- Introduction
- Key Elements in Defense Manufacturing
- Building the Machines that Make the Machines
- Unpacking the Smart Bullet Project
- Strategic Partnership: QA & Incoming Component Standards
- One of our Favorite Projects
- No Job Too Small
- Conclusion
INTRODUCTION
In this blog, we cover a lot of industries, but a large vertical that we have yet to discuss is manufacturing for the Defense Sector. We’ve done some great work in this space and to shed some light on the subject we went and chatted with a resident expert. One of our machine design project managers and spare part fabrication managers for Re:Build Optimation with a scope of work and responsibility that focuses on manufacturing machine and equipment development, building, and maintenance were able to enlighten us more on this subject.
This interview offers a fascinating glimpse into the intricate world of manufacturing high-precision equipment. The discussion revolved around Re:Build Optimation’s pivotal role in producing cutting-edge machinery for a wide range of applications, including the defense sector.
One of the standout projects highlighted was building an assembly line for ‘Smart Bullets’ production. The team at Re:Build Optimation not only conceptualized but also constructed a state-of-the-art machine capable of churning out these specialized munitions with remarkable speed and near-perfect accuracy. The bullet had over 20 components, significantly more than one might expect from a traditional bullet.
There are many items emphasizing on the importance of quality control and safety measures in the production of defense-related items. Most importantly, PRECISION is crucial, and we dedicate ourselves to the high degree of accuracy required in the manufacturing processes.
After a long, contemplative pause during the interview, a clear and solid statement was given. Re:Build Optimation is far from your typical job shop. While some companies in the industry specialize in crafting unique, one-off items, Re:Build Optimation takes a more strategic approach, engaging in project-management-based work for our manufacturing clients. Our projects often involve creating highly specialized components tailored to precise requirements. Any custom needs will determine our workflow and result in custom solutions.
Key Elements in Defense Manufacturing
Defense manufacturing is a highly specialized and regulated field that demands precision, reliability, and adherence to stringent standards. The top three key elements required in defense manufacturing are:
1. Precision Engineering
Precision is critical in defense manufacturing. Components, systems, and equipment must meet exact specifications and tolerances to ensure optimal performance and safety. High levels of precision are required in the design, fabrication, and assembly of military hardware and technology.
2. Compliance and Quality Assurance
Adherence to strict quality control and compliance standards is non-negotiable in defense manufacturing. These standards encompass everything from materials sourcing to production processes, testing, and documentation. Ensuring the reliability, durability, and safety of defense equipment is of utmost importance.
3. Security and Confidentiality
Defense manufacturing involves sensitive and classified information. Maintaining security and confidentiality is crucial to protect intellectual property, designs, and proprietary technologies.
These elements, among others, contribute to the successful and responsible production of defense equipment and technology. Re:Build Optimation naturally focuses on all three in all cases, but we affirm our commitment to these aspects as we work on defense projects.
Building the Machines that Make the Machines
Re:Build Optimation is in the business of “building the machines that make the machines.” Crafting production equipment allows us to serve as the backbone for various industries. One of Re:Build Optimation’s critical competencies includes roll-to-roll base converting equipment as well as custom machining centers for the automotive and consumer market segments. This allows us to be specialists in treating and converting critical aspects of everyday manufacturing materials like aluminum foil, cellophane, and even automobile tires. This involves intricate processes such as coating, treating, slitting, and forming materials, all of which play a vital role in the final product.
Unpacking the Smart Bullet Project
The “Smart Bullet Project” was a marvel of engineering. This complex assembly line involves the need to connect about 20 distinct components. The product that the new assembly line would manufacture was FAR more intricate than the standard bullet – which consists of merely Casing, Primer, Bullet, and Powder. This was not only a piece of brass with gunpowder; it housed intelligent chips, adding layers of complexity.
When crafting a smart bullet, precision is key. The quality requirements are seemingly astronomical, demanding an output of 99.999% accuracy. There’s no room for error, making high-precision automation of the process a necessity. The project required a finely tuned set of machines, each responsible for a specific segment of the bullet. One machine handled the lower section, another the middle, and yet another the upper. Finally, a fourth machine seamlessly integrated the components, all without any human intervention.
The entire system spanned a colossal 300 feet by 300 feet (90,000 Square Feet). Despite its size, only a handful of operators were needed. Re:Build Optimation focuses on efficiency and fully automated processes.
The smart bullet project was not without its challenges. With gunpowder in the equation, every gram of gunpowder was meticulously weighed to the millionths, ensuring accuracy and safety. The interview explained how this demanded sophisticated scales on air bed platforms, leaving no room for external interference.
Last but not least, the smart bullet project brought with it the need for extensive safety measures. Gunpowder by nature and requirement is a combustible explosive material. Heat and the potential for anything “sparky” had to be reduced to “intrinsically safe” standards. Even so, Re:Build Optimation designed and implemented blast walls to contain potential explosions because safety is ALWAYS the most important part of a project. This thereby safeguarded both the equipment and the workforce.
Strategic Partnership: Quality Assurance and Incoming Component Standards
To ensure the quality of incoming components and the quality of the final output, Re:Build Optimation currently relies on trusted partners to provide quality reports. This approach allows a higher level of transparency, which is extremely vital in manufacturing to achieve and deliver products that meet and exceed exacting standards.
Re:Build Optimation especially focuses on strategic partnership models that allow them to efficiently manage resources and only engage specific capabilities when needed. For instance, fans of Re:Build Optimation’s work might assume that we’ve got in-house CNC Machining capabilities. Instead, maintaining large-scale, in-house CNC machining operations, without continuously using it, would not be cost-effective. We opt for a streamlined approach that leverages strategic partners for specialized tasks. This model aligns with Re:Build Optimation’s production capacity and ensures a very efficient use of resources.
Our experts are personal fans of CNC technology. Its complexity and dynamic nature are not only needed but also a bit of a wonder to behold. Re:Build Optimation are true fans of craftsmanship. During the interview, it was also mentioned that while Re:Build Optimation currently emphasizes collaboration with strategic partners, we have a deep understanding and expertise in CNC technologies which allows us to be high-value partners in creating complex parts.
Through the strategic partnership with established partners, redundant internal quality checks are unnecessary. The company trusts its partners to deliver components meeting the required standards. This also creates an unbiased environment that allows a completely transparent, honest, and precise quality assurance.
By collaborating with specialized partners, they can focus on their core competencies while relying on trusted associates for specific tasks. This approach allows them to tap into expertise and resources that may not be readily available in-house, ultimately leading to more efficient and high-quality outcomes.
One example of a resource aspect that was utilized is for machinery cost efficiency management. When the team recognized that some machines are not designed for continuous operation due to cost constraints, they adopted a strategic approach to utilize these resources judiciously, ensuring that they are deployed when their unique capabilities are most needed.
Our blog interviews are always casual and fun – and as such our experts at Optimation get to riff on their favorite projects. Our experts have a bunch of them and though not defense-specific one particular project was both fascinating AND has the potential to have elements that could benefit defense projects. So… we decided to share one of our favorite projects.
- Display Technology with Kodak – One of our favorite projects involved creating displays for cell phones and laptops in partnership with Kodak. This ambitious undertaking required a sophisticated web conveyance coding process to produce touch-sensitive screens. The project showcases Re:Build Optimation’s ability to push technological boundaries and create innovative solutions for the consumer electronics industry.
- Printing Silver Nanowires: Within the Kodak partnership, we were involved in a cutting-edge endeavor involving the printing of microscopic silver lines, known as nanowires, onto a web. This intricate process demanded precision at every step, from handling the silver material to reprocessing it and conducting meticulous inspections. This required advanced materials and expert capability to pioneer new technologies.
- Global Installations: Beyond the technological innovations, the project’s scope extended to global installations. Our team not only developed the technology but also successfully installed the machines at Kodak Park and in Xiamen, China. This international reach underscores their ability to manage complex logistics and deliver turnkey solutions on a global scale.
The project with Kodak exemplified Re:Build Optimation’s position at the forefront of technology. They were not only creating products but also pushing boundaries by introducing new processes and materials. We delved into a fascinating project centered around a substantial stencil designed for precise silver deposition. The team successfully removed an impressive 99% of the silver, leaving behind a meticulously crafted pattern. The application process itself utilized a contact printing technique, demonstrating the precision and innovation involved. What’s particularly noteworthy is the careful recovery of the remaining silver, showcasing a commitment to efficiency and sustainability in their processes.
No Job Too Small
Our company’s philosophy is ‘never turning down a project, regardless of its scale.’ This approach, instilled by our founder, Bill Pollock, emphasizes that even small projects can lead to significant relationships. The key is to be diligent with each opportunity we are trusted with.
While the smart bullet project remains a standout achievement, Re:Build Optimation is keen and open to any opportunities in defense manufacturing. Our enthusiasm for taking on any challenge, from two-dollar widgets to multi-million-dollar projects, shows our confidence and ability to deliver exceptional results.
Conclusion
In this deep dive into Re:Build Optimation’s pivotal role in the defense manufacturing sector, we’ve focused on precision engineering, innovation, and strategic partnerships. With our engineers’ wealth of experience and expertise, they continue to provide invaluable insights into the intricate projects that define Re:Build Optimation’s legacy.
Key elements in defense manufacturing, including precision engineering, compliance, and security, are at the forefront of Re:Build Optimation’s operations. Their emphasis on quality assurance through trusted partners exemplifies their dedication to transparency and unwavering commitment to producing defense-grade products.
The philosophy of ‘No Job Too Small’ speaks volumes about Re:Build Optimation’s approach, highlighting their willingness to tackle any challenge, regardless of scale. This mindset, coupled with a strategic partnership model, ensures optimal resource allocation and project execution.
As Re:Build Optimation continues to push boundaries and explore new horizons, one thing is clear: they’re not just building machines; they’re shaping the future of manufacturing, one project at a time.
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