DEFENSE LOGISTICS AGENCY THE NATION S COMBAT LOGISTICS SUPPORT AGENCY

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1 DEFENSE LOGISTICS AGENCY THE NATION S COMBAT LOGISTICS SUPPORT AGENCY Large Scale Shade Instrumentation Pilot Project Dr. Ali Ahmed, Tech/Quality Director November 2017 WARFIGHTER FIRST

2 Industry Movement Towards Instrumental Shade Technology Streamlines the shade evaluation process by adopting spectrophotometric color measurements of solid colors Past evaluations of digital samples are available and used to further refine tolerances and predict likely future decisions. Technical personnel within a plant and better understand numerical values than comments resulting from visual evaluations Digital color standards and tolerances never fade or wear with handling Capability to conduct predictive analysis shade readings can be tracked to identify processes trending towards out of tolerance ranges as an early indicator of issues Removes some of the variations between human evaluations May not be a universal replacement for 100% visual evaluation 2 WARFIGHTER FIRST

3 Instrumentation Pilot Introduction The DLA Shade Instrumentation Pilot has been established to provide the basis for determining the following: Can instrumentation technology be leveraged to improve the shade quality of military fabrics supplied to the Government? Can a methodology be developed for implementing the use of shade instrumentation data within the DLA C&T environment? Currently conducting the Large Scale Shade Instrumentation Pilot based upon positive results from Small Scale Pilot that concluded in April WARFIGHTER FIRST 3

4 Overall Goals Increase industrial base shade production consistency With proper acceptable digital variance, suppliers will be able to better control production Digital information will help keep production and sample submittals more in line with the acceptable shade range established by visual assessment Government labs could monitor production lots submitted for confirmation that the color is coordinating well from all sites in the industrial base producing the same color Government labs could also identify any negative trends from a single or multiple sites The key is to make sure each production site is consistent in production to the established standard and tolerance. WARFIGHTER FIRST 4

5 Small Scale Pilot Scope Afghan Foreign Military Sales Program Air Force 27/P Flyers Coverall Duffle Bag 5 Color/Fabric Material Types 4 Fabric Mill Suppliers 2 Government Labs (DLA PTC, Natick TMET) 1 Independent Measurement Site (LMI) WARFIGHTER FIRST

6 Small Scale Pilot Lessons Learned Correlation Between Spectrophotometer types at mills/labs was acceptable compared with industry best practices Mills were able to assess production using the digital physical standard provided Visual correlation of acceptable digital readings at the shade labs at DLA PTC and Natick was very good. Digital assessment comparing lot samples to the digital physical standard will help mills to reject and not submit off-shade lots internally. WARFIGHTER FIRST 6

7 Example : Setting Centerpoint for Production Application SG1659 Visually Evaluated by DLA and Natick Colorists To Original Physical Standard To New Physical Standard All Samples failed visually to original physical std All Samples approved visually to new physical std Result: Digital and Visual Correlation would have been perfect in this case - 100% New Physical Standard was very close to the average of current production approvals WARFIGHTER FIRST 7

8 Initial Set of Pilot Volunteer Participants/ Materials Under Consideration Mill Name Fabric End Item (s) Color Kenyon Nylon APFU Jacket & APFU Pant Black 557 Brittany Load Bearing Equipment, Kit, Bag Flyer s, and Duffle 1000D Nylon Bag, Regular & Improved CG 483 Burlington (Raeford) Poly/wool Shirt/blouse USMC M-1 Poly/wool Coat Blue 450 Burlington (Finishing) Polyester AF PT Suit Blue 1651 Polyester AF PT Trunks Blue 1650 Milliken Polyester Shirt, Gen III, Layer 1 Tan 499 Polyester Drawers, Gen III, Layer 1 Tan 499 modacrylic/nomex Utility Coveralls, ifrv Dark Blue 3392 Nylon/Cotton Shirt & Trouser, ODU USCG Blue 3362 Cotton and Polyester Blend Utility coveralls, Basic Blue 3329 Cotton and Polyester Blend Utility coveralls, Basic Green 3454 Carlisle Cotton and Polyester Blend Utility coveralls, Basic Blue 3329 Cotton and Polyester Blend Utility coveralls, Basic Green 3454 Polartec Poly/spandex Undershirt, Gen III, L2 Tan 499 Poly/spandex Drawers, Gen III, L2 Tan 499 Trelleborg coated nylon bag, clothing waterproof CG 483 WARFIGHTER FIRST 8

9 Shade Instrumentation Pilot Approach Step 1 - Develop Baseline of Participating Mills Collect variables on mill s shade instrumental measurement process (instruments, software, conditioning, calibration, etc.) Current process for monitoring lot to lot and roll to roll variation Step 2 Assess Production Samples Determine Shade Consistency/Quality across the Supplier Base Determine Shade Consistency/Quality across supplier base Samples measured by mill and pilot team Measurement communicated by standard QTX file format Step 3 Assess Using Data to Support Waiver Process & Digital Submittal Thresholds Evaluate production lot submittals and their shade acceptability Identify any preferred hue direction for specific shades Large Scale Pilot Scheduled to Conclude April 2018 WARFIGHTER FIRST 9

10 Pilot Will Demonstrate Proper digital readings for physical standards, production samples and digital threshold targets can be communicated within the military industrial base The feasibility of using digital thresholds to reduce the number of visual assessment failures How useful instrumental readings provided to Government evaluators in support of the waiver process Whether production can be monitored to confirm the same shade is coordinating well across the industrial base If instrumentation shade data can be used by Government organizations for proactive, early identification of negative trends from a single or multiple sites WARFIGHTER FIRST 10

11 Goal of Submittal Thresholds 1. Mills internally reject samples that are outside the submittal threshold do not submit 2. Provides Consistent Production results 3. Improves Color Coordination between multiple mills 4. Monitors Metamerism WARFIGHTER FIRST 11

12 Schedule WARFIGHTER FIRST 12