LW155
Advanced Planning
Briefing to Industry
Mr. Jim Shields
DPM, LW155
29 May 2002
LW155 System
XM777 and TAD
The Future of Towed Cannon Artillery
XM777 Howitzer
 Lightweight High-Strength Titanium
 Improved Strategic Deployment
 Improved Ground Mobility
Towed Artillery
Digitization
(TAD)
 Improved Survivability
 Dispersed – Flexible Operations
Harder to Find,
Harder to Hit,
Harder to Kill!!
 No Survey
Radio
Antenna
Assistant Gunner’s Display
Vehicle
Motion
Sensor
Section Chief Control
& Display Unit
(SCCDU)
Inertial Navigation
Unit (INU)
 Improved Accuracy
 More Responsive
April GAO Brief
Mission Computer,
Battery & Power
Supply
Gunner’s
Display
Radio & GPS Receiver
2
Joint Requirements for
XM777 & TAD
The Future of Towed Cannon Artillery
XM777E1









9500 - 10,500 Lbs. - Deployable and Mobile
Emplace in 3 Min*
Displace in 2 Min*
All USAF (2 per C130, LW155 & FMTV in C141)
Rate of Fire 4-8 RPM, Sustained 2 RPM
Max Range 30km with Rocket Assist
Bold Shift in 3 Min
Primer Feed Mechanism
800 to 900 Rds Between Systems Abort
Towed Artillery Digitization (TAD)





Digital Indirect Fire Control
Inertial Navigation with GPS Backup
1-Mil Pointing Accuracy
Advanced Direct Fire Sight
TAD Weight: 200-500 Pounds
3
April GAO Brief
Program Evolution
The Future of Towed Cannon Artillery
2006
2005
US Army TAD IOC
USMC IOC
2002
OT & Full Rate Production Dec.
2002
OA & MS C
2001
Final Developmental Testing
1998
Extensive Developmental Testing
1997
Textron Novation
1996
Contract Award & EMD Gun Design (8 Guns)
1994-95
LW155 Shoot-off
1990
Accuracy Demonstrations
1989
USMC & US Army Field Evaluation
First Prototype Fired
4
2004
April GAO Brief
Engineering and Manufacturing
Development
The Future of Towed Cannon Artillery
 Applied Shoot-Off Lessons Learned
 Maximize Safety, RAM and HFE
 Comprehensive Evaluation of EMD Prototypes
 Joint Marine & Army Live Fire Tests
 Detailed Logistics & Fielding Plans
 Production Preparation & Decision
5
April GAO Brief
Allied Involvement
in LW155
The Future of Towed Cannon Artillery
 Italy and United Kingdom
 Trilateral EMD MOU, March 99
 Both Provided Supplemental Funding
 Production MOU Under Negotiation
6
April GAO Brief
Digital Fire Control
General Dynamics
Burlington, VT
The Future of Towed Cannon Artillery
7
April GAO Brief
Operational
Assessment
Video
The Future of Towed Cannon Artillery
8
April GAO Brief
Production Readiness
The Future of Towed Cannon Artillery
 All EMD Weapons Manufactured by BAE SYSTEMS in the UK
 Corporate Decision to Produce >70% in the US (Excluding GFE)
 EMD Contract Modified to Incorporate Pilot Production
 BAE Selected US Partners
 Production will Introduce Over 30 Castings
 Pilot Production Gun Tested Prior to Milestone C
 LRIP Insertion Lowers Production Risk
 GUN and DFCS Efforts Combined
 Pursuing Multi-Year Procurement Strategy for USMC LRIP
 Pursuing Joint Multi-Year Strategy for FRP (FY05 – FY09)
9
April GAO Brief
Elevating Mass
Castings
The Future of Towed Cannon Artillery
Balancer Eye (P.C.T.)
Front Bridge (P.C.C.)
Breech Bridge
(Howmet)
Buffer Yoke
(Howmet )
Axle Housings (Howmet)
Trunnion
Caps (P.C.T.)
April GAO Brief
Axle Caps (P.C.T.)
Elevating Yoke
(Howmet )
10
Elevating Mass
Castings
The Future of Towed Cannon Artillery
Front Bridge
Breech Bridge
Elevation Yoke
Buffer Yoke
Trunnion Cap
Axle Housing
Axle Cap
Balancer Eye
11
April GAO Brief
Lower
Carriage Castings
The Future of Towed Cannon Artillery
Stabiliser L.H. (P.C.C.)
Saddle Arm L.H. (P.C.T.)
Trail Casting L.H. (P.C.C.)
Saddle Base
Casting (P.C.C.)
Stabiliser R.H. (P.C.C.)
Saddle Arm R.H. (P.C.T.)
Trail Casting R.H. (P.C.C.)
12
April GAO Brief
Lower Carriage Castings
The Future of Towed Cannon Artillery
+
+
LH Arm
RH Arm
Base
=
Saddle
Stabilizer
Trails
Body Lugs
13
April GAO Brief
Saddle Base Fabrication
The Future of Towed Cannon Artillery
 Comprising 75 Pre - Prepared





Component Parts.
416 Manhours
Complex Fixturing Required.
Complex Purging.
Skilled Fabrication Resource.
High Risk Of Re-Work, Due To Shrinkage
& Distortion Problems
All Eliminated
by One Casting
14
April GAO Brief
TAD/XM777
Integration Status
The Future of Towed Cannon Artillery
• TALIN 4000 Selected as INU
• Mounting Locations On Gun 1008
• Incorporating Excalibur Platform
Integration Kit (PIK) Interface
Axel Mods
• Successful PDR Held Apr 9th
Stabilizer Mods
Cradle Modifications
15
April GAO Brief
XM777E1 Schedule
The Future of Towed Cannon Artillery
XM777E2
P3I Mat’l Release
Block 2
TAD Objective Software,
Direct Fire Sight & MVS P3I
Block 1
APS+ DFCS
Development
XM777E1
MS C
MSIIIa
XM777E1 System
Integration & Test
Design
Integration
XM777 Gun
Development
XM777 Gun
LRIP & OTE
April GAO Brief
XM777E1
LRIP & OTE
M777A1
IOC
M777A1
Prod
M777 Gun
Production
Objective
M777A2
System
(M777 with
Full TAD)
XM777
FRPD
MSIIIb
XM777
MS C
MSIIIa
FY02
XM777E1
FRPD
MSIIIb
FY03
FY04
FY05
FY06
FY07
16
JPMO LW155
Recent Program Additions
The Future of Towed Cannon Artillery
• Improved Position and Azimuth Determining System (IPADS)
-- New start, successor to PADS
• Gun Laying and Positioning System (GLPS)
-- In final stages of fielding
• M198: 155mm Howitzer (Medium Towed Artillery)
-- Fielded, sustainment initiatives
• M119: 105mm Howitzer (Light Towed Artillery)
-- Fielded, sustainment initiatives
Newly Chartered Life Cycle / Management Oversight
-- Result of AMC – ASA(ALT) Reorganization
-- Management / Execution based out of Rock Island, IL
17
April GAO Brief
Summary
The Future of Towed Cannon Artillery
Near Term Focus
 Completing OA
 Incorporate Changes from OA Onto PPG
 Complete Test of Pilot Production Gun
 Complete MS C Documentation
 Facilitization and Readiness of Value Chain for Production
 Continue DFCS Development and Integration Efforts
Program on Track for for MS C
18
April GAO Brief
Back-Ups
The Future of Towed Cannon Artillery
19
April GAO Brief
TDP Status
The Future of Towed Cannon Artillery
 OA Build standard
 2062 Drawings
 100 % complete
 Pilot Production build standard
 107 planned changes from OA standard




59 incorporated in TDP
28 in progress
9 accelerated for PP2 build standard
11 deferred to LRIP
 Process in place to incorporate any additional producibility
changes from supply chain during PP build
20
April GAO Brief
Joint Lightweight 155mm Howitzer (LW 155) Funding
FY02 Fiscal and Congressional Information
11, 12
13
6
5
14
8
3
2
4
9
15
7
1
10
1. New Jersey
SEN Robert Torricelli (D)
SEN Jon Corzine (D)
REP Rodney Frelinghuysen (R-11th) (HAC)
Government
City (Dist) MajorComp FY02$ FY03- FY07$
ARDEC
Picatinny Engineering
5.0M
20.0M
SEN Patrick J. Leahy (D) (SAC)
2. Vermont
SEN James M. Jeffords (I at large)
REP Bernard Sanders (I at large)
Contractor
City (Dist) Major Comp FY02$ FY03-FY07$
GDAS
Burlington
TAD
SEN Charles Schumer (D)
SEN Hillary Rodham Clinton (D)
REP Michael R. McNulty (R-21st)
Government
Watervliet Arsenal
City (Dist)
Watervliet
10.0M
140.4M
3. New York
Major Comp FY02$
Barrel Assy 3.4M
SEN Mike DeWine (R) (SAC)
SEN George Voinovich (R )
REP James A. Traficant, Jr. (D-17th)
Contractor
City (Dist)
RTI International Metals
Niles
FY03-FY07$
106.6M
4. Ohio
Major Comp FY02$ FY03-FY07$
Titanium
80.3M
SEN Richard G. Lugar (R)
5. Indiana
SEN Evan Bayh (D)
REP Julia M. Carson (D-10th)
Contractor
City (Dist) Major Comp FY02$ FY03-FY07$
Major Tools & Machine Inc. Indianapolis Spades/Trails
37.1M
6. Illinois
SEN Richard J. Durbin (D) (SAC)
SEN Peter G. Fitzgerald (R)
REP Lane Evans (D-17th) (HASC)
Gov/Contractor
City (Dist) Major Comp FY02$
Rock Island Arsenal
Rock Island
B.O.L.T.S.
FY03-FY07$
21.1M
7. Mississippi
SEN Thad Cochran (R) (SAC)
SEN Trent Lott (R)
REP Gene Taylor (D-5th) (HASC)
Contractor
City (Dist) Major Comp FY02$
United Defense
Hattiesburg Final Int/Assy
FY03-FY07$
$51.5M
8. California
SEN Dianne Feinstein (D) (SAC)
SEN Barbara Boxer (D)
REP Howard P. (Buck) McKeon (R-25th) (HASC)
Contractor
City (Dist) Major Comp FY02$ FY03-FY07$
Hydro-Mill
Chatsworth Body
74.2M*
9. Kentucky
SEN Mitch McConnell (R ) (SAC)
SEN Jim Bunning (R) (SASC)
REP Ken Lucas (D-4th)
Contractor
City (Dist) Major Comp FY02$ FY03-FY07$
Rotek, Inc
Florence Traverse Rack
20.5M
SEN John Warner (R) (SASC)
SEN George Allen (R)
REP Virgil Goode (I-5th) (HAC)
REP Bob Goodlatte (R-6th)
Contractor
City (Dist)
Wegmann
Lynchburg
10. Virginia
Major Comp FY02$
Elevation Assy
11. Oregon
SEN Gordon Smith (R)
SEN Ron Wyden (D)
REP David Wu (D-1st)
Contractor
City (Dist) Major Comp FY02$
Precision Castparts Corp Portland Castings
FY03-FY07$
15.5M
FY03-FY07$
37.1M
SEN Gordon Smith (R)
12. Oregon
SEN Ron Wyden (D)
REP Peter DeFazio (D-4th)
REP Darlene Hooley (D-5th)
Contractor
City (Dist) Major Comp FY02$ FY03-FY07$
Pacific Cast Technologies Albany Castings
37.1M
13. Michigan
SEN Carl Levin (D) (SASC)
SEN Debbie Stebenow (D)
REP William Clay, Jr. (D-1st)
Contractor
City (Dist) Major Comp FY02$ FY03-FY07$
Howmet Castings
Whitehall Castings
49.4M
14. Missouri
SEN Christopher Bond (D) (SAC)
SEN Jean Carnahan (D) (SASC)
REP Peter Hoekstra (R-2nd)
Contractor
City (Dist) Major Comp FY02$ FY03-FY07$
Seiler Instrument & Mfg St Louis Optical Fire Control 0.9M 19.4M
15. Mississippi
SEN Thad Cochran (R) (SAC)
SEN Trent Lott (R)
REP Gene Taylor (D-5th) (HASC)
Contractor
City (Dist) Major Comp FY02$ FY03-FY07$
Camp Shelby
Hattiesburg Acceptance Testing
2.2M
LW155 Team
The Future of Towed Cannon Artillery

Program Management


Major Tool & Machine Inc., Indianapolis, IN
General Dynamics, Burlington, VT
Hydro-Mill, Chatsworth, CA
RIA, Rock Island, IL
Cannon Assembly

Watervliet Arsenal, Watervliet, NY

US Integrator Final Assembly

Traverse Rack



Seiler Instrument & Mfg, St Louis, MO
Breech Operating & Loading Tray System



Body Assembly


Optical Fire Control
Digital Fire Control



Pacific Castparts Corp, Portland, OR
Pacific Cast Technologies, Albany, OR
Howmet Castings, Whitehall, MI
Spades & Stabilizers


RTI International Metals, Niles, OH
Titanium Castings



BAE SYSTEMS, Barrow-in-Furness, UK
Titanium



Prime Contractor & Developer, Cradle Assy


JPMO LW155, Picatinny Arsenal, NJ
United Defense, Hattiesburg, MS
Rotek Inc., Florence, KY
Elevation Assembly

Wegmann, Lynchburg, VA
22
April GAO Brief
ELEVATING MASS TEAM
The Gun
UPPER CARRIAGE TEAM
LOWER CARRIAGE TEAM
FULLY ASSEMBLED
ELEVATING MASS
INTEGRATION TEAM
LOADING SYSTEM
ASSEMBLY
BASIC
SCAVENGING
ORDNANCE
ASSEMBLY
BALANCER
ASSEMBLY
BREECH
ASSEMBLY
BUFFER YOKE
ASSEMBLY
ACCUMULATOR
ASSEMBLY
BUFFER
ASSEMBLY
CRADLE
ASSEMBLY
COMPLETE
EQUIPMENT
MUZZLE BRAKE
ASSEMBLY
FULLY ASSEMBLED
CARRIAGE
HANDWHEEL
ASSEMBLIES
ELEVATION
ASSEMBLY
TRUNNION GEARBOX
ASSEMBLY
INTEGRATED BODY AND
SADDLE WITH ASSEMBLED
ELEVATING GEAR
SADDLE ASSEMBLY WITH
BALANCING POST ASSEMBLIES
SUSPENSION AND WHEEL
ASSEMBLY ON BODY
DAMPER
ASSEMBLY
STABILISER
ASSEMBLY
TRAVERSE
RACK ASSEMBLY
BODY
ASSEMBLY
SPADE
ASSEMBLY
Producibility Mods for Pilot
Production
The Future of Towed Cannon Artillery
 8 EMD guns manufactured using manual TIG
 3200 lbs of titanium per gun
 6000 welding hours per gun
 Early distortion issues
 21 Castings introduced for gun 1009 (PP1)




Reduces welding hours by @ 50%
Reduces Ti structures part count by 51%
Reduces manufacturing variability
Allow for ‘targeted’ strengthening of structures
 New Jigs and process controls
 Greatly reduced distortion and variability of fabrications
24
April GAO Brief
Casting vs. Fabrication
Part Count
The Future of Towed Cannon Artillery
Titanium Structure
Fabrication
Casting
Cradle
Body
Saddle
Stabilisers
Spades
Trails
Elevating Yoke
Buffer Yoke
324
215
116
70
120
98
19
11
172
166
9
2
120
8
1
1
Total Part Count
973
479
51% Part Count Reduction for Ti Structures
25
April GAO Brief
Schedule
FY02
FY03
FY04
2002
2001
J F M A M J J A S O N D
O N D
TAD Block 1 Development
PDR
EUA
FY05
2003
DDR
FY06
2005
2004
J F M A M J J A S O N D
J F M A M J J A S O N D
J F M A M J J A S O N D
J F M A M J J A S O N D
TAD Block 2 - Delta Development (SW, Direct Fire, & Objective MVS)
TFT Event 2:
Components
Qualified
Fire Control HW
Bench Integration
Testing
Development
Land Warrior Assess.
RQMTS
Procure/Fab & Qualification
DESIGN
SW CODE & TEST
APS+ Bench
DVT
1 Oct 01 Assumed
Start of Focused
APS+ Development
Material
Release
HW FAB/PROCURE
INTEGRATION
Validated Interface
Environments
FY07
2006
CONF TEST
VERIF / FQT
Functionally
Verified APS+
Qualified APS+
Components
OTE
OTE Systems
IAT&C & Safety
Release
OA Training
XM777E1 Integration
EUA
E1
PDR
E1
DDR
DFCS / M777E1
IAT&C
TFT Event 1:
Interfaces &
Environments
Validated
TAD IF & Mass Mock Up
Production
IF Design
IF Prototype
TFT Event 4:
Integrated TechnicalFQT
Test
Start
JOINT DVT (12mo)
LOG DEM
MS C
LUT
MS
FRPD
Report / MS Prep
XM777E1 LRIP
IF Eval
PP1 TEST
Howitzer/DFCS
Interface Design
Review
FQT
Complete
OA Systems IAT&C
& Safety Release
PP2 TEST
OA Training
OTE
Report / MS Prep
OTE Systems
IAT&C
TFT Event 3:
Integration
Evaluated
XM777 Development
Legend:
LLIPR
Block 1 Development Task
XM777 EMD
OA
WIP
REPORT
5
2
XM777 Development Task
XM777E1 Integration Task
1008 (TAD I/F)
First Production XM777
Deliveries
PP1 M/F
Block 2 P3I Task
PQT/FAT
PP2 M/F
TFT Event “Test-Fix-Test” Event
OTE
MS C
MS FRPD
Program Milestone
Report / MS Prep
M777E1
IOC