TOBYHANNA ARMY DEPOT, Pa. -- A multi-faceted effort here provides troubleshooting capabilities for the Common Remotely Operated Weapon Station (CROWS) II M153 through the fabrication and assembly of CROWS Diagnostic Kits (CDK).
The kits are all-weather, portable diagnostic test sets that are compatible with multiple CROWS variants. Each kit is comprised of 23 specialized cables and harnesses, 11 test adapters and an Interface Device (ID) with LCD video display, and takes more than 200 hours to fabricate, perform final testing and assemble. The ID, which alone requires 40 hours of work to fabricate, allows soldiers to troubleshoot the weapon station in the field.
"Tobyhanna does everything in-house for the kits, including fabricating cable harnesses and ID boxes, assembling the cables and fitting them with adapters," said Strategic Systems Cable Branch Chief Carol Kubilus, adding the caveat that circuit cards are purchased and not fabricated here. All cables are tested using an automated wiring analyzer that performs circuit continuity tests for open circuits, as well as resistor, relay and capacitor tests, ensuring the kit functions properly prior to fielding.
In 2011, Picatinny Arsenal contacted Tobyhanna's Production Engineering Directorate to design, develop and build 202 initial production units. To date, however, more than 300 have been completed and shipped for fielding. Chris Sankovich, CDK program manager at Picatinny Arsenal, said the work of depot personnel is top-notch.
"The manufacturing quality of the CDK has met all of our rigorous requirements," he said. "The quality control measures in place at the depot ensures the best possible product is delivered to the Soldier." He added that monthly face-to-face and bi-weekly teleconference meetings have created an open line of communication directly between the Program Manufacturer and Tobyhanna, allowing both to "dynamically adapt to challenges."
Continuous process improvement has played a large part in the process from start to finish. A plastic tool to wind cables was developed by depot employees and prototyped in both cardboard and wood prior to being 3D printed. The tool ensures cables are wound properly to be fit with adapters. A Lean event conducted in 2012 resulted in other process improvements.
"We implemented a new way to label cables inside the ID boxes using a marking machine that hot stamps each cable," said Electronics Mechanic Leader David Olander, "and established a more effective and efficient way to shrink the insulation sleeving by heating it in an oven instead of by hand with a heat gun."
Program accomplishments include three engineering design modules (EDMs) that were fabricated and evaluated by Picatinny's Automated Test Systems Division. Feedback from the initial EDMs was used to refine the kit's design.
Various depot shops play a role in building each kit, ranging from equipage to machining, and painting to plating. Coordination between all areas has ensured a smooth process and a positive relationship with Picatinny.
"The biggest challenge has been tracking parts from one process to the next," said Kubilus. The newly-implemented Complex Assembly Manufacturing Solution will improve tracking by enabling access to detailed information for shop technicians.
Fifteen kits are scheduled per month to complete the workload. Use of the diagnostic kit will eventually expand to other systems, including the Bradley Wheeled Vehicle.
Tobyhanna Army Depot is a recognized leader in providing world-class logistics support for C4ISR systems across the Department of Defense. Tobyhanna's Corporate Philosophy, dedicated work force and electronics expertise ensure the depot is the Joint C4ISR provider of choice for all branches of the Armed Forces and industry partners.
Tobyhanna's unparalleled capabilities include full-spectrum logistics support for sustainment, overhaul and repair, fabrication and manufacturing, engineering design and development, systems integration, post production software support, technology insertion, modification, foreign military sales and global field support to our Joint Warfighters.
About 3,200 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 Communications-Electronics Command. Headquartered at Aberdeen Proving Ground, Maryland, 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.
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