New "force-multiplier" equipment to improve sustainment, increase combat readiness

ROCK ISLAND ARSENAL, Illinois - Gear, parts, and weapons keep the Army protected, moving, and fighting, but when they get damaged or destroyed, a unit's combat effectiveness is reduced and its ability to perform its mission is substantially impacted.

Employees assigned a project currently underway at Rock Island Arsenal's Joint Manufacturing and Technology Center have been working diligently to resolve this dilemma.

Michael Krebs, program manager of the Machinist Working Metal Shops Shelters project at RIA-JMTC, believes the project to produce the MWMSS will improve readiness and combat effectiveness, while saving the Army a lot of time, energy, and money.

The shelters are designed to keep the warfighter in the fight and more mission-capable.

"The units are a one-stop shop -- the literal definition of advancing Army / military readiness -- and actually combine and replace 13 other pieces on the battlefield," Krebs said.

The MWMSS is comprised of a two-part set (Type I and Type II), and each set takes approximately 45 days to produce. The main differences in Type I and Type II are in their principal capabilities -- Type I has a computer-controlled lathe, while Type II has a computer-controlled mill.

The two types combined include a control panel, torches, welders, a plasma cutter, dies, power tools, hand tools, drills, shears, metal-cutting saws and measuring devices, allowing operators to weld and cut any type of material and to fabricate a variety of products. The items are all sealed with preservatives that aren't removed until shelters go to the field.

The MWMSS project was first proposed at Rock Island in 2010, and a prototype was produced in December 2014. The current version is set to be fielded this year to Active and National Guard Army, Navy, and Marine units, all of which have members currently training to operate the systems.

Each shelter is also equipped with an advanced Computer-Aided Design / Computer-Aided Manufacturing (CAD/CAM) system that can be used to take an image of any part or item and create a new one from a blank piece of stock. A computer-controlled system can be used to run grinders, cutters, and machine tools, enabling the production of parts within tight tolerances.

"The units are force multipliers," Krebs said. "They have the capability to manufacture any kind of part in the field out of steel, copper, aluminum, plastic, etc. They can be used replace anything from vehicle and weapons parts to individual gear such as Kevlar helmets, flak jackets, and even fire-resistant Nomex suits."

The units are also equipped with generators, solar-powered fans, and heating and air conditioning units, along with an external air compressor that maintains 100 pounds of pressure. The compressor can be run by hoses from the Type I to the Type II unit to supply them both with constant air pressure.

MWMSS units can be transported by road, rail, airplane and helicopter. Upon arrival, the shelter's internal components can be arranged to expand and maximize internal operating space.

"The units measure 8 feet by 10 feet by 20 feet, but they're like packing 10 pounds in a 5-pound can," Krebs said. He added that they're fitted with black-out lights and Tactical Operations Center-compatible communications panels, and are designed to imitate a typical storage container. This allows commanders to get them close to the front lines without drawing the enemy's attention.

"We always hear about 'In the right place, and on time.' This is going to promote that," said Steven Harvey, the project's lead assembler. "It's going to allow [warfighters] to do that work themselves on site. As long as they have the raw material, they can either refurbish a part or make a brand new part."

The on-the-spot-repair element that the MWMSS brings to the battlefield can be a lifesaver, Krebs said.

"The initial plan is for every Brigade Combat Team to have an MWMSS, but ideally every battalion would have one," he explained.

"We are hoping that the program can become as productive as the M7 Forward Repair System (FRS) program, [a predecessor project similar to the MWMSS]."

Krebs expects that, once combat units begin using the MWMSS demand will take off, like it did for the FRS. JMTC is hoping to produce more than 10 a month.

The MWMSS project is currently in Low Rate Initial Production (LRIP) status, a precursor for new release to services.

"This occurs prior to Full Rate Production," Krebs explained. "One unit will be used to further develop the technical manual, with one each for training to several installations. This will be determined by (the project manager).

RIA-JMTC is currently producing several sets for initial issue to various venues, Krebs said, then will start the fulfilling the remaining production order.

"RIA-JMTC is scheduled to produce multiple sets with the possibility of increased funding for additional units, depending on the needs of the military," Krebs added.

The MWMSS is expected to be in high demand once combat commanders are exposed to its battlefield capabilities. These capabilities, Harvey believes, will improve military readiness and sustainment exponentially.

"That's why the project is so important to all of us," he stated.