Diversified Products for the National Defense

40mm Reliability Trends in the

System Contract

NDIA Small Arms Forum

June 2, 2015

Presented by: Matt Eckel

Premise
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The high reliability of the US Army’s ARDEC

designed 40mm fuzes and tactical cartridges
has been demonstrated through 10 years of
two Systems Contracts.

Photo: US Army
From Break-out to System Contract
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In 2005, the US Army awarded the largest

ever Small Business Set-Aside System
Contract. The new Prime Contractor
assumed responsibility for overall 40mm
cartridge reliability results.

M918 M430A1 M385 M781 M433 M583A1 M661 M662 M992 M585
Bottom Line Up Front
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• Implementation of System Management

Contract has confirmed 40mm System
Capability and Warfighter Utility
Bottom Line Up Front
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• Performance – Repeatability and

Reliability Exceeding Requirements

• Availability – Production Rate and

Schedule Meets US Army Needs
Reliability
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Two Types of Reliability:

Functional
High Order Main Charge Detonation

Safety
It detonates when it supposed to, safe to
handle, and compliant to MIL-STD-1316
M433 HEDP 40mm Cartridge
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The Specification Reliability Requirement1:

M433 HEDP Low Velocity - .958

AMTEC Reliability2 - .993

1 MIL-DTL-50872
2 114 LATs over 9 years representing 2.9 Million units
M433 HEDP LAT Results
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M433 HEDP Cartridge

1.000 3,500,000
0.995
3,000,000
0.990
0.985 2,500,000

Cumulative Quantity
0.980
Reliability

2,000,000
0.975
1,500,000
0.970
0.965 1,000,000
0.960
500,000
0.955 Reliability
0.950 0
Specification
07 08 09 10 11 12 13 14 15
Production Year Cum Quantity
M430A1 HEDP 40mm Cartridge
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The Specification Reliability Requirement1:

M430A1 HEDP High Velocity - .968

AMTEC Reliability2 - .995

1 MIL-DTL-50863
2 307 LATs over 10 years representing 14.7 Million units
M430A1 HEDP LAT Results
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M430A1 HEDP CARTRIDGE

1.000
14,000,000
0.995
0.990 12,000,000
0.985

Cumulative Quantity
10,000,000
0.980
Reliability

8,000,000
0.975
0.970 6,000,000
0.965
4,000,000
0.960
2,000,000
0.955 Reliability
0.950 0 Specification
06 07 08 09 10 11 12 13 14 15
Production Year
Cum Quantity
M550 PIBD Fuze
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The Specification Reliability Requirement1:

M550 PIBD Fuze Low Velocity - .962

AMTEC Reliability2 - .999

1 MIL-DTL-50869
2 68 LATs over 9 years representing

3.9 Million units

M550 Fuze LAT Results
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M550 PIBD FUZE

1.000 4,500,000
0.995 4,000,000
0.990 3,500,000
0.985

Cumulative Quantity
3,000,000
0.980
Reliability

2,500,000
0.975
2,000,000
0.970
1,500,000
0.965
0.960 1,000,000

0.955 500,000 Reliability

0.950 0 Specification
07 08 09 10 11 12 13 14 15 Cum Quantity
Year of Production
M549A1 PIBD Fuze
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The Specification Reliability Requirement1:

M549A1 PIBD Fuze High Velocity - .968

AMTEC Reliability2 - .998

1 MIL-DTL-32175
2 104 LATs over 9 years representing

13.2 Million units

M549A1 Fuze LAT Results
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M549A1 PIBD FUZE

1.000 14,000,000
0.995
12,000,000
0.990
0.985 10,000,000

Cumulative Quantity
0.980
Reliability

8,000,000
0.975
6,000,000
0.970
0.965 4,000,000
0.960
2,000,000
0.955 Reliability

0.950 0 Specification
07 08 09 10 11 12 13 14 15 Cum Quantity
Production Year
Reliability Contributors
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Contributors to High Reliability:

• 10+ years of Contractor “Lessons Learned“
• Increased Automation
• Robust Inspection Criteria
• Variability Reduction
Reliability Contributors
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Contractor “Lessons Learned“

• Process Improvements have occurred at
all levels from component manufacturing
to Cartridge LAP
• Inspection and Sampling
• Integrated Product Team (IPT)
• Engineering Change Proposals (ECP)
Reliability Contributors
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Contractor “Lessons Learned“

• Fuze Modeling Addressed Stack-up
Tolerance Issues
• Capitalization Improvements in Assembly
Equipment Capabilities
Reliability Contributors
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Increased Use of
Automation
• Sensors
• Auto Recognition
cameras
• Digital X-Ray
• Robots
• Networking
Reliability Contributors
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Inspection Criteria
• Critical Characteristics Control Plans
• Automatic Acceptance Inspection
Equipment (AAIE)
Reliability Contributors
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Variability Reduction
• The System Contractor and suppliers have
imposed tighter tolerances than allowed in
the TDP based on analysis of key
characteristics that drive variability

• Charge Evaluation Charge Verification

(CECV) & Automated Propellant Loading
Benefits Realized
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Program:
• Repeatability and Reliability Demonstrated
to exceed Requirements
• Subject Matter Expertise (SME’s)
Strengthened
• Production Continuity through Single Fuze
Manufacturer
• Mature Supply Chain Management
Benefits Realized
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Warfighter:
• Ammunition Available – Inventory
Established
• Performance Repeatability
• Operational Safety
• Weapon Interface –Stoppage/Jam Risk
Minimized
• CONFIDENCE IN 40MM
Conclusion
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Under the current management teams of the

U.S. Army Product Director for Medium
Caliber Ammunition, ARDEC, and the System
Prime Contractor, the fuze safety, arming,
and functional reliability characteristics of the
40mm fuzes and their integration with the
high explosive cartridges have been
demonstrated to exceed the published
military specification requirements.
 Diversified Products for the National Defense

Matt Eckel
busdev@amteccorp.net