BUNKER SUPPLY CO LLC — Department of Defense SBIR Phase I: N221-008

Description

Ammunition conveyance is a crucial step in the stockpile-to-safe separation sequence (S4) that is critical to combat aircraft readiness. M61A1 and M61A2 gun systems installed on both legacy and Super Hornet F/A-18 variants rely on the Linkless Ammunition Loading System III (LALS III) to load and download 20mm rounds to and from the aircraft magazines. Despite past attempts to improve the reliability of the LALS III, the system’s current design has a high rate of failure that is responsible for mission delays, increased maintenance burdens, and reduced aircraft readiness. Conventional Ordnance Discrepancy Reports (CODRs) have revealed that reliability issues stem from several system assemblies, including the conveyor assembly, aircraft interchange unit, and chain ladder assembly. Components in these assemblies are prone to severe damage and timing issues if sequential operation steps are not carried out in the correct order. Furthermore, shortcomings in design and/or manufacturing have led to inadequate component performance and reliability in the demanding environments LALS III units are used in. Considering these reliability issues, Bunker Supply Co. proposes the development of various design improvements to the LALS III to improve the Mean Time Before Failure (MTBF) for high-failure rate components. The solution will identify low MTBF areas through CODR data and will create rectification plans through innovative uses of material, construction, and geometric substitutions. Additionally, the solution will seek to minimize opportunities for human error and reduce opportunities for unintentional misuse. All facets of the solution will consider use-cases on aircraft carriers and Forward Operating Bases and designing for the rigors to which each environment will subject the LALS III assembly. During the Phase I effort, Bunker Supply will define, develop, and demonstrate the feasibility of its proposed concepts to increase the reliability of failed components of the LALS III. Since no CODRs are available prior to award, the solution is implicitly defined by the process of reaching these innovative concepts and procedures. Inherent to the solicitation, Bunker’s strategy is to break this down into the identified three key phases of define, develop, and demonstrate. Full definition of the high-failure areas and components begins with a thorough understanding of the CODRs and the inherent root causes of the issues. Leveraging the Bunker Supply team’s vast experience in Root Cause Analysis (RCA) will ensure problems are identified such that appropriate solutions can be systematically developed and implemented to prevent future issues and eliminate repeat reliability issues. Solutions based on the CODRs and RCA summaries can take many forms ranging from material updates to fundamental design changes to the system, and even to procedural updates to minimize human error.