An electo-mechanical ordinance-arming device for a ground-launched missile sporadically failed shock and lateral arming tests in production, precipitating missile field delivery delays. Numerous agency "red" team investigations had been unable to identify the root cause of the problems. The program manager responsible for deliveries of the arming device, distinct from the agency responsible for the design, requested an independent review and this was conducted. The root cause of shock sensitivity in one of the principal axis was identified. Regarding timing, it was determined that the device was structurally robust in only two of its three principal axis. The inherent weakness in the third axis, the root cause, was responsible for the timing anomalies exhibited during lateral arming tests. Easily implemented design changes were recommended to correct the deficiencies and simplify the device as well. The agency performed a producibility enhancement of the device, included the recommendations, and the device then satisfied all operational test requirements.

Established designs, even if promoted and

approved by official agencies, can be flawed.

Proposal responses to Request for Quotations (RFQ) are always a risk. Proposals are evaluated on Cost, Management and Technical merit, usually in that order. Is it within budget? Is the team capable? Does it satisfy requirements? The correct balance of all disciplines is essential. Two very capable companies were competitors for a high performance air launched defensive weapon. They each took a separate path in determining the physical characteristics of their flight weapon system. Pre-award development flight tests suggested that either candidate was a viable contender. A significant difference existed however, in the captive carry and launch requirements of these new weapon systems. One company developed a design which used two different existing launchers. The second company developed a design which required a new launcher and could not be deployed with existing launchers. The second company approach would impact the cost and logistics of the customers field equipment. The second company lost the competition and the award went to the first company with the simpler overall system solution.

Never offer the customer more than requested when it is not a benefit.

The solicitation of a competitive second source can be a useful cost reducing purchasing tool. A candidate second source manufacturer for a high performance weapon system was failing field qualification tests. A top quality system manufactured to the primes engineering data package was not satisfying the top level requirement specification. Failure to become a second source manufacturer was imminent. Determined to succeed, the environmental parameters of the field qualification test envelope were replicated by the candidate second source in the laboratory, and it was found that the "built to print" system did not meet top level specifications. A fatal flaw was uncovered which rendered it useless in certain areas of the operational envelope. It was found later that the prime knew of this problem and could not solve it. The candidate second source wrestled with the problem and eventually solved it ensuring that the weapon system satisfied all top level requirement specifications. The competitive second source became firmly established. The prime was later directed to incorporated the solution.

Never assume a "build to print" system is a guarantee of success.

I've rebuilt many internal combustion engines successfully. One in particular stands out. My dad's old Plymouth, with a slant six cylinder engine, had more than 200,00 miles on it when it finally threw a rod. "Want to fix it?" I asked. "Yes" the reply. The slant six engines came in two versions, 170 cubic inch and 225 cubic inch which my dad had, and were very simple. I dismantled the engine, assessed the damage and proceeded to refurbish and/or replace parts as required. This included a re-ground crank, new pistons, valve and head reconditioning, new bearings, gaskets and seals, oil pump, etc. and lots of labor. All of this transpired at my dad's home, about 22 miles from my home, and at times I could be available. Finally finished, the moment of truth. It started immediately and was the quietest and smoothest running engine I ever heard. I put it in gear and was unable, literally, to move the vehicle an inch. In fact as soon as I depressed the accelerator pedal it ceased to run. What had I done wrong? Finally exasperated and almost clueless, I towed the vehicle to my home where I could devote more time directly to solving this puzzle.

To shorten the story, I'll conclude that I had to completely dismantle the engine, change some pieces and rebuild it. It then worked perfectly. The puzzle pieces are identified, perhaps not obvious which ones are suspect, and I leave them for your guess at the solution. One of my many mentors, once made the point; "The big things go by themselves, it's the details that will trip you up."

Pay attention to details!

The best sounding board for a man has always been a good woman. The keel is kept straight, balance is maintained, the storm is weathered and safe harbor is achieved.

Delores, my loving wife, is truly more than my better half.

She has, thankfully, a place in heaven with family and friends.