Design for Demilitarization Overview LTC Johnny Figueroa PM Demilitarization 973-724-5276 johnny.figueroa@us.army.mil 3 February 2009

Presentation Outline Design for Demil Policy Requirement Why DFD? Demil Challenges DFD Goal Demil Execution Background Munition Design Impact on Demil DFD Integrated Process Team Implementation Strategy Summary 3 February 2009

DFD Policy Requirement DFD policy signed 4 Aug 08 by Mr. John Young, Undersecretary of Defense for Acquisition, Technology & Logistics. The importance of DFD has been recognized at the highest levels within the DoD. On 4 Aug 08, the Undersecretary of Defense for Acquisition, Technology and Logistics, Mr. John Young, signed a policy memorandum requiring DFD to be implemented in the Joint Services. In the memorandum, he stated that “Good systems engineering addresses all aspects of the life cycle, including systems' demilitarization and disposal.” and required that all Services “include in their acquisition documentation for all … conventional ammunition programs how they intend to address demilitarization design requirements throughout system design.” Specific requirements were deliniated. In addition to this memorandum, the concept of DFD has been supported by Senior Leaders in all the Services. 3 February 2009

Why Design for Demil? Traditionally, munition designers focus on item performance & may not be aware that design decisions can lead to difficult demil problems at the end of the item’s life cycle. In the past, OB/OD “took care of the problem”. Munition design historically had little impact on the ability to conduct effective and efficient demil (OB/OD). Designers typically don’t think about the fact that a munition must one day be demilled and so don’t incorporate that into their design. This can result in problems at end of the life cycle. In the past, OB/OD was the demil execution method of choice, so demil execution could be carried out effectively irrespective of the munitions design. However, this is no longer the case. While OB/OD is still conducted, it is not the preferred method of demil, and is phasing out due to environmental concerns and other pressures. Newer “closed disposal” demil operations are being developed and employed. They require munition disassembly and/or extraction of energetic components for processing and/or recycle/reuse. The efficiency of these operations is directly dependant upon the design of the munition. Consequentially, how a munition is designed now does have a big impact on demil operations. But things have changed … 3 February 2009

Environ-mental Regulations Demil Challenges Growing Stockpile Recycle & Reuse Projected Limited Storage Increasing Cost It should be noted that the stockpile of munitions awaiting demilitarization is not small. Currently there are approximately 500,000 short tons of munitions that need to be demilitarized. The demil stockpile has historically grown as new generations outpace the funding available to eliminate stocks. There are a number of constraints and challenges that limit the ability to keep pace with generations. The Army is constantly faced with the need to “think out of the box” to reduce the demil stockpile. Environ-mental Regulations Limited Funding 3 February 2009

Design for Demil Goal Demil is a life cycle requirement that typically is inadequately addressed in the design phase. Goal: Influence munitions design early in the life cycle to incorporate demil considerations & positively impact future demil execution. Demil is required at the end of a munitions life cycle. Munitions designers typically do not consider demil as a design requirement during munitions design. The goal of DFD is to make designers aware of demil and incorporate demil considerations and requirements up front and early in munitions design to positively impact future demil execution. Offset Costs: 3 February 2009

Demil Execution: Then/Now/Future While OB/OD is still conducted, it is not the preferred method of demil, and is phasing out due to environmental concerns and other pressures. Newer “closed disposal” demil operations are being developed and employed. They require munition disassembly and/or extraction of energetic components for processing and/or recycle/reuse. The efficiency of these operations is directly dependant upon the design of the munition. Consequentially, how a munition designed now does have a big impact on demil operations. 3 February 2009

Munition Design Impact on Demil ADAM MINE SPARROW 17A/B WARHEAD Depleted Uranium Salt requiring $1M+ additional demil equipment These examples illustrate difficulty a design can present to demil operations. Each of these increases cost of demil operations& potentially exposes operators to increased hazards. Impact of neglecting DFD Cost- Designs that do not efficiently accommodate demil processes or present difficulties in dissassembly, add unnecessary labo/time to demil ops; Contributes to increased life cycle cost; Current demil stockpile + 5 yrs estimated generations= approx’ly $1.5B to demil; Cost reduction of 2% due to DFD would result in $30M savings! R3: The current demil stockpile is viewed as an asset as much as a liability; cost approximately $5B to produce; Design of a munition doesn’t always lend itself to cost effective recovery of materials/components for recycle or reuse, resulting in missed recovery opportunities. If munitions were made easier to disassemble through DFD, even only recovering 2% of this value would result in $100M of revenue. ENVIRONMENTAL: Increasingly restrictive environmental regulations demand consideration of construction materials to reduce potential hazardous emissions from demil processes. SAFETY: Personnel interact with munitions during demil disassembly/processing. This consideration must be incorporated into munitions design to assure safety for demil operators. HARM WDU-21B NAVY WARHEAD Conduit traps explosives Glue requires extra process steps Small wash out hole PBXN-107 fill does not melt 3 February 2009

Item Performance Design for Demil is not intended to detract from achieving item performance. Design trade offs will be handled by the Item PM. Low cost design changes that do not impact performance could be made … if someone were thinking demil. A common concern is the impact of DFD on a munitions performance. It is understood that DFD is not intended to detract from performance. The developing PM will need to make tradeoff decisions regarding competing design requirements. However, low cost design changes that do not impact performance could be made throughout the design process if demil considerations were included in early design criteria. 3 February 2009

Design for Demil Implementation PM Demil executes the SMCA demil mission for all Services’ munitions DFD - a key strategic goal of the PEO Ammo approved Demil Enterprise Strategic Plan. Multi-Service DFD Integrated Process Team (IPT) chartered to establish a DFD program. Design for Demil Handbook – expect publication by August 2009 Acquisition and demil are represented 3 February 2009

DFD Implementation Strategy Lessons Learned: Design recommendations from demil execution experience Metrics: Verify accomplishment. Policy: Impose the requirement Contractual Requirement: Translate the requirement to the defense contractor. Munitions IPT Participation: Get involved “In the trenches”. Tools: Provide practical help (web based handbook). DESIGN FOR DEMIL … influencing munitions design for effective and efficient demil PROGRAM OVERSIGHT LESSONS LEARNED METRICS POLICY CONTRACTUAL REQUIREMENT MUNITIONS IPT PARTICIPATION TOOLS SHOWS HOW WE ARE ATTACKING THE PROBLEM … each pillar and foundation element represents a separate initiative that is important to ultimately achieving the goal of DFD (the “roof”). The approach is BASED ON AN ACKNOWLEDGEMENT OF THE CHALLENGES AND DIFFICULTIES WE FACE PROVIDES A MULTI-FACETED APPROACH TO ENSURE SUCCES; NO “SILVER BULLET” OR SIMPLE ANSWER; SYSTEMATICALLY TAKES OUT THE VARIOUS ROADBLOCKS AND HURDLES; Current focus of our efforts is developing a handbook to assist the acquisition community. ACQUISITION COMMUNITY AWARENENESS DOD/SERVICES SENIOR MANAGEMENT SUPPORT 3 February 2009

PM Demilitarization website contains information on Design for Demil Summary The acquisition community has the opportunity to further improve life cycle benefits by incorporating demil considerations into munitions design. Implementing DFD will positively impact the demil legacy left behind, with little cost or performance impact. The DFD IPT will continue to develop tools and resources to assist the acquisition community in this endeavor. Cultural change: must get PMs and designers to think differently and understand end of life cycle impacts/ramifications to what they are doing and change the design/acquisition process Not unprecedented: maintainability, supportability, operability, producibility – is in the spirit of systems engineering We have a good plan in place As we continue to work change will happen, though slowly DFD won’t dominate design, but forethought will positively impact … IF SOMEONE WAS JUST THINKING DEMIL Fulfills systems engineering approach Enhance future Warfighter readiness Facilitate demil stockpile reduction goals Control life cycle cost Avoid intractable demil problems (e.g. ADAM Mine) Provide a future source of supply for new munitions Enhance the Army’s environmental stewardship Maintain and enhance safety PM Demilitarization website contains information on Design for Demil https://www.pica.army.mil/pmdemil 3 February 2009