S ALVO “Service to the Line, On the Line, On Time”Vol. 12, No. 2 U.S. Army Watervliet Arsenal, Watervliet, NY Feb. 29, 2012 She served us well since 1916 By John B. Snyder Although she was a little overweight, having tipped the scales at more than 540,000 pounds, she moved with grace and pre- cision providing support to our warfighters in every conflict since World War I. The 217-ton crane that once aligned the ceiling in the historic “Big Gun Shop” was installed in 1916. Since then, she has moved millions of pounds of barrels ranging from the 16-inch guns for U.S. battleships to the artillery weapon systems that were widely used by U.S. forces in Vietnam. Her last run was in 1982 and since then, she has qui- etly slept until this month. Burt Crane & Rigging, a local company from Green Island, N.Y., lowered this once powerful crane and dismantled her on the floor where she once saw Ar- senal workers toil to near exhaustion to provide our Nation’s warfighters with guns that made them suc- cessful in every conflict. The crane was removed to reduce the weight on the Photo by John B. Snyder building’s structure. Commander’s Corner Tool Design Force Protection MLK Award Page 2 Page 3 Page 4 Page 8
Page 2 Salvo Feb. 29, 2012 Commander’s Corner You may have recently seen your fellow workers beingpulled from their jobs and into upper level strategy ses-sions that we call Value Stream Analysis. To those whogot pulled, they may not have seen the immediate or directvalue of participating in these sessions. And so, I want totake some time this month to try to explain the purpose ofthese strategy sessions and how they are tied to our opera-tions and to the long-term viability of the Arsenal. Value Stream Analysis, which is part of the Lean Enter-prise, had its origins with the Toyota car company in the Photo provided by Billy Martin1980s. The Lean Enterprise’s purpose at the Arsenal is to The Arsenal Commander Col. Mark F. Migaleddi addressing the work-identify and eliminate waste, while preserving and or im- force during the town hall meeting on February 16th.proving our quality and value to our customers. The bottom are doing everything in our control to position our defenseline is that we must use Lean initiatives to make us more businesses for the declining budget headwind, includingcompetitive amongst the sea of defense contractors, fellow continuous improvement initiatives, restructuring, divestinggovernment-owned manufactures, and civilian manufac- non-core businesses, and headcount reductions.”tures. We must reposition ourselves, too. You can’t pick up a newspaper today or watch a 6 p.m. That is why conducting strategy sessions such as whatnewscast without being reminded that there are significant we recently did for Business Development, purchasing newbudget reductions coming to our military. Nearly $500 bil- machines that can perform five machining functions versuslion is the current budget reduction target and those cuts one function of the older machines, and looking for andwill touch the entire fabric of our Army, from personnel to eliminating waste all fits into ensuring the long-term viabil-weapons systems. ity of the Arsenal. We cannot be blind to impending defense budget cuts by So, what do I need from you?thinking that our current business or future work will not I need everyone to: look for and find better, more ef-change. It will and so, what can we do about it? ficient ways to do their jobs; to do things right the first time I foresee on our horizon that we must go beyond simply so that we don’t waste time and money correcting mistakes;being “transformational.” We must look at every aspect of and I need everyone to step up to the plate when called andour operations as if our “survival” is at stake. We all have become an active participant in future Value Stream Analy-“skin in this game” ensuring the Arsenal has the ability to sis sessions.answer our Nation’s call by providing weapons for the de-fense of our country. A recent Bloomberg news story highlighted the plight of Mark F. Migaleddidefense contractors as they work their way into a future of Commandingdeclining U.S. defense dollars. In this article, a CEO from Manufacturer 6one of the largest defense contractors in the world said, “WeCommander, Col. Mark F. Migaleddi The Arsenal Salvo is an authorized monthly publication for members of the DepartmentPublic Affairs Officer, John B. Snyder of Defense. Contents of the Salvo are not necessarily the official views of, or an endorse-Editor, John B. Snyder ment by the U.S. Government, the Department of Defense, the Department of the Army, orPhotographer: John B. Snyder the Watervliet Arsenal.Arsenal Facebook Page @ News may be submitted for publication by sending articles to Public Affairs Officer, 1 Buffington Street, Bldg. 10, Watervliet, NY 12189, or stop by office #102, Bldg 10,http://on.fb.me/sq3LEm Watervliet Arsenal. The editor may also be reached at (518) 266-5055 or by e-mail: email@example.com. The editor reserves the right to edit all information submitted for publication.
Page 3 Salvo Feb. 29, 2012Tool Design: Where history shapes the future By John B. Snyder fixtures were required to assist in the manufacturing of Arse- nal products during a distinctive time period. John liked the I was recently wandering around the inside of the Arse- word “distinctive,” but maybe “historic” might be a better usenal’s 1840s-era barracks building thinking about what life of words. Nevertheless, in these files, one could look up themust have been like at the Arsenal 170 years ago when I sud- tooling that was required for such products as a mortar tubedenly realized that I had wandered into a place where few during the Koreantravel. Tucked away in a back room on the third floor of a War or an engineer’sbuilding, to which I still don’t know bridge during thethe number to, was a place called Vietnam War or anthe tool design office. Inside were Abrams Tank can-John Zullo and Greg Tilley, the Ar- non during the war insenal’s two remaining tool design- Iraq.ers. And so, I asked John told me that in the early John the obvious1990s there were 15 tool designers question, “Why doat the Arsenal. He tried to explain we need to keep all of these cards?to me that the Arsenal lost 13 de- John offered a couple of exam-signers due to the nine reductions ples of why the Arsenal maintainsin force that occurred in the 1990s. these cards.But I knew better. I have no doubt A few years ago, the U.S. Airthat those tool designers couldn’t Force came to the Arsenal to manu-find their way back to this remote facturer 105mm cannons for theiroffice and simply settled for some AC-130 gunships. Well, the Arsenalother job. had not made these cannons since For those of you who don’t know the 1960s but thanks to having theJohn, he started working at the Ar- data cards, tool designers and plan-senal as an apprentice in 1970 and ners had a foundation from whichhas been a tool designer since 1975. to begin production. This savedWow, 37 years later and he still Photos by John B. Snyder thousands of dollars in productionhasn’t found his way out his office. Greg Tilley, left, and John Zullo comb through the vari- planning time, John said. Greg was cut from a different ous tool card drawers to demonstrate the degree of He added that recently the Ar-cloth. He joined the Arsenal work- detail that each historical record holds. In the top photo, senal prepared a quote on a newforce four years ago after graduating John is working on a 3-D sketch. bridge for the U.S. Army. Tuckedfrom the University of Buffalo with a degree in mechanical away in John’s files were the requirements for a bridge theengineering. According to John, Greg is his succession plan. Arsenal manufactured during the Vietnam War — another The stark difference between John and Greg was only foundation from which to assist the Arsenal’s planners.overshadowed by the visual differences that I saw in this of- The contrast to all of this was that on John’s computerfice. was a 3-D drawing of a fixture he was currently working on. As I walked into the office, just off to the right were a se- I was fascinated as he moved this computer-aided design of aries of filing cabinets that one would find at the Arsenal about fixture to show how it would work once it was manufactured.the time the Arsenal completed its first 16-inch gun. The year This 3-D designing was a far cry from the old days whenwas 1902. John started at the Arsenal. Back then, he would painstak- Those old cabinets had hundreds of files drawers that were ingly stand over a draftsman table for days to pencil in a tooljammed with record of tooling cards that date back to World design. Now he can do the same design on his computer inWar II, if not longer, John said. significantly less time. Although he still has that old drafts- When I looked at the rows upon rows of files, I immediate man table in his office, it now holds the printouts of the toolthought of the A&E television series called Hoarders. But design that he does on his computer.John and Greg assured me there was a method to their…mad- John explained that he and Greg design fixtures, gauges,ness. This is my word usage, not theirs. and tools that will be required to support the production of John said each card told a story. a specified product line. These items will either hold or lift The stories they tell explain what special tools, gauges, or products during their manufacturing process.
Page 4 Salvo Feb. 29, 2012 Arsenal turns to dogs to sniff out threats By John B. Snyder Doesn’t everyone like a story about dogs? After all,those fun-loving, floppy-eared animals are like a familymember to many households. That is, unless you are a ter-rorist or a person carrying drugs at the Watervliet Arsenal. The City of Albany Police Department’s K-9 unit con-verged on the Arsenal earlier this month in support of anantiterrorism exercise initiated by the Arsenal’s Director ofEmergency Services, Joe Claus. This exercise was not done tocounter any current threat, but totest and evaluate the Arsenal’santiterrorism program, as wellas threats to the health and wel-fare of the Arsenal by those who Photos by John B. Snyderwould bring drugs onto this Army Top: Albany K-9 unit checked outgo-installation, Claus said. ing vehicles, as well incoming cars, “In the past year, we have for drugs.ramped up our force protection Left: Albany police officer with his dogpreparedness and we have done observes Arsenal Security Officers inspecting incoming cars.so by involving more supportfrom emergency responders from outside of our fence line,” an antiterrorism exercise.Claus said. “For example, just last month we conducted “Having this canine unit added an entirely new dimen-antiterrorism exercise at the Arsenal with a SWAT team sion to our level of preparedness, as well as improving thefrom the FBI and this month we had a canine unit from the image of our law enforcement capability to the ArsenalAlbany Police Department.” workforce,” Claus said. The Albany Police Department sent four team members As much as the Arsenal would like to train with this dogand three dogs to support more than 16 Arsenal Law En- unit again, trying to work into the K-9 unit’s schedule mayforcement Officers in the search of incoming and outgoing be a challenge. After all, this team did more than 750 “uti-vehicles during the two-hour exercise on February 7. lizations” or missions last year, Cotter said. Despite it being more than 10 years since 9/11, there Claus said the key take away was a continuing commit-were several firsts associated with this exercise. ment from the Arsenal to improve communications and “Prior to 9/11, we rarely trained with communities or relationships with emergency responders from outside thegovernment installations outside of the city,” said Sgt. Eric arsenal fence line.Cotter, who supervises the Albany Police Department’s K-9 “Having the Albany Police Department support us willand mounted units. “But since then, we have been very pay huge dividends not only in future training opportuni-aggressive in working with local communities and govern- ties, but also in protecting the health and welfare of the Ar-ment agencies that do not have a canine unit.” senal’s workforce,” Claus said. But despite Cotter’s expanded mission to venture out- Although the U.S. Army requires all installations toside of the city, this was the first time his unit had trained train, exercise, and test their antiterrorism program at leaston an Army installation, Cotter said. once each year, the Arsenal has exceeded that requirement Claus also said that this was the first time that a dog unit by conducting force protection exercises about once ahad trained with the Arsenal’s law enforcement officers in quarter, Claus added.
Page 5 Salvo Feb. 29, 2012 A time when the President met the Arsenal’s Greatest Generation By Mark Koziol Arsenal Museum Left: President Franklin D. Rooseveltshakes the hand of Arsenal Work ManagerFrank Miller, as Brig. Gen. A.G. Gillespiedoes the introductions. FDR was greeted atthe Arsenal gates with the traditional 21-gunsalute because of his status as the Commanderin Chief of the Armed Forces. Even beforethe president’s visit, the Arsenal had already Photos provided by the Watervliet Arsenal Museumbegun increasing production capacity and adding newworkers to the payroll. In late 1940, there were more Hyde Park home. Then, early afternoon on Monday,than 3,000 people working at the Arsenal. October 7, President Roosevelt left at 12:30 p.m. for a America was in a state of partial emergency as of drive north to visit the Albany region. According to hisSept. 8, 1939 due to Nazi Germany invading Poland schedule, FDR and party were to be at the Watervlieton September 1, igniting the Second World War. Arsenal at 2:30 p.m.Twelve days after FDR’s Watervliet visit, on Oct. 16, Bottom Right: Army Maj. Stephen L. Conner1940, the federal government held the first peace time discusses with Roosevelt the different weapons beingdraft. manufactured at Watervliet Arsenal. To the far right of Top Right: FDR mixed business with pleasure the photo, a Secret Service Agent watches the crowdduring the beginning of October, 1940. During the attentively as he stands on the right front running boardweekend, he relaxed from campaigning by visiting his of the president’s car.
Page 6 Salvo Feb. 29, 2012 Two-fer... On February 16th, the Arsenal commander conducted a town hall meeting, as well as a Diver- sity Day Luncheon. During the town hall, two special things hap- Ken Governor Rensselaer County pened... American Legion Mike Dumas, supervisor of pro- duction planning control, re- ceived the Annual Martin Luther King Award from Col. Mark F. Migaleddi (more on page 8). And for the first time, leadership from the American Legion ad- dressed the workforce. After the remarks, the Legion members Tom Pond Director of Operations were taken on a tour of the Arse- nal. Kin Ting Rose Sopok Lt. Col. Pablo Rivera LMP Master Cell Former Disability Chaplain for TACOM LCMC Speaking Chinese Program Manager Speaking Spanish
Page 7 Salvo Feb. 29, 2012 Two cents and more for your thoughts By John B. Snyder suggestion does not directly save the Arsenal money. “Unlike Value Engineering, a suggestion to the Okay, so you believe that you have the “idea of Army Suggestion Program does not have to producea century” that will make the Arsenal safer, more a tangible benefit, such as a cost savings or costefficient, or that will improve a process. But where do avoidance,” said Marhafer. “A suggestion mayyou turn to get that idea moved from concept to action provide an intangible benefit that may affect theor better yet, how can you make a buck by offering up Arsenal’s functions, mission, or personnel.”your suggestion? Improving workforce safety is a prime example The path may not be as clear to take as one might of an intangible benefit. A suggestion to improvethink because the Arsenal uses two types of programs workforce safety may be difficult to determine whatto sift through recommendations by the workforce that the tangible cost or labor savings might be to themay award cash for good ideas. Arsenal, but an evaluator can estimate a value for Two of the newer Arsenal employees, by the these types of suggestions based on the perceivednames of Jim Rossini and Josh Gypson, tried to make value and reach of the suggestion, which then mightsense of one of one of the programs called Value qualify an individual for a cash payment.Engineering to me. Both Jim and Josh work in the Individuals may receive up to 10 percent of the costOperations Directorate, and Josh oversaw the VE savings or avoidance up to $10,000, and anotherprogram last year. He has since passed his VE duties three percent for anything over $10,000.to Jim. By the way, for those of you who have submitted Anyone who knows these two will truly understand recommendations that would do away with thewhen I say that the interview with them was quite public affairs officer position as a cost savings, thoseentertaining. A 30-minute interview turned into 90 suggestions have been forwarded to my office forminutes as they passionately tried to explain VE, as consideration. I’m a little behind right now and it maywell as the meaning of life at the Arsenal. be some time, in fact a very long time before I will VE, according to Jim and Josh, is mainly about get to them. But keep them coming because I enjoy aprocess improvements. And by the way, VE is a good laugh.TACOM regulatory requirement that has been placedon the Arsenal in which we must attain a savings of1.5 percent of our total financial obligations every Army Suggestion Program Successyear. Although a process improvement may make the So far in FY 2012...Arsenal more efficient, it may also mean a financialaward for those who make the suggestion. -13 Suggestions have been adopted For example in 2011, a VE project suggested using -$1,000 was the top awardseamless tubing instead of a forging to make 120mmmortar tubes. The total cost avoidance was more than -$2,049 is the total amount awarded$800,000 totaled over FY11, 12, and 13. An amountof $5,000 was given as an award, distributed among Value Engineering Programthe people involved with the project at Benét Labs. Success in FY 2011 If VE isn’t your flavor, then you might take yourgreat idea to Stacey Marhafer, who is the Arsenal’s -1 ProjectArmy Suggestion Program Manager. Stacey said -$800,000 in cost avoidanceher program rivals the VE program in that it too may -$5,000 cash awardaward a cash incentive for a suggestion, even if the
Page 8 Salvo Feb. 29, 2012 2012 MLK Award RecipientMike Dumas received the 2012 Martin Luther KingAward during the town hall meeting on February 16 due tohis dedication and support to the Watervliet Arsenal’s EqualEmployment Opportunity Program.As Supervisor of Production Planning Control in the Indus-trial Operations Directorate, Mike worked to increase thediversity of the workforce through: recruiting and hiringinitiatives; encouraging and maintaining an environmentwhere all groups of employees realize equality and potentialfor advancement; and he exhibits the spirit and intent of Mike Dumas receiving his Martin Luther King AwardEqual Opportunity as seen through his actions and works by from Col. Mark F. Migaleddi, Arsenal commander,developing the same in each of his subordinates. on Feb. 16, 2012. Photo provided by Billy Martin. City of Watervliet Memorial Day Parade Monday, May 28 Save The Date: The Arsenal is participating in the City of Watervliet Memorial Day Parade on May 28, at 10 a.m. We will be looking for volunteers to help us build the floats and to march in the parade. We have also been asked by two other communities to support their Memorial Day Parades, which we are considering to support.
Page 9 Salvo Feb. 29, 2012 Stories from the Sandbox National Guard Veterans speak about ‘their’war in Iraq National speak about their war in Iraq Where: NYS Military Museum and Veterans Research Center, 61 Lake Avenue, Saratoga Springs When: 1 to 2 p.m. Saturday, March 24, 2012 NY Army National Guard veterans who served during different periods in Operation Iraqi Freedom from 2003 to 2009 will share stories about what happened inside the combat zone. The stories you have never heard… COMBAT OPERATIONS: NATION BUILDING: HUMANITARIAN SUPPORT: The rise of the insurgency Training Iraqi security forces Delivering aid to the poor The introduction of IEDS Facilitating national elections Providing medical services The dangers of patrolling Reconstruction efforts Supporting schools, orphanages The Baghdad Airport Road Working with local leaders And much more… First Sergeant Joseph Martel, Albany, 105th Military Police Company, OIF 2003-4 nd th Major Vincent Heintz, White Plains, Company A, 2 Battalion 108 Infantry, OIF 2003-4 st th Sergeant First Class Luke Chiarenza, Clifton Park, HQ Company, 1 Battalion 69 Infantry, OIF 2005 st th Staff Sergeant Don Leinfelder, Troy, Company A, 1 Battalion 69 Infantry, OIF 2005, Purple Heart Medal st st Sergeant First Class James Montesano, Watervliet, Company D, 1 Battalion 101 Cavalry, OIF 2005, Lt. Col. Jamie Green, Saratoga Springs, 466th Medical Company, OIF 2006 nd Col. Mark Heffner, Troy, Headquarters 42 Infantry Division, OIF 2005 Sponsored by the Friends of the NYS Military Museum and the Division of Military and Naval Affairs
Page 10 Salvo Feb. 29, 2012Arsenal employee, family race to danger By John B. Snyder What would you do? You have probably seen this scene played out many times on the local 6 o’clock news of a story involving a home fire in your community. At first, the fire is the size of a car’s hubcap, but within seconds the fire shoots up the back of the home. On your TV, you see neighbors rush to the fire only to then see them stay back, out of danger, to capture the burning home on their cell phones. Once the home John “Jack” Maloney had been destroyed, those same neighbors would often post the videos onto their social media sites, such as Facebook, or might relay those videos to the local news organizations for their 15-seconds of fame. After all, this may be the new era when people are more concerned about capturing such scenes on their personal video acquisition systems than they are to inject themselves into the danger…or is it? John “Jack” Maloney, who is one of the production planners in the Operations Directorate, had his opportunity for his 15-seconds of fame on the evening of February 13 when he and his family noticed a small fire, about the size of hubcap, at a neighbor’s house. But he didn’t seek his 15-seconds of fame. Instead, Jack grabbed the house phone and dialed 911 to report the fire. As he was on the phone, his wife, Johanna, and daughter, Maggie, went into the burning house to alert the two families who were home. Jack soon joined them. What would compel the Maloney family to put themselves at great risk, Jack said he can’t explain. “When I saw the fire, I immediately thought about the young child who lived on the second floor of the house, as well as others who lived in the house,” Jack said. “There was no hesitation by my family to enter the burning building.” Jack and his family were able to alert the two families and thus, saved three lives, as well as two dogs. Although Jack is not seeking any notoriety, what Jack and his family did on that Monday evening certainly deserves some recognition. Jack’s photo by John B. Snyder - Background photo is not of the Cohoes fire This story should not end by just the personal courage displayed by Jack and his family earlier this month. We should take this as a learning to point to be more sensitive to our environment and when something seems out of place, albeit as small as a hubcap, that we take immediate and deliberate action. It may be hard to measure the value that Jack and his family added to his com- munity that night, but suffice it to say that it must be significant. We can be significant, too.
Page 11 Salvo Feb. 29, 2012Arsenal’s WWI Veteran quietly retiredIf only this old workhorse could talk of thestrains of lifting tens of thousands of barrels andguns since arriving for work in 1916. After manyyears of no activity, the Arsenal leadership de-cided to remove the crane to lighten the weighton the historic Big Gun Shop.A local company from Green Island, Burt Crane& Rigging, won the contract to remove the crane.Starting in the bottom left photo and goingclockwise is the progression of the final days ofthe 217-ton crane. In the bottom right photo, wediscovered the signatures of the 1942-1943-1944Victory Gang “Men of the Watervliet Arsenal.”Those WWII employees signed in lumber crayonon the end of the beam. Photos provided by John Snyder, Billy Martin, and Bryan Myers