machine uptime
dependency reduced • Machine Uptime > >95%
• Machine uptime 90% and increasing. • TPM incorporated
focus • Reduced defects on all equipment
• Reduced cycle time • Trend analysis prior
from value stream to creating defects
mapping • Kanban
• Supplier variation in • Supplier variation in • Reduced part • Reduced part cost,
parts parts variance. number of parts, and
variance
Automation of MOFA Battery_ 4_28_2004.ppt
Slide 8
MOFA Battery ATK Ordnance and Ground Systems, LLC
Power Sources Center
Now: Material Identification and Handling
• Pin-stamping required for lot identification
purposes 12984980 D a y C o d e E x p la n a t io n
1216TU 1216T U
• Date-coding added to record material
pedigree information W e ld e d o n D e c . 1 6 th ,
B A M ’d o n T u e sda y.
• Auto-laser has Telesis PINSTAMP Dot
Peen Marking System
A TQ 03M
• Started implementation of Lean 0 0 5 -0 0 2
Manufacturing using value stream mapping
and Kanban to reduce cycle time and WIP
Next Step: This will be added…
• 2-D code direct part marking (DPM) and
reading capability. Improves quality and
satisfies DoD’s new UID initiatives
• Complete implementation of Kanban
Automation of MOFA Battery_ 4_28_2004.ppt
Slide 9
MOFA Battery ATK Ordnance and Ground Systems, LLC
Power Sources Center
Battery Assembly
Machine (BAM)
• 8 dies to punch
anode, cathode, and
separator.
• 5 robots to assemble
stacks.
• Rate = 800 batteries
per shift.
• Automated SPC on 14
characteristics
Automation of MOFA Battery_ 4_28_2004.ppt
Slide 10
MOFA Battery ATK Ordnance and Ground Systems, LLC
Power Sources Center
Auto-Welder
• 1 robot
• 4 position
index table
•Terminal plate to
case
• 240/hour
• End plate to case
• 240/hour
• Lot marking
• Date marking
Automation of MOFA Battery_ 4_28_2004.ppt
Slide 11
MOFA Battery ATK Ordnance and Ground Systems, LLC
Power Sources Center
Fill Machine
• Fill and seal battery
• 1 robot
• 8 position index
table
• 800 per shift
• Automated SPC on
fill weight.
Automation of MOFA Battery_ 4_28_2004.ppt
Slide 12
MOFA Battery ATK Ordnance and Ground Systems, LLC
Power Sources Center
Summary
• LESSONS LEARNED: Automated equipment by itself did not achieve
the results we wanted. It took a team focused on DFSS/Lean Six
Sigma at the Enterprise level using automation as another tool for
continuous improvement
• We have the proven capability to manufacture high volume battery
programs through the use of automated equipment.
• Power Sources Center has embraced DFSS/Lean Six Sigma concepts
throughout our facility to make improvements in quality, cost, and
reduced risk.
• We are a leader in the design, production, test, and analysis of lithium
batteries.
• We appreciate the sponsorship and technical contributions of the U.S.
Army ARDEC and US. Army Research Laboratory
Automation of MOFA Battery_ 4_28_2004.ppt
Slide 13
