Watervliet Arsenal: A place where foreign contracts and machines make good business sense

By John B. Snyder, Watervliet ArsenalMarch 22, 2017

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1 / 3 Show Caption + Hide Caption – There is an art and science to the planning and installation of new machinery. The arsenal cannot build new infrastructure to house new machines and so, new machines must fit into the same footprint as the machines they replace. It may take years to ... (Photo Credit: U.S. Army) VIEW ORIGINAL
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2 / 3 Show Caption + Hide Caption – Arsenal Equipment Specialist Frank Salvatore, right, talks to Franco Morlino, the installer from Tacchi North America, about the installation of a new hollow-spindle lathe in February 2017. Morlino, who is from Italy, has installed four machines at t... (Photo Credit: U.S. Army) VIEW ORIGINAL
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3 / 3 Show Caption + Hide Caption – (Photo Credit: U.S. Army) VIEW ORIGINAL

WATERVLIET ARSENAL, N.Y. (March 2017) -- What arsenal leadership may not have envisioned in 1813 when their small Army post opened its gates was just how much their manufacturing center would eventually rely on the support from foreign countries and businesses. After all, two centuries ago the arsenal was considered a forward outpost against an invading British army.

Fast forward to today, one cannot walk through the arsenal without being touched by something foreign, whether it is shipping mortar systems to the Iraqi army or production workers planning the manufacture of howitzer cannons for the Indian army. Interestingly, many of the machines here that manufacture the parts for U.S. and allied armies are made by a foreign manufacture.

Whereas, using foreign-made machines in 1813 may have been an act of heresy, today it makes good business sense, said Frank Salvatore, an arsenal equipment specialist.

"The decision-making criteria we use when we purchase a manufacturing machine goes beyond the old adage that the Army only buys from the lowest bidder," Salvatore said. "The machines that we buy must be custom made to support our unique machining processes that are required in the manufacturing of weapons systems that deal in extremely high pressures and temperatures. There are not many manufacturers who can make the customized machines to our tight tolerances and at a cost that is beneficial to the American taxpayer."

What many here may not appreciate, however, is the art and science that goes into the purchase of each new machine. The arsenal's manufacturing center is not going to receive any money to build new structures to house new machines and so, planners must do extensive research and design to bring in new capability that will fit in the same footprint as the old capability. In essence, an old machine must be pulled off line, new foundation poured, and electrical systems updated before the arrival of a new machine into the same space.

Earlier this month, Salvatore was working with representatives from an Italian firm as they were installing a new hollow-spindle lathe here to support howitzer and tank manufacturing. This is the fourth multimillion-dollar machine that this company has installed at the arsenal in recent years.

Salvatore explained that it took years of planning and coordination before the new Italian lathe was brought here. For this lathe, Salvatore and machinist Brant Wert traveled to Italy to work with the manufacture to ensure that the machine would meet the scope of work. Once they had the technical aspects of the new lathe worked out, then the foundation here to support the new machine could be designed.

"When it takes years and millions of dollars to bring on line new capability, we must be closely involved in the manufacturing of every machine," Salvatore said. "Due to our tight production schedules, we don't have time to get a new machine in and then try to make it fit our manufacturing requirements. It (machine) must be ready to start production within a week or two of installation."

One of the interesting and quite visible phenomenon that occurs when a new machine is placed on line has nothing to do with cutting metal chips.

"This is a great morale builder," said George Pusins, an arsenal machining supervisor, as he observed the arrival of the new lathe in his building. "Because this is the first new machine in this production building in at least 10 years, my guys are excited because it is a symbol that their efforts have not been forgotten."

Pusins added that thanks to the great design work by Salvatore, the new lathe will actually replace two machines.

"This machine will allow us to conduct two major operations on one machine, versus having to use two separate machines," Pusins said. "Additionally, having a state-of-the-art machine will require less maintenance than the 35-year-old machine that it replaced, thereby, increasing our production capacity and flexibility."

The arsenal has four main production buildings that house nearly 600 machines. When new machines may cost up to $2 million or more, it is understandable why one building may not see much change. Nevertheless, in Pusins' production building there have been millions of dollars invested to improve, not replace, existing capability in recent years.

The Watervliet Arsenal is an Army-owned-and-operated manufacturing facility and is the oldest, continuously active arsenal in the United States having begun operations during the War of 1812. It celebrated its 200th anniversary on July 14, 2013. It is a subordinate command to TACOM LCMC and the Army Materiel Command.

Today's Arsenal is relied upon by U.S. and allied armies to produce the most advanced, high-tech, high-powered weaponry for cannon, howitzer, and mortar systems. This National Historic Registered Landmark had revenue in fiscal year 2016 that exceeded $126 million and provides an annual economic benefit to the local community in excess of $90 million.

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