Manufacturing Issues for Multimode Seeker Domes

TA&T has demonstrated the capability to produce 7” diameter, hemispherical domes of transparent spinel by cold isostatic pressing (CIP) of spinel powder, followed by sintering without application of pressure, and finally followed by hot isostatic pressing (HIP). TA&T has exercised its dome manufacturing process sufficiently to have solved many process problems. At the same time, TA&T has gained a qualitative understanding of where the greatest costs are incurred and where the greatest risks remain. The proposed program will study the manufacturing process in greater detail in order to confirm current cost/risk reduction priorities and to quantify anticipated cost savings. A plan will be developed for scaleup to full manufacturing mode and to clarify opportunities for process improvement and substantial cost reductions. Value Stream Mapping and Theory of Constraints analyses will be used to identify/confirm the process steps that must be improved, by way of cost reduction or increased throughput. A revised manufacturing process that incorporates the needed improvements will be developed. Risk assessments will be performed for the revised process to assure that product and process objectives will be met.