Transcript Document 7459655

History, Design, Manufacture and
Quality of XBT 1962-Present
Lockheed Martin Sippican
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Aeronautics
Electronic
Systems
Information
Systems &
Global Services
Space
Systems
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Electronic Systems
Missiles and Fire Control
MS2
Advanced Technology
Laboratories
Simulation Training &
Support
Systems Integration
Sandia National
Laboratories
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MS2
Defense and
Surveillance Systems
Surface-SBMD
Systems
Coast Guard & Homeland
Security
Radar
Systems
Littoral Ships &
Systems
Tactical Systems
Undersea and Security
Systems
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Lockheed Martin Sippican
Countermeasure
Systems
Sea-Air Systems
Polaris Contract Manufacturing
Underwater Vehicles
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Location
Lockheed Martin
Sippican’s facility is
located in Marion,
Massachusetts on
Buzzards Bay. We are
only an hour from
Boston, and 45 minutes
from Providence and
Newport, Rhode Island.
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Facilities
•70 acres, 6 buildings
in Marion, MA
•225,000 sq. ft. facility
manufacturing space
•55,000 sq. ft. facility
in Jùarez, Mexico
•10,000 sq. ft. warehouse
and office in El Paso, TX
Lockheed Martin Sippican
is an ISO-9001Certified Company
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Sea-Air Systems designs and
manufactures oceanographic
instrumentation and data
acquisition systems. It also
designs and manufactures
meteorological
instrumentation and
submarine communication
systems.
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Sea-Air Systems
Expendable Oceanographic Instrumentation
Lockheed Martin Sippican’s
SSXBT
expendable probes collect data
XCP MK 10
on physical properties of the
ocean such as temperature,
sound velocity and current
velocity. The probes can be
launched from aircraft, surface
ships and submarines.
XBT / XSV
XCTD
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Sea-Air Systems
Expendable Oceanographic Instrumentation
•Lockheed Martin Sippican’s expendable probes collect data on physical
properties of the ocean such as temperature, sound velocity and current velocity.
The probes can be launched from aircraft, surface ships and submarines.
•Expendable Bathythermograph (XBT): The XBT provides an ocean temperature
versus depth profile and is useful for anti-submarine warfare (ASW). Also
available as a submarine launched version, the SSXBT.
•Expendable Sound Velocimeter (XSV): The XSV obtains accurate sound velocity
profiles for the support of ASW operations, mine countermeasure operations, and
oceanographic research. Also available as a submarine launched version, the
SSXSV.
•Expendable Current Profiler (XCP): The XCP provides real-time profiles of current
speed, direction, and temperature to depths of up to 1500 meters. Also available as
an airlaunched version, the AXCP.
•Expendable Conductivity Temperature and Depth Profiler (XCTD): The XCTD
profiling system collects salinity profiles to depths of up to 1850 meters. Also
available as a submarine launched version, the SSXCTD and as an airlaunched
version, the AXCTD.
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Sea-Air Systems
Data Acquisition Systems
AN/BQH-7/7A
EC / MK8-F
MK 10
MK 21
•Military recorders are used aboard surface ships and
submarines. The recorders display and stores plots of
depth vs. temperature, depth vs. sound velocity, and /or
depth vs. temperature and conductivity; then output this
data to an external combat system or work station.
•Commercial recorders are used aboard research
vessels and ships of opportunity. The MK10A collects
data from the expendable current profiler (XCP). The MK
10A receives the radio frequency output of the probe in
real-time and converts the signal into digital format. The
system processes the data and displays the readings of
temperature and current velocity on the screen.
• The MK 21 Data Acquisition System runs on a laptop or
personal computer using Microsoft Windows
compatible software. Features include auto GPS input
capability and improved post-processing options. The
system is compatible with Lockheed Martin Sippican
XBT, XSV, and XCTD probes.
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Story of the XBT
1944 Dr. Spilhaus @ WHOI developed the
mechanical BT
1960 US Navy developed a requirement for
an expendable bathythermograph
DTUPC
$115.00
1962 Sippican’s design wins competition
against GM-Delco, Bissett Berman
1968 Sippican awarded a production
contract for 1,000,000
1995
Production moved to Juarez, MX
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XBT Production Facility
Production equipment, tooling,
test stations and all capital
equipment moved to Juarez in
1995.
Process controls, inspection,
sampling test and verification
processes remained the same
and include oversight from
Marion support personnel.
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XBT Production Facility
Copper wire winding process is
tightly controlled with a 100%
verification to defined process
limits. Assures consistency and
monitors in-control process
parameters.
XBT matching, thermistor leak
tests and continuity test stations
are semi-automated and have
built-in mistake proofing.
Process has not been changed
since earliest XBT production
approved in Marion.
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XBT Production Stability
•Since the start of XBT production, there have been very few changes in
physical configuration of the T-4, T-5, T-6, T-7, T-10 and DB family of probes.
The next several slides will explain the changes and the measures taken to
avoid any adverse effects in performance.
•Probe noses and plastic molded components are being made using the
same tools and are supplied by the same suppliers as they were since
the beginning of production.
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XBT Production Stability
• Move to Juarez – In 1995 the XBT production line was moved to Juarez, Mexico. All
parts, processes, and equipment were sent to Mexico with the Marion line people to
start up production. The Marion line supervisor remained in Mexico for over 2 years
and has remained directly responsible for the line to this day. While the production
staff did change in 1995 there were no product changes made at that time. In addition,
the Marion QA team has continued to sample product from Mexico heavily and done
visual inspections and at sea tests to confirm that probe reliability was not adversely
affected. The following chart shows a summary of XBT QA results for reliability for
the period preceding the move to Mexico up until today. Immediately after the move
to Juarez the deepblue probe was re-qualified with NOAA with an at sea test (see next
graph).
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XBT Production Stability
• Move to Juarez – Bermuda Sea Trial Results
Lockheed Martin Sippican QA Sea Trial Results
Production in Juarez
105.0%
100.0%
Successful Drops
95.0%
90.0%
85.0%
80.0%
75.0%
70.0%
65.0%
60.0%
Feb-82
Nov-84
Aug-87
May-90
Jan-93
Oct-95
Jul-98
Apr-01
Jan-04
Oct-06
Jul-09
Test Date
XBT
NOAA DB Qual
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XBT Production Stability
• Wire coating change – In 1996 LMS (then Sippican) was no longer allowed to apply
the coating to the BT wire in house for environmental reasons. The same raw wire
continued to be used but a new environmentally compliant coating process was
developed and qualified. The new wire coating resulted in a change to the probes as
built. The weight in air of the new coated wire was slightly lighter than the legacy wire
and therefore the probe winding specifications were changed to account for the
weight change, assuring that the wet weight of the probes and the weight per foot of
wire deployed in water was unchanged from the baseline design.
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XBT Production Stability
• Netting Added – In 1999, in an effort to improve probe
reliability related to the effects of shipping where the wire could
be shifted due to shock and vibration, a light plastic netting
was added over all wire spools that lightly holds the wire in
place. Shipping, shock, and vibration testing demonstrated
that this held wire spools in place better than the latex binder
alone that was previously used on wire spools. The netting
applies a very light tension to the top windings (a few grams)
which diminishes as the wire pays out. Probes were tested in
side by side, at sea, drops to demonstrate no measurable effect
on the drop rate.
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XBT Production Stability
• Recorder change – While not related to XBT production there has been changes to
recording systems used in support of XBT data collection. The original XBT users
had analog recording systems. These were followed by the Sippican MK9 recorder
(HP based) in the 1980’s, the MK12 PC based system was released in 1991, and the
MK21 PC based system replaced the MK12 in January of 2000. Along the way there
have been other, non-Sippican, systems used that have had performance issues and
concerns. LMS has been careful to ensure that any system released
provides improved data collection accuracy
while not changing the basic launch detection
techniques. The MK12 and subsequent MK21
offer the selection of the original equation or
IGOSS. The equation used is clearly shown in
the raw data file.
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Backup Slides
Marion Senior Leadership Team
William Walsh
Vice President
Business Growth
Business
Development
Bill Stark
Chief
Technologist
Apostle “Butch”
Cardiasmenos
Chief Scientist
Mike Balboni
Lines of Business
Functions
Sea Air Systems
Larry Hall
Director
Underwater
Vehicles
Doug Dapprich
Director
Communications
Tracy McNeil
Communications
Rep Sr.
Contracts
Karen Leary
Manager
Countermeasure
Systems
Tom Jarbeau
Sr. Manager
Polaris
Bob Egan
Manager
Finance &
Business
Management
Jim Hickey
Director
Human Resources
Donna Hogan
Manager
International
License Control
Keila Gonzalez
Operations
Matt Sheran
Manager
Sourcing
Bill St. George
Sr. Manager
Mission Success
& Information
Technology
Dave Maher
Sr. Manager
Security
Sarah Innes
Manager
Technical
Operations
Mark Whalen
Sr. Manager
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S ip p ic a n , In c .
Sippican Oceanographic Products
Juarez Transition Approach
 Preparation for ISO 9001 certification required that the process
documentation be reviewed, checked carefully, and put under
additional controls. Preparation took several months and resulted
in ISO certification being granted in July 1995, two months after
production began in Juarez.
 All process documentation and existing assembly stations and
fixtures were disassembled in Marion and taken to the Juarez
facility.
 The XBT/SSXBT Production Supervisor of 20 years relocated to El
Paso, Texas to start up the Juarez facility and manage the new
plant for two years.
 Several long-term Sippican employees worked for the production
supervisor to reset-up the equipment and fixtures and qualify the
lines.
 Product manufactured in Juarez was shipped back to Marion for
quality assurance testing using the same test procedures and in the
same test fixtures still used today.
 Lot sampling continues to this day for all products out of Juarez.
 The Juarez plant is now managed by the 20 year Sippican
employee who was the Senior Quality Manager for the
Oceanographic business in Marion.
Ocean Systems Division
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S ip p ic a n , In c .
Sippican Deep Blue (Surface XBT, 20 knots/2500 ft)
Mexico vs. Marion Production Quality Comparison
 First Article Test was performed by NOAA (National Oceanographic
and Atmospheric Administration) to qualify probes built in Juarez for
contract 50-DGNC-5-00005
 Test performed 10/15/95 through 10/16/95 (assembly of probes in
Juarez began 5/95)
 Purpose of Test: Determine the functional reliability of the XBTs
being assembled in the Juarez facility. Pass/fail criteria was a
minimum reliability of 94%.
 Results of Test:
100 probes (Deep Blues) launched
96 probes met all requirements (96%)
 Sippican Sea Test results for XBTs built 1994/95 (immediately prior
to the move):
122 probes launched
117 probes met all requirements (96%)
NOAA conclusion was that Juarez probes and Marion probes are
comparable. NOAA went on to purchase 25,000 probes in 1996 and
50,000 probes in 1997.
Ocean Systems Division
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