ENGINEERING EDGE - NOV 13

THE ENGINEERING EDGE

EDGEWOOD CHEMICAL BIOLOGICAL CENTER

Volume 5, Issue 11

November 2013

ECBC Engineering

Celebrates Veterans Day

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hat has come to be known as Veterans Day was originally set as a U.S. legal holiday to commemorate Armistice Day—the end of World War I, which occurred on November 11, 1918. In 1938, Congress named November 11 as a day “dedicated to the cause of world peace and to be hereafter celebrated and known as “Armistice Day.” As such, this new holiday honored World War I veterans and commemorated the end of “the war to end all wars.”

With the approval of this legislation on June 1, 1954, November 11 became a day to honor American veterans of all wars.

To access the electronic version of this newsletter, visit: http://www.ecbc.army.mil/news/ENG/ APPROVED FOR PUBLIC RELEASE

In 1971 in accordance with the Uniform Monday Holiday Act, Veterans Day was moved to the fourth Monday of October.

On September 20, 1975, President Gerald R. Ford signed a law which returned the annual observance of Veterans Day to its original date of November 11, beginning in 1978. Since then, the Veterans Day holiday has been observed on November 11.

No matter when you celebrate Veterans Day, take time to reflect on the sacrifices made by the 21 million veterans living in the United States today. These words from President John F. Kennedy on Veterans Day, 1961, say it best: “We celebrate this Veterans Day for a very few minutes, a few seconds of silence, and then this country’s life goes on. But I think it most appropriate that we recall on this occasion, and on every other moment when we are faced with great responsibilities, the contribution and the sacrifice which so many men and their families have made in order to permit this country to now occupy its present position of responsibility and freedom, and in order to permit us to gather here together.”

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INSIDE THIS MONTH’S ISSUE: pg.2-3|Enhancing Reliability Tests: Highly Accelerated Life Testing (HALT) Embraced at TREB pg.4-5|Veterans Day pg.6-7|A New Home: Packaging Branch Moves into New Laboratory pg.8|Employee Spotlight: Dave Vincitore

ENHANCING RELIABILITY

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chain is only as strong as its weakest link, and a well-designed product is only useful to the Warfighter until a component fails. Highly Accelerated Life Testing (HALT) can expose the inherent weak links of a product design and allow engineers to eliminate these weaknesses before the product matures and enters into manufacturing. This method differs from Accelerated Life Testing (ALT) as the test is not attempting to quantify a life cycle but rather provide qualitative data.

The Test, Reliability and Evaluation Branch (TREB) located within Edgewood, Chemical Biological Center (ECBC), Bldg E5165, is a branch of the Engineering Test Division (ETD) which focuses on staying innovative and current with the latest technology. Do P. Nguyen, TREB Branch Chief, invested in the HALT chamber to enhance ECBC’s test mission of providing the highest standard of reliability testing and quality services to serve the Warfighters. This chamber will not just provide a return on investment for the ECBC

Engineering Directorate, but also for the Warfighters risking their lives, as they will be able to attain more reliable, robust products to accommodate the JPM programs’ budget and acquisition test requirements.

HALT operates on the principle of exposing a product to thermal and vibration cycles in excess of normal to find potential design limitations in the early stages of product development. Each test is systematically designed to stress the product beyond the intended operating limits by subjecting a product or end item to specified conditions.

“The goal is not to find when a product will fail but what will fail first” states Daniel O’Neill, TREB Mechanical Engineer. By finding the weakest link and performing failure analysis and corrective actions, the design as a whole will improve. The chain’s weakest link has been strengthened and thus the entire chain becomes stronger and more reliable.

The chamber has a 4’ by 4’ interior vibration table that is divided into four sub quadrants, which can be utilized to test several smaller items using various stresses (temperature, vibration, shock) simultaneously. This type of testing (multivariate) allows for the optimum variable combination to be exposed, ensuring confident test results.

“Having the capability to write programs that create temperature and vibration profiles in addition to powering the test item on

This newsletter was published through the Balanced Scorecard.

For article suggestions, questions or comments please contact Ed Bowen at edward.c.bowen8.civ@mail.mil

SharePoint Tip: Selecting a URL for Your Site When selecting a URL for your new SharePoint site, remove spaces in between words to ensure that your link is both shorter and less likely to break when shared via email or instant message. For example, a site which is titled “My New Site” will render in a browser as https://cbconnect. apgea.army.mil/My%20New%20Site, whereas a title entered as “MyNewSite” or “My-New-Site” will render more concisely as https://cbconnect.apgea.army.mil/MyNewSite or https://cbconnect. apgea.army.mil/My-New-Site.

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TESTS:

THE ENGINEERING EDGE |November 2013| 3

Highly Accelerated Life Testing (HALT) Embraced at TREB

the board at specific time intervals makes the HALT chamber unique. This control provides the TREB with the flexibility of altering each test to best suit the test item and customer test request,” states O’Neill.

The HALT capability allows for additional accelerated reliability tests and screenings including Environmental Stress Screening (ESS). ESS is applied specifically during the production of electronic systems to yield significant improvements in field reliability.

Electronic systems or components that contain Printed Circuit Boards (PCB) are some of the best items to test in the HALT chamber because of the rapid changes in (thermal) stresses.

Although HALT chambers are not limited to electronic boards, they are an excellent tool for finding latent (hidden) defects.

According to Steve Marshall, TREB Reliability Team Lead, “Identifying weaknesses early in the production phase increases customer confidence and ultimately, customer satisfaction.”

Customer satisfaction is a huge benefit to this capability that will fuel future business and the HALT/ESS lifespan.

In addition, budget cuts and overall costs are becoming more prevalent in our ever changing work environment. In today’s world such budget restraints are inevitable for many organizations while the need for growth and production is still there. This HALT/ESS capability offers a solution to this struggle, as it enables manufacturers to save in sustainment costs.

Having the ability to improve the reliability of the end item at an early stage in design allows for the reduction in warranty and support costs later in the life cycle.

Not only does HALT/ESS save the customer in sustainment costs, but identified failure modes and design weaknesses are revealed in a tighter timeframe than traditional test methods.

They are exposed within hours or days of the start of testing, which induces the start of corrective actions and increases the test item’s reliability.

The TREB is not just confident in this capability, but eager to progressively initiate testing. Striving to remain a leader in the test and evaluation field, HALT/ESS continues to strengthen the Reliability Analysis area and has the potential to establish a new workload for the center. TREB personnel have already received the necessary certification training for use in reliability testing. Aside from HALT being a new capability for the TREB

and the ETD, the chamber is the only one of its kind located on base, both in Edgewood and Aberdeen. The TREB also acquired several ReliaSoft data analysis packages within the past year.

Utilizing analysis packages and tools throughout the life of the product, in addition to conducting tests such as HALT/ESS, provides for smoother development and acquisition cycles.

The TREB has received notification of interest in this capability from the Joint Product Manager-Protection and the Army Materiel Systems Analysis Activity (AMSAA) and hopes to partner with these organizations in testing for future projects.

Collaborating with private industry organizations can also benefit the HALT/ESS capability as it would increase its successfulness and longevity in the test and evaluation industry, ultimately providing the Warfighters with a more reliable end item. TREB foresees this capability as a benefit to the research and development community as well.

For more information on the HALT capability, chamber and all business inquiries please contact Do Nguyen, 410-436-4237, usarmy.APG.ecbc.mbx.treb@mail.mil.

Ask a Tech Tip: Removing Oil Stains from Your Driveway Mike Kauzlarich, of the Pyrotechnics and Explosives Branch, reveals how the techniques and lessons learned in labs can help you solve your household problems. Submit a question to him at usarmy.APG.ecbc.mbx.engineering-directorate@mail.mil.

You were working on the car this summer and you spilled some oil on your driveway. It’s unsightly and makes a cool sheen your children enjoy every time it rains. How to remove it? Use Dawn dishwashing soap. It is one of our favorite multiuse products. Work some full strength on the stain, let it sit for a while, and then hose it off completely. It may take several applications, so please be patient and repeat the process as necessary.

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VETERANS DAY “This Veterans Day we find our nation emerging from the longest continuous time of war in its history. A new generation of veterans have deployed to locations from the deserts of Iraq to the mountains of Afghanistan, and elsewhere around the world. They return home with the heavy burden of multiple deployments, long separation from loved ones and the tragic consequences of war. America owes each of our veterans from every generation gratitude and support.

So too, do we owe their families our gratitude and support. To that end, November is Military Family Month, a time for all Americans to do more to recognize and support the members of their community who have fought on our behalf. ECBC supported military families when we delivered winter apparel that we collected in early fall to those in need. We continue to support military families as we collect canned food and toys for our annual Food, Toy and Gift Drive that is currently underway. These campaigns are a great way to support our local Soldiers and their families.

In some small way, on Veterans Day and every day, I ask you to please find a way to thank a veteran who served for us with such valor and distinction. Nothing means more to them than knowing that their service and sacrifice is appreciated right here at home.

–Suzanne Milchling, Director, Program Integration Directorate, ECBC

“In the life of our nation, across every generation, there are those who stand apart. They step up, they raise their hands, they take that oath. They put on the uniform and they put their lives on the line. They do this so that the rest of us might live in a country and a world that is safer, freer, and more just. This is the gift they’ve given us. This is the debt that we owe them.

Our troops wear the uniform for a time, yet they wear another proud title, the title of ‘veteran,’ for decades – for the rest of their lives. As a nation, we make sure we have the best-led, best-trained, best-equipped military in the world. We have to devote just as much energy and passion to making sure we have the best-cared for, best-treated, best-respected veterans in the world. So when we talk about fulfilling our promises to our veterans, we don’t just mean for a few years; we mean now, tomorrow, and forever – and not just for generations past, but for this generation of veterans and all who will follow.”

–President Barack Obama APPROVED FOR PUBLIC RELEASE

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The ECBC Engineering Directorate honors all of the men and women in our workforce and community who have served in the U.S. military. A special thank you to those employees who shared their personal photos and stories to help commemorate this day.

“Veterans Day is equally important for non-veterans, because it is an opportunity for the American people to learn more about the great sacrifices that have been made on their behalf – especially during the past twelve years of war. The United States is now winding down the longest period of sustained combat in our history, but America’s obligations to those who answered the call to serve are only beginning.

Like generations before them, America’s newest veterans are poised to help our nation thrive and prosper in the 21st century. They are professionals who have mastered advanced technologies, honed their leadership skills, and demonstrated character, courage, and a profound sense of duty.

From the oldest veterans to the men and women currently serving our nation, all Americans who have served in uniform deserve the nation’s appreciation and respect on this uniquely special American Day.” –Secretary Chuck Hagel

William ‘Bill’ Lake, Engineering Support Division Chief, United States Marine Corps, 1974–1977

“ECBC has supported me as a veteran and civilian employee through the course of two deployments to Iraq, a recent one to Afghanistan, and multiple military training schools. Although far away from home, knowing that I am still part of such an organization is a fond memory of Veterans Day for me.”

–Stephen Harper

Brad Graper

Armor, 1977-1988

“I served in the United States Navy from 1984–1992. While serving my country I learned much about team work and pulling together to get tasks done while at sea and docked in port. I had the privilege to be on a six month deployment to the Mediterranean Sea. We visited a number of countries and learned a lot about the different cultures. We were part of a big operation with the Coast Guard and served as the Command ship for ‘Drug Ops.’ There are many experiences I had over the years which have changed my life and it was a pleasure to have had the opportunity to serve my country.”

–John Call, IPTL Bids TDP, Engineering Technician, Engineering Drawing Development, Advanced Design and Manufacturing

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A New Home:

Packaging Branch Moves T he ECBC Engineering Packaging Branch has a new home! Packaging Branch Chief Dave Vincitore and his five-person team of military packaging specialists moved from E3331 to the C100 Quad of the Berger Building, and opened a new, 1,200 square foot Packaging Laboratory.

The new facility allows the Packaging Branch to combine all of their capabilities under one roof, streamlining their prototyping and packaging data development operations.

Said Vincitore, “Our equipment and materials used to be very spread out. We had small items, like a scale and a small heat-sealer in the back of a copier room in our old building, while most of our packaging materials were scattered and stored in other facilities. Our larger packaging equipment was entirely packed away, because we didn’t have the space to set up and operate it. We had to go back and forth between facilities to get our work done.”

The new Packaging Laboratory changes all of that. The new facility is equipped with multiple workstations, providing Vincitore and his team room to evaluate packaging samples, to use their equipment, and to organize their specialized milspec packaging materials. The improved workspace permits the highly-skilled team to weigh and measure parts and systems to be packaged, fabricate prototype packages, and document packaging designs for configuration management and lifecycle support of the items. Debbie Brooks-Harris, a packaging specialist with the branch, noted the advantages of the new workspace immediately for her evaluation of a vendorsubmitted packaging design.

“Before, I had to work from my desk, going to another building to work on the larger containers, or to use a particular piece of equipment,” said Brooks-Harris.

“Now I am able to get everything done here in the lab, which makes life a lot easier.”

Biological Chemical Reconnaissance Vehicle (NCBRV), Joint Expeditionary Collective Protection (JECP), and Joint Biological Point Detection System (JBPDS), as well as all ECBC commodity teams. But Vincitore is also hopeful that the new Packaging Lab will allow them to expand their support to all of ECBC and all ECBC customers. “This new facility definitely improves our capabilities, and we hope that it will allow us to improve our offerings. We will use our new lab space to expand our services internally and externally.

Our team’s ability to design prototypes or evaluate a vendor’s packaging proposals can save JPM program funds and ensure efficient world-wide transportation of materials to the Warfighters.” “[We] want to expand our expertise and utilize it in different areas,” said Vincitore. “For example, we have staff who are certified in HAZMAT and are authorized to sign HAZMAT shipping papers. They can advise ECBC and ECBC customers on proper packaging, marking and transportation of HAZMAT, and also assist with waivers, exemptions and HAZMAT policy interpretations at the DA and DoD level. We want ECBC, the Joint Program Executive Office for Chemical Biological Defense (JPEO CBD), and others to know that we have this HAZMAT expertise and we are here to help.”

Upgrading the Packaging Branch’s ability to create specialized packaging solutions and to develop packaging technical data is just one of the numerous ways that Engineering is positioning itself for success both now and in the future.

With continued upgrades like this, the Directorate continues to set the standard for excellence in the ChemBio community.

Packaging Specialist Karyn Merson added, “Just having the space and the right cutters to fabricate my own fiberboard pads is helping my filter canister re-design project. I have the materials at hand and can make size changes as required, instead of paying a vendor to cut the pads for me.”

The highly-qualified Packaging Branch is currently assigned to various programs, including Chemical and Biological Protective Shelters (CBPS), Dismounted Reconnaissance Sets, Kits, and Outfits (DR-SKO), Nuclear APPROVED FOR PUBLIC RELEASE

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into New Laboratory

From left to right: (a) Dexter Jennings, ECBC HAZMAT Certifier, evaluates hazardous material packaging. (b) Randy Weber sizes water vapor proof bags for a prototype package. (c) Mary K. Peck heat seals prototype samples for comparison study.

Packaging Branch Products and Services: More Than a Century of Combined Military Packaging Experience • Represent ECBC on Army Packaging Policy Group: support to Chair in G-4

• Packaging design • Packaging acquisition services throughout the lifecycle • Contracts: configuration controlled and field accessible

• Member of Standardization Organizations

• Hazardous material expertise: certification of shipments, packaging design and test for compliance

• Certified Military Packaging Professionals • Military Packaging Hall of Fame members

• Packaging design evaluation and onsite support: test planning and reporting, validating of new designs, and first article test activities

• Provide Joint Independent Logistic Assessments (JILA) for Packaging, Handling, Storage, and Transportation (PHS&T)

• Retrograde support

• Complete contract development, monitoring, consulting, and assistance

• Field support

• Certified Acquisition Workforce members

• Training in blocking and bracing

The new 1,200 square foot Packaging Laboratory will serve ECBC, JPEO, and other program teams.

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Employee Spotlight:

Dave Vincitore

This month’s Engineering Edge Employee Spotlight is on Dave Vincitore, Packaging Branch Chief, Packaging Specialist, former basketball coach, and Yankees fan.

What is your background with ECBC, including other positions you have held?

It is pretty remarkable that I have spent my entire 23 years here at ECBC. I graduated from Rochester Institute of Technology in Packaging Engineering. There, we did not do any military packaging. It was mostly medical, pharmaceutical, food, and cosmetic packaging. The only reason I had the opportunity to experience military packaging was I took the summer intern position at the Packaging Branch for co-op credit. So I came here in the summer of 1989 and worked with the Packaging Branch to learn about military packaging and found it to be exciting and a great experience. I went back to school, completed my degree, and had several job interviews including ECBC. In my 23 years here, I did not spend all of my career at the Packaging Branch. After four years, I was re-assigned to several development program teams under Engineering, cross-training in producibility engineering and serving as the program’s packaging SME. I returned to the Packaging Branch in early 2007 as a full-time packaging specialist. Last year, I took up the position as the Packaging Branch Chief, following in the footsteps of previous Branch Chief Nancy Waltman.

Why military packaging?

I chose military packaging over commercial packaging.

People tend to think military packaging is boring and cut-and-dry. I think the opposite. Cosmetic packaging is all about the appearance to the customer, the attractive packaging, the marketing, the labeling, the point of purchase displays. In military packaging, you have to make sure you design adequate packaging that will withstand the military distribution cycle versus commercial. Military distribution cycle is much more stringent and complex and that makes it challenging, such as surviving a minimum of 10 years storage, transporting through all modes of transportation, and sustaining through various climatic conditions – hot, cold, tropical.

Tell us about your new role as Branch Chief of the Engineering Packaging Branch.

Other than the administrative purpose and the overseeing of a staff of five highly qualified Packaging Specialists, my role is to make sure that we provide our expertise and support to all the program/commodity teams, Rock Island, and the Joint Program Executive Office for Chemical Biological Defense (JPEO CBD). I want to make our team more visible and more exposed to other programs. This is important to me. I also serve as the Center’s representative on the Army Packaging Policy Group.

What are your goals in your new position?

When I came onto this team, there was a very good foundation as a team that was recognized by a lot of programs. I want to carry on that solid reputation and continue to build relationships with our customers. If we make ourselves more visible and more accessible, we can help ECBC, JPEO, and program teams carry on the mission successfully together to get the products delivered undamaged to our Warfighters. This will help us find new customers and expand our services. We want to keep our customers happy. During the time of furloughs, it is very tough, but I want my team to be visible and working with others, and I want them to have fun. My team has been pretty positive through this uncertainty.

What is one of the most exciting projects you’ve worked on at the Packaging Branch?

The M100 Sorbent Decontamination System project was really my first project that I got to experience an item going through the entire acquisition lifecycle. I learned about the acquisition documents required for each milestone, experienced the various logistics activities involved, as well as attended several development testing and operation sites.

This was also a time period for me when I learned a lot about leadership. In my 23 years of being here, I have been very fortunate to have great leaders – my supervisors and team leaders. We have unbelievable leadership here, which is what makes ECBC great. I have learned from them, their expertise, their philosophies and their beliefs, and I will carry that on.

Tell us more about yourself. What is a little-known fact about you that other’s might not know?

I was an assistant basketball coach and recruiter for 3-1/2 years, one year at the high school level and 2-1/2 years in Men’s Division III basketball at Gallaudet University, which was an awesome experience not only being part of the basketball environment but also being part of the ‘deaf world.’ While some may or may not know, I am profoundly deaf, with a 91+ decibel hearing loss. I am very fortunate with the help of my hearing aids that I can interact pretty well with the ‘hearing world.’

What are your hobbies outside of work?

Working out, watching sports, following the Yankees, cooking and wine tasting, and spending time with my wife and two daughters.

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