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MONTEREY, CALIFORNIA - page 86 / 153





86 / 153

Following Tier 2 and lower level suppliers, the value stream flows to the prime contractor level, in which the vehicles are assembled and receive the first DCMA



delivered to


Upon inspection, vehicles from Charleston, SC, for integration and

all five manufacturers installation of GFE. At

are this

site, DCMA conducts yet contractors to resolve any phase. Given the multiple

another quality vehicle

acceptance inspection and works with the prime issues during the GFE integration and installation variants and ever-changing GFE requirements that

vary by Service, bottleneck in the

the integration effort at SPAWAR was an production process. Following integration,

initial area of concern and selected vehicles are fitted

with MEAP (MRAP Expedient Armor Program)18 armor at Charleston area and are then moved to the Port of Charleston Base for movement to the CENTCOM area of operations (AO).

multiple facilities or Charleston Air

in the Force

This next section of the report focuses on key processes within the value stream, starting with critical resource constraints at the supplier level and actions taken to mitigate these potential bottlenecks to production. It also provides an overview of the actual production process, with vignettes from two of the largest MRAP manufacturers, a major Tier 2 supplier, and the integration effort at SPAWAR. The interaction and quality assurance provided by DCMA is critical throughout this process and is also examined.



Some of the primary components and subassemblies supplied at the Tier 2 level include axles from three manufacturers, four different engines from three manufacturers, multiple transmissions from one manufacturer, and suspension components from nine manufacturers (Hansen, 2008, June 4, slide 11 and MRAP JPO, 2008, June 2). Of these items, as well as most other components, sufficient capacity existed within the defense and commercial industrial bases to meet the demands of the MRAP program. When added to existing demands from commercial businesses as well as other programs within

18 MEAP is additional armor applied to the sides of MRAP vehicles as added protection against

explosively formed penetrators (EFP) which became prevalent after the start of the MRAP program. It is installed in the Charleston area vice at the OEM (original equipment manufacturer) site due to its weight and bulk.


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