Product realization

ALAN GORENZ (1766) confirms a 100 percent success rate for machine-vision reading of 2-D data matrix-encoded Sandia piece parts for full traceability supporting an electronic production control system. (Photo courtesy of Alan Gorenz)
We’ve built a machinevision recognition system for fast, error-free parts handling in support of a defect-prevention strategy for our small form-factor HBT — heterojunction bipolar transistor — products. The system removes the human operator from multiple data entry steps from package lidding to final package delivery. Human data entry now occurs only once in the product’s life. The reading system uses high-resolution camera software to recognize each part in an image of an array of parts to enable our software system to interface seamlessly within an electronic production control system framework. (1700) NW [NW]
In partnership with NNSA, Sandia’s Neutron Generator Enterprise (NGE) developed an NGE Integrated Program Plan (NIPP), a key element of customer management assurance. The NIPP communicates the approach used to plan, manage, and operate the enterprise to meet required deliverables per negotiated funding targets. In FY14, the NGE met or exceeded all production and development NIPP deliverables. A noteworthy FY14 highlight for the NGE was the realization of a $4.5 million recapitalization gain for critical equipment needs as a result of continuous improvement activities. (2700, 2800, 2100, 2500, 8200) NW [NW]
The B83 ALT353 Gas Transfer System Product Realization Team overcame technical and programmatic challenges to successfully complete all deliverables, culminating in First Production Units in 2014. The team applied its strengths in metallurgy, material science, and computational analysis to address production challenges and establish a robust qualification process. The aggressive timeline necessitated outstanding communication and coordination among Sandia, the Kansas City Plant, and the Savannah River Site. The ALT353 motto is “One Team” and they have exemplified that maxim in their efforts and in their success. (8200, 8300, 8500, 8100, 1800, KCP, SRS) NW [NW]
Center 5400 met key milestones for the B61-12 LEP with the assembly, integration, testing, and delivery of three Compatibility Test Units (CTU-2) and seven Flight Body units (FB-2). The CTU-2 is a representation of the B61-12 used by Aircraft Compatibility (2951) to evaluate the weapons’ pre-release functionality and ultimately certify the B61-12 weapon for use on the F-15, F-16, B-2, and PA- 200 aircraft. The FB-2 is a representation of the front end of the B61-12 intended to support tail kit assembly development and qualification by the Air Force. (5400, 2100, 2900, 6500) NW [NW]
The Common Engineering Environment Portal is the first dedicated website available for engineers to access all components (i.e., processes, tools, training, best practices) needed to excel in the practice of engineering. The impact will lead to improved systematic quality approaches through consistency in preferred engineering practices. The Portal will result in more efficient workforce skills mobility across Sandia. The Labs may realize cost savings through corporate tool purchases including multi-user licenses. The site was created through collaboration across all PMUs via the Common Engineering Environment Steering Committee. (9010, 9500, 9300, 8900, 2200, 1500, 8200, 10600, 5500, 6500, 6900, 0100) IMS [LF]
The final lot of the MC4698 thermal battery for the W76-1 LEP was delivered in September 2014, free of defects. The entire production run of batteries was accomplished through a close partnership with Sandia External Production, the Sandia Quality organization, and a commercial supplier. A Lean Six Sigma approach and a concerted effort to communicate Sandia requirements were critical to meeting schedule and cost targets. The resulting collaboration has built a solid foundation for future work. (2500, 400) NW [NW]