Original Date: 08/10/1998
Revision Date: 01/18/2007

Naval Air Warfare Center (NAWC), Lakehurst’s Prototyping and Manufacturing Department (PMD) developed and implemented a Fleet Emergencies and Contractor Defaults process. This process enables the PMD to provide an immediate response to Aircraft Launch and Recovery Equipment (ALRE) emergencies and investigations, as well as emergency manufacturing of Support Equipment (SE) due to supply system shortages or contractor defaults. Previously, the Naval Fleet relied on non-government contractors for emergency manufacturing support, resulting in long leadtimes for product deliveries and reduced Fleet readiness caused by contractor defaults (e.g., bankruptcy, missed delivery schedules, unacceptable units).

Responding to Fleet Emergencies and Contractor Defaults involves the rapid turnaround of products and services to the Fleet. The PMD performs manufacturing modifications to malfunctioning equipment to comply with Fleet requirements and/or meet sail dates. This process relies on concurrent engineering practices, emergency budget authorization, departmental cooperation, emergency on-call personnel, and a manufacturing planning and control system capable of developing emergency project estimating. Concurrent engineering is handled by Integrated Program Teams composed of members from various on-site departments (e.g., the PMD, In-Service, Design, Test). The use of these teams and their relationship among various NAWC divisions enables the PMDto be the first source for Fleet Emergencies and Contractor Defaults, and a key ingredient for successful Fleet support.

The Fleet Emergencies process starts when the Fleet contacts NAWC, Lakehurst to report a problem or an emergency situation. NAWC, Lakehurst personnel (e.g., in-service engineering support; test and manufacturing engineers; technicians; mechanics) investigate the situation at the problem site and assess possible solutions using the Lakehurst facilities. Discrepant or malfunctioning components may be shipped directly to Lakehurst where formal engineering investigations are initiated. If the emergency requires a new component, a redesign, and/or immediate repair, then the engineering, design, and manufacturing team personnel work together to achieve this goal. New or repaired items are installed and tested at NAWC, Lakehurst’s test sites to verify form, fit, function, and performance. This step ensures the final products will meet or exceed the Fleet requirements, and facilitates shipboard installation. The components are then dispatched to the problem site, where the installation/modification is performed.

In the case of a Contractor Default, the PMD brings all materials and assets in-house for full inspection. After inspecting the components, the PMD determines the work required to complete manufacture. If redesign and/or process improvements are required, then a formal engineering investigation is performed and NAWC, Lakehurst personnel work together to develop and manufacture the components. After completing the repair and/or manufacturing effort, the components are dispatched to the ship for installation and/or to the Navy Supply System Agency.

Operating as the core team, the PMD’s well-trained, experienced staff provides immediate response and service during emergencies and default situations. The core team is usually on the scene within 24 hours after notification, and can perform analyses and/or cut material within an hour after assessment. In addition, no contract leadtime is required. NAWC, Lakehurst has funding and capabilities in place to support Fleet requirements or emergencies immediately. A typical example is the Forward Ground Handling Equipment situation. The Fleet required 12 units to be delivered within 30 days. The contractor estimated a delivery time of six months at a cost of $18,000 per unit. The PMD reviewed the design and determined that the drawing package was incomplete. After generating a revised drawing package, the PMD fabricated and delivered the 12 units within 30 days at a cost of $6,700 per unit, a savings of more than 62%.

For more information see the Point of Contact for this survey.