Firefinder test equipment expands capabilities

By Ms. Jacqueline Boucher (AMC)October 5, 2009

Firefinder test equipment expands capabilities
(Photo Credit: U.S. Army) VIEW ORIGINAL

TOBYHANNA ARMY DEPOT, Pa. - Firefinder technicians here are testing radar systems using high-tech equipment that can simulate the heat of the desert - in the mountains of Pennsylvania.

Depot officials and distinguished visitors participated in a ribbon-cutting ceremony Sept. 23 that unveiled a new 5,400 square-foot Firefinder Elevated Burn Test Facility located in Building 3005. The enclosed $2.2 million facility will be used to conduct tests on the AN/TPQ-36 and 37 Firefinder radar systems for the Army and Marine Corps.

"The purpose of the elevated burn test is to increase long-term reliability by inducing, isolating and correcting early faults in the system," said Michael Rusinko electronics engineer, Industrial Modernization Division, Productivity Improvement and Innovation (PII) Directorate. "This procedure exposes the radars to desert-like conditions often experienced when they are deployed to Southwest Asia." The systems undergo two 20-hour burns following Reset and overhaul repairs.

Joe McCafferty explained that the first burn helps technicians find and correct any faults in the system. For the test to be successful, the second burn must run without interruption. McCafferty is the chief of the Q-37 Systems Branch.

The new equipment delivers hot air [120 degrees] to multiple components of the radar systems, for extended periods of time, while the systems are in full radiating mode, according to Rusinko. "We'll be able to see if the components will stand up under the rigors of extreme conditions," he said. "If something's not going to function properly, we can fix it here before it [the radar] goes to the war zone."

Rusinko noted that although the new facility is fully operational, it will be several weeks until the final processes are in place and personnel familiar with the new equipment and procedures. He added that engineers and technicians are working alongside Lean process improvement specialists to establish standard operating procedures and standard work documents.

"We're helping implement proven efficiency methods into the new facility," said Bill Stevens, process improvement specialist with PII's Process Improvement Division. "These methods are implemented in other work areas around the depot."

Stevens pointed out that the facility will implement visual management techniques such as shadow tool boxes, taped floors and production control boards.

"Our role is to reduce the manual cycle and flow time of the product being delivered to the customer," said Chris Simko, another process improvement specialist. "This is exciting to set things in motion as a new building comes online."

The new facility boasts three 14-foot roll up doors on one wall and a Para-Port roll up door on the other. The Para-Port door is 25 feet high by 60 feet wide, can withstand winds up to 100 mph and is made from a material that eliminates interference from outside sources when the Firefinder is in radiating mode. The building is also lightning protected.

"We designed everything to be up out of the way," Rusinko said. "There are a lot of automatic sensors, dampers, and temperature and pressure controls. Plus there are two touch screens employees can use to check each phase of testing at each intake and exhaust port."

With this facility, technicians will have tighter controls over outside influences while conducting the lengthy procedure, according to Rusinko. Previously, employees had to contend with the weather [good or bad] because the AN/TPQ-36 burn test took place outdoors.

"This is a big improvement for us and we are looking forward to using this equipment," said Frank Fallebel, Firefinder electronics mechanic. "Working outdoors, in inclement weather has, in the past, posed a number of challenges for the shop personal and meeting deadlines."

Tripping hazards are a thing of the past, noted Fallebel. He explained that there are trenches in the floor to house cables, and the extension cords and hoses that attach to the radar during testing, hang from the ceiling.

"I've been working in Firefinder for at least four years and it will be nice to work inside for a change," said Steve Kinney, Firefinder electronics mechanic.

Tobyhanna Army Depot is the Defense Department's largest center for the repair, overhaul and fabrication of a wide variety of electronics systems and components, from tactical field radios to the ground terminals for the defense satellite communications network. Tobyhanna's missions support all branches of the Armed Forces.

About 5,600 personnel are employed at Tobyhanna, which is located in the Pocono Mountains of northeastern Pennsylvania.

Tobyhanna Army Depot is part of the U.S. Army CECOM Life Cycle Management Command. Headquartered at Fort Monmouth, N.J., the command's mission is to research, develop, acquire, field and sustain communications, command, control computer, intelligence, electronic warfare and sensors capabilities for the Armed Forces.