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The W76-1/Mk4A First Production Unit was delivered in September 2008. This milestone represents the most significant product delivery by the nuclear weapons complex in more than a decade, made more significant because Los Alamos National Laboratory was able to certify the warhead without an underground test. The delivery required significant contributions from across Sandia and was made possible by teaming with partners at Los Alamos and the nuclear weapons complex production agencies and working effectively with Sandia’s NNSA and Navy customers. (2100, 1300, 1500, 1800, 1700, 5300, 2400, 2500, 2700, 2800, 2900, LANL, production agencies, NNSA, US Navy) NW
Developing and implementing the Realize Product SubSystem (RPSS) of the Nuclear Weapons Strategic Management Unit was a significant undertaking, affecting the way thousands of people perform their jobs. The RPSS integrates thousands of requirements and practices into approximately 130 mandatory procedures. The newly formed, director-level Realize Product Council ensures leadership engagement and continued sustainment and improvement of the system. The RPSS simplifies Sandia’s approach to meeting requirements, improves consistency and reduces redundancy, accelerates learning for new employees, and provides a baseline for communication, training, and continuous improvement. (Supported by all NW centers) NW
Significant progress was made toward the use of one universal three-dimensional computer-aided design (CAD) model for the MC4532 neutron generator project. This concept will allow increased utilization of one model for all stakeholders, including design, manufacturing, and analysis, throughout the design life cycle. A top-down modeling approach was used by specifying design criteria, including parameterization, at the top-level assembly and passing those criteria down through the model structure. Because of this approach, incorporation of design changes was simplified, resulting in significant design-to-analysis cost and schedule savings. (1500, 2400, 2700, 2900) NW
Responsive Neutron Generator Product Deployment Center 2700 in July 2008 became the first public-sector organization to be awarded the Shingo Prize for Operational Excellence. The Shingo Prize recognizes excellence in using lean principles to achieve operational excellence and consistent business results. Center 2700 received the prize for demonstrated results in cost reduction, quality, and productivity by using lean tools; integrating the neutron generator life cycle from science, through development and production, to sustainment; and affecting a culture change toward lean thinking across the organization. (2700) NW
As part of the Tech Area 55 (TA-55) upgrade at Los Alamos National Laboratory to support manufacturing requirements, Sandia developed a discrete-event simulation for plutonium processing to analyze process and transport times within the machining and foundry areas, as well as a three-dimensional visualization to demonstrate proposed material transport scenarios within Wing 300. Both the simulation and 3-D visualization were used to evaluate proposed part transportation scenarios within the facility. The results of Sandia’s Wing 300 production analysis were used to make recommendations to NNSA concerning facility upgrades. (6400) NW
The MC4082A Power Supply Product Realization Team concluded that massive updating was required for the MC4082A power supply drawing set. After six months, more than 2,700 person-hours, intense requirements mapping, and 331 drawing changes, the MC4082A was manufactured to a new set of 45 drawings and subsequently submitted for final product acceptance, with no errors, issues, or findings. (12300, 2500) NW
A reliability assurance methodology was developed that addresses the need to obtain highly reliable nuclear weapon components from small production builds. The method combines fault tree and expert critique to identify a manageable number (typically about 20) of fatal defects that must be prevented, and identify controls that must be implemented. The method, which is both efficient and effective, focuses attention on what is essential and helps resolve conflicts. It has been successfully applied to reliability assurance of energetic components. (12300) NW
A Sandia-invented, power-free leak tester was implemented at Pantex. The Lightning-Immune Leak Tester is compact and easy to use and meets leak test requirements without the use of AC power, which enables weapons testing to continue even during lightning warnings. Recently a moisture sphere was incorporated, enabling efficient screening of moisture levels in weapons for component reuse decisions. Since implementation, significant savings (greater than $10,000 per month) and reduced processing times contributed to a recent effort being completed two months ahead of schedule. (12300, 1800) NW
Sandia science, technology, and product realization expertise enabled the development, qualification, and delivery of the first optical transceivers for space applications. Sandia worked in concert with Peregrine Semiconductor, ULTRA Communications, and n-Light Corporation to deliver the final products. Once on orbit, each optical channel of these radiation-hardened devices will provide low-noise, 2.5 gigabit-per-second, bidirectional transmission of critical sensor data to onboard processors that configure data for satellite downlink. This revolutionary, high-bandwidth data processing capability is a key enabler for next-generation space-based remote sensing systems. (5700, 5300, 5500, 1800, 1700, 1500, 12300, 10200, 2400, Peregrine Semiconductor, ULTRA Communications, n-Light Corporation) DS&A