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S ALVO
                                  “Service to the Line, On the Line, On Time”

Vol. 12, No. 4                            U.S. Army Watervliet Arsenal, Watervliet, NY                                      April 30, 2012


                                        Honors students turn
                                        labs into classrooms




                                                                                                            Photos by John B. Snyder


    Steve Smith, the acting branch chief for Benét Labs fatigue fracture analysis group, prepares the group for a live firing. Fifteen hon-
    ors students, who were all high school seniors, helped turn many of Benét’s labs into classrooms on April 25th.

                      By John B. Snyder                                 on the Watervliet Arsenal, shifted several of its op-
                                                                        erations into science classrooms for 15 local high
     High school honors students, who are enrolled
                                                                        school honors students who are enrolled in the New
 in a college-preparatory science program called
                                                                        Visions’ Science, Technology, Engineering, and
 New Visions, helped turn Army laboratories at the
                                                                        Math program that is administered in Rensselaer,
 Watervliet Arsenal into classrooms April 25. The
                                                                        Greene, and Columbia counties.
 purpose of the visit was to give students a firsthand
                                                                           The students were from Troy, Tamarac, Maple
 look at the role science and technology has in the de-
                                                                        Hill, Taconic Hill, Averill Park, Berlin, Hoosic Val-
 velopment of military weapon systems.
    The Army’s Benét Laboratories, which is located                                 Story continues on page 3, see Students

  Commanders Column                      Boiler Plant Test              Take Your Child to Work                    Visitors’ Center
       Page 2                                 Page 5                            Page 6                                  Page 8
Page 2                                                       Salvo                                                   April 30, 2012




          Commander’s
            Corner
    I was outside my quarters the other day doing some
spring cleaning when the sound of bees caused me to put           in our environment that we move into a safety trap because
off that cleaning until maybe … next fall. All kidding            everything was fine the last time we drove on that road or
aside, you may not hear the sound of bees at the Arsenal          worked on that machine that we become blind to the trap
before you become SWARMED. I’m talking about our                  before it closes on us.
new safety awareness program.                                        To give you a sense of how big a problem overlooking
    Our safety gurus have come up with an innovative way          safety is, I took a look at Google news for just a 24-hour
to remember a safety process, commonly called an acro-            period leading into the drafting of this column and there
nym in the military, which should add a new dimension to          were more than 11,000 stories posted. Many of these sto-
our safety program. I know, some of you are thinking that         ries involved death, such as a jury recommending that any-
this is just what we need … something else to memorize.           one involved in felling trees should wear a safety helmet
So, don’t memorize it. Convert it into a checklist.               following the tragic death of a father-of-five. Another story
                                                                  involved the death of a worker due to his company failing
SWARMED                                                           to use energy control, or “lockout/tagout,” procedures prior
    	Signs and barricades in place                               to allowing the employee to enter the machine’s danger
    	Where PPE properly                                          area.
    	Administrative Controls in place                               Wow, more than 11,000 safety accident stories in 24
    	Risk free walking/working space                             hours. As much as I like getting the Arsenal into the news,
    	Machine Guarding in place                                   this is not one story that I want my public affairs officer to
    	Energy hazard controls in place and functional              have to write.
    	Disposal of chemicals...properly                               Although you may get SWARMED at work, please do
                                                                  not become complacent this coming summer as you venture
    SWARMED is just part to help you LOOK FOR IT,                 more outside. You are too important to the Arsenal — too
FIND IT, AND FIX IT! But keep in mind that safety is              important to your family — to have you injured for some-
more than a cute tagline or acronym. Our success in pro-          thing that could have been prevented.
tecting the workforce, on and off duty, must be a conscious
part of our thought process every hour, by leaders and the
workforce.
                                                                                        Mark F. Migaleddi
    Some of you may believe that injury or loss of life due
                                                                                          Commanding
to an unsafe act won’t happen to you. After all, it is al-
ways someone else. But sometimes, we get so comfortable                                  Manufacturer 6

Commander, Col. Mark F. Migaleddi           The Arsenal Salvo is an authorized monthly publication for members of the Department
Public 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, or
Photographer: 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:
                                         john.b.snyder.civ@mail.mil. The editor reserves the right to edit all information submitted
                                         for publication.
Page 3                                                Salvo                                             April 30, 2012


Students cont.
ley, and Cohoes high schools, said Tammie Bor-
land, the New Visions teacher who coordinated
the visit.
    “This is a special program for high school
seniors who want to concentrate in science and
engineering in preparation for college,” Borland
said. “What is great about the New Visions
program is that we live and
breathe hands-on education                                                                       Photos by John B. Snyder
and that is why we like to vis-
                                                                                    Top: New Vision honor students
it such places as the Army’s
                                                                                    check out the weight difference
Benét Labs.”                                                                        between steel and composite base
    Sara Makowiec, an elec-                                                         plates. The composite was most
                                                                                    favored, something Benét would
tronics engineer with Benét
                                                                                    like to hear from the Army.
Labs, coordinated with Bor-                                                         Left: Students, with great restraint
land for the visit. After all,                                                      by not touching, get a close look at
                                                                                    some of the Benét fatigue lab work.
who better than Makowiec
to know what the students
would like given that she had                                                       Strang said. “I was most
gone through the same New                                                           impressed, however, at how
Visions program five years                                                          the many fields of science are
ago.                                                                                brought together to achieve
    “This was great for us to                                                       a common purpose at the Ar-
interact with students who                                                          senal.”
have interest in the type of                                                           Most of the students have
science and technology that                                                         never visited the Watervliet
we work with at Benét,”                                                             Arsenal. But if Strang’s fel-
Makowiec said. “For me, I                                                           low students left the Arsenal
still remember how exciting                                                         feeling the same way as he
it was going through the New Visions program five         did, then Benét Labs did a lot more than simply shar-
years ago because the program gave me great insight       ing their work with high school students — they also
into a wide variety of scientific fields of study.”       educated some of America’s future science and engi-
    But it is often easy to please teachers and Arsenal   neering experts about the value of military manufac-
workers who like to share their knowledge with folks      turing.
outside of the Arsenal fence line and so, the value of       According to the New Visions website, the STEM
the visit truly rested with the students.                 program is located at Rensselaer Polytechnic Insti-
    If one could measure the body language, such as       tute (RPI) in Troy, N.Y., and is part of the Questar III
the smiles and looks of inquiring interest, then the      program that is sponsored by the New York Board
visit was a success for Benét Labs and for the New        of Cooperative Educational Services. As part of the
Visions program. But better than body language were       curriculum, students interact with more than 80 pro-
the comments from Robert Strang, a Troy High School       fessionals each year, including researchers from Rens-
senior.                                                   selaer, as well as technology organizations such as
    “This was my first time visiting the Watervliet Ar-   General Electric and Benét Labs. This program is an
senal and I was surprised at how much science and         ideal choice for students who want to know what it re-
technology is used to manufacture weapon systems,”        ally means to be an engineer or scientist.
Page 4                              Salvo   April 30, 2012




Albany Devils
Military Appreciation Game
       April 14, 2012

         Photos by John B. Snyder
Page 5                                                            Salvo                                                    April 30, 2012



Sweating test results in the boiler room?
                                                                        new technology on a similar boiler burning natural gas would
                      By John B. Snyder                                 have an expected annual fuel savings of $125,000, and for a
                                                                        boiler using oil, the annual savings would be nearly $140,000.”
    Do you remember the old test days when you were in                      The digitally-controlled prototype added a computerized
school? You may not have been able to eat or sleep, and for             system that continuously monitored the concentrations of oxy-
others, they sometimes developed strange rashes and other ail-          gen and carbon dioxide in the exhaust fumes to optimally ad-
ments that we won’t go into. Suffice it to say that tests were          just the amount of fuel and air fed to the boiler, thus improving
very stressful to many of us.                                           its efficiency, Poncia said.
    But what may have been more stressful than taking a test?               But the results of this test may have a far greater conse-
    Finding out the results.                                            quences than simply improving the efficiency and environment
    Well, the Arsenal has been undergo-                                                            at the Watervliet Arsenal.
ing a nearly $250,000 test for the past                                                                Dr. Jim Galvin, the ESTCP Energy
year and this month the results were in.                                                           & Water program manager who was in
But for once, the Arsenal didn’t have to                                                           attendance when UTRC rolled out its
sweat it.                                                                                          results, said “The Department of De-
   “United Technologies Research Cen-                                                              fense is seeking ways to reduce its $4
ter, out of Connecticut, installed a digi-                                                         billion-a-year energy costs at military
tally-controlled prototype system on one                                                           installations. Watervliet Arsenal served
of our steam boilers last year that trans-                                                         a critical role as an energy test bed for
formed 1970s technology into a state-of-
                                                                                                   the Department of Defense to find in-
the-art system,” said Richard Hoshko,
                                                                                                   novative ways to enhance boiler plant
the Arsenal boiler plant supervisor.
                                                                                                   efficiencies.”
    The Arsenal site was selected primar-
                                                                                                       “To replace boiler systems through-
ily due to its close proximity to UTRC
                                                                                                   out the Department of Defense is too
and to Fireye, which is a division of
                                                                                                   costly,” Galvin added. “But if we can
United Technologies’ Climate, Controls
                                                                                                   find a cost effective way to improve
& Security Systems and is located in
                                                                                                   boiler efficiency, which saves energy
New Hampshire. Fireye supported
                                                                                                   and reduces the production of green-
UTRC in the development and instal-
lation of the prototype device. An-                                       Photo by John B. Snyder house gases, and do so with a relatively

other strong consideration as to why the UTRC, briefs the results of the test to members short investment payback period, then
                                              Dr. Guido Poncia, c, who is the project leader at

Arsenal site was selected speaks to the                                                           that process or modification may have
                                              who represented such organizations as the Army
Arsenal leadership’s willingness to sup- Corps of Engineers and DoD’s Environmental Se- great utility for the Department of De-
port testing of advanced technologies that curity Technology Certification Program office. fense. This technology demonstration at
may benefit the Army and the Depart-                                                              the Army’s Watervliet Arsenal appears to
ment of Defense.                                                        be meeting all those objectives.”
    But the main selling point to the Arsenal leadership in al-             According to Poncia, the estimated potential of savings
lowing this test to occur was that the test came at no cost to the      across DoD, based on the demonstration at the Arsenal, indi-
Arsenal. The Department of Defense’s Environmental Secu-                cates a nearly $56 million annual fuel cost reduction and the
rity Technology Certification Program (ESTCP) fully funded              avoidance of approximately 600,000 tons of CO2 going into
the test.                                                               the environment each year.
    Dr. Guido Poncia, who is the project leader at UTRC, said               The Arsenal has four main boilers that provide heat and
that when his company installed the new control module they             limited power. Some of these boilers were installed as far back
anticipated the Arsenal would attain better efficiency in its           as the 1950s and therefore, lack computer controls that would
boiler operations, as well as a significant reduction in green-         enhance the efficiency, as well as the environment. The boiler
house gasses.                                                           undergoing testing was installed in the 1978, Hoshko said.
    So, with a sense of excitement and hope for solid test re-              The demonstration would not have been possible without
sults, the Arsenal and UTRC waited … and waited until this              the constant support of the Watervliet Arsenal, who hosted the
month.                                                                  demonstration, Poncia said.
    “During a one-year testing campaign between February                    “We acknowledge the amazing help we received from Rich
2011 and March 2012, the new system demonstrated a fuel                 Hoshko, the Arsenal’s Boiler Plant Manager, and to Vanessa
savings of about 4 percent and a corresponding reduction of             Duenas, the Arsenal’s Energy Manager of Watervliet Arsenal,
CO2 emissions,” Poncia highlighted. “The investment in the              for supporting and enabling the demonstration,” Poncia said.
Page 6                                                        Salvo                                                 April 30, 2012



                                Watervliet Arsenal:
    A place where children inspire 198 years of pride
         By John B. Snyder                                                                             gram was dusted off last
                                                                                                       year to gauge interest. The
     Working in the historic                                                                           feedback from the kids,
 Watervliet Arsenal has giv-                                                                           their parents, and from the
 en nearly eight generations                                                                           workforce who provided
 of workers a sense of pride                                                                           demonstrations was so
 that may be rarely equaled                                                                            positive that the Arsenal
 anywhere in the Army. But                                                                             leadership decided to con-
 give it to children, who                                                                              tinue the program.
 participated in the Arsenal’s                                                                             The kids ranged from
 Take Your Child to Work                                                                               5th to 12th grade, and the
 Day on April 12, to take that                                                                         ratio of males to females
 sense of pride to a higher                                                                            was balanced. But wheth-
 level.                                                                                                er they were 12 or 17, the
    The Arsenal, with sup-                                                                             smiles were universal.
 port from the Army’s Benét                                                                                Eight grade student
 Laboratories, opened its                                                                              Daniel J. Whelan IV said
 manufacturing operations                                                                              that he never knew much
 to nearly 30 children of the                                                                          about where his mother
 Arsenal’s workforce and                                                                               worked.
                                                                              Photo by John B. Snyder
 showed them the work of        Eight grade student Daniel J. Whelan IV said that he never knew            “It was really cool,”
 skilled artisans and engi-     much about where his mother worked until the Take Your Child           Daniel said. “Although
                                to Work Day. Daniel is standing in front of a 155mm tube that was I liked all the demonstra-
 neers who develop, manu-
                                just forged.
 facture, and sustain our                                                                              tions, my highlight of the
 nation’s military with large caliber tubes and cannons.            day was seeing a cannon tube go through the forge.”
 This was an opportunity that is rarely shared with the                 Although the importance of what the Arsenal
 public.                                                            workforce does has never been lost, it sometimes
    “This was no small undertaking as more than 20                  takes people from outside of the Arsenal fence line,
 workers, from machinists to firefighters to engineers,             in this case children, for the workforce to know that
 provided presentations and demonstrations throughout after nearly 200 years of providing military hardware
 the day,” said Howard Kindell, the Arsenal’s Equal                 to our nation’s warfighters that what they do is still
 Employment Opportunity Officer who oversaw the                     “cool.”
 event.                                                                                           The kids weren’t the only ones
    “Our goal was to strengthen                                                                   who got something out of the
 the bonds between the Arsenal                                                                    day.
 and the Arsenal’s family mem-                                                                        “The questions asked
 bers,” Kindell said. “And if                                                                     showed a true interest in the
 you could measure success by                                                                     science and technology and I
 the excitement shown on the                                                                      think I saw one or two of my
 kids faces, then we achieved                                                                     replacements in that crowd,”
 tremendous success.”                                                                             said Timothy O’Connor, an en-
    For many years, the Arsenal                                          Photo by John B. Snyder gineering technician at Benét
                                      Matthew Woelfersheim, a mechanical engineer who
 did not conduct a Take Your          works in Benét Labs, points out some of the capabilities
                                                                                                  Labs who provided a presenta-
 Child to Work Day, but the pro- of an Abrams Tank.                                               tion in laser scanning.
Page 7                                                    Salvo                                                    April 30, 2012



     Making sense
            of
     historic photos
                    By Mark Koziol
                    Arsenal Museum

     The Watervliet Arsenal Museum, like many other
 institutions, has thousands of unique photographs in
 its collections. Unfortunately, incomplete captions are
                                                                                                    Photo provided by Arsenal Museum
 a common problem when collecting old photographs.            The Arsenal Museum has a fairly large library of historic photos, such
 This said, last year the museum was fortunate to receive     as this one with former Arsenal Commander Brig. Gen. Alexander G.
 a thoughtful gift of six photos from a local donor where     Gillespie who commanded the Arsenal during World War II.

 each photo was captioned with the names of the people        one published here along with the date of the party: June
 seen in each image.                                          16, 1942. Glued onto the same page as the photo was a
     The photograph included in this month’s SALVO            copy of the June 17, 1942 Troy Record newspaper article
 newsletter was taken during World War II and depicts         about the celebration:
 Arsenal Commander Brig. Gen. Alexander G. Gillespie
 standing alongside four Arsenal employees who, at the            “A surprise party was given for Gen. Gillespie
 time, had 40 years or more of employment:                        in the R. W. Building, to celebrate his 40th anni-
     Left to Right: Wilmot H. Roblin, George Tofte,               versary of entering the army. The 20 Year Club
 Ernest R. Oathout and Edward P. King. The occasion for           was invited, along with the department heads
 the photo was a party at the Arsenal celebrating the 40th        and all the officers on the post. A keg of beer
 anniversary of Gillespie entering the West Point Military        was on hand as well as plenty of cold cuts and
 Academy in 1902. Unfortunately, the exact date of the            sandwiches. There was community singing
 event was missing.                                               and a great time was had by all 100 present.”
     After doing a little detective work, we located in the
 museum’s archives a scrapbook for the Watervliet Arse-       The museum is continuing its research for more informa-
 nal 20th Anniversary Club, 1919-1952. After checking         tion about the lives of the four men standing alongside
 the entries for 1942, we discovered a similar photo to the   Gillespie.


                                                         Speaking of photos....
                                                         It is amazing the type of stuff sent to the
                                                         public affairs officer. One of these two
                                                         cuties has worked at the Arsenal since
                                                         World War II or so it seems. Suffice it to
                                                         say...a very long time. A Free Arsenal T-
                                                         Shirt to the 1st person who not only guess-
                                                         es the name of the person in the picture,
                                                         but also who picks the correct twin. Call
                                                         the humble public affairs officer at x5055.
Page 8                                                            Salvo                                                     April 30, 2012


Improving force protection, first impressions
                      By John B. Snyder                                     “In regards to our force protection at the south gate, we
                                                                        have been like Soldiers since 9/11 in that we, too, have had
     The old adage about first impressions cannot be under-             to improve our foxholes,” said Robert Shadlock, the Arse-
stated and for those who have in recent years ventured into nal’s senior facility engineer.
the south gate guard building of the Arsenal know firsthand                 Shadlock said that in the past 11 years, the Arsenal kept
the value of a recent and significant change to how visitors tweaking the south gate operations to not only add more
now enter the Arsenal.                                                  force protection obstacles, but also to improve safety in and
     The Arsenal’s main gate used to be the historic entry              around the south gate.
point on Broadway in the city of Watervliet where since                     “Because of limited funding through the years, we have
1813 workers and visitors                                                                                   yet to build the ideal solution
gained access to the Army post.                                                                             for worker and visitor ac-
The attacks on 9/11 forever                                                                                 cess,” Shadlock said. “Nev-
changed not only the fabric of                                                                              ertheless, we have done quite
American life as we once knew                                                                               well with the resources we
it; those attacks also changed                                                                              had and this month’s opening
the Arsenal.                                                                                                of a new Visitors Center is
     The Broadway main gate no                                                                              just one example.”
longer offered an entry point                                                                                  Just behind the south
that would mitigate or elimi-                                                                               gate guard building is a new
nate a forced, illegal entry.                                                                               $250,000 Visitors Center that
After a quick, but thorough                                                                                 began operations this month.
security analysis, the Arsenal                                                                              The new center greatly im-
leadership moved its main en- The south gate guard building in the foreground once handled the proves safety and is support-
                                                                                   Photo by John B. Snyder

try point to its south gate off of flow of traffic, as well as processing visitors. Those two opera-       ive to those with disabilities,
                                     tions are now separate as all visitors are now processed through Shadlock said.
  rd
3 Avenue in Watervliet.
     Three significant things        the Visitors’ Center in the background.                                   As part of the Visitor
happened as a result of that decision in 2001.                                                             Center cost, there was also a
First, the Arsenal has steadily made improvements to its                significant upgrade to the electrical system that provides
force protection by making it very difficult for an attacker            power to the south gate area.
to gain rapid, unimpeded access to the Arsenal. Such                        “We more than doubled the amount of the transformer
things as concrete protection barriers commonly called                  capability, as well as installed underground power for the
“Jersey Barriers” to pop-up barriers to a vehicle inspection force protection lift gates,” said Benjamin Dedjoe, the Ar-
area have been put in place during the last 11 years.                   senal’s electrical engineer.
     The second outcome from the relocation of the main                     But probably one of the most obvious changes is a visi-
gate deals with a false perception by many from outside of              tor’s first impression.
the fence line. When the Arsenal used the original main                     Arsenal Security Officer Mike Valle commented that in
gate, thousands of travelers driving along I-787 could see              the former south gate access point, the lines of people try-
the flow of vehicular traffic into and out of the Arsenal               ing to get an access badge would often run out the door.
every day. With the relocation to a side street, interstate                 “This was a very unsafe condition as we had people run-
drivers no longer could see any movement into or out of the             ning back in and forth in front of cars entering the Arsenal
Arsenal, which gave many a false impression that maybe                  all trying to vie for space in a small building,” Valle said.
the Arsenal had closed.                                                 “Now, all visitor traffic is away from the gate and visitors
     Finally, the guard post at the south entry gate was never enter a very nice facility that enhances their first impres-
intended to be a main entry point. The small structure,                 sions of the Arsenal.”
which doubled as a visitors center, was not conducive to                    This addition was so significant to the Arsenal’s access
logging in and out visitors, and had a degree of safety risk            operations that during a recent visit to the Arsenal by the
as visitors had to park their cars and then crossover the en- Army Materiel Command’s Commanding General, Gen.
try lane to get into the south gate to sign in. Once inside,            Ann E. Dunwoody, she awarded her commander’s coins
the small building became rather crowded with security of- for excellence to Al Columbus, chief of Arsenal security,
ficers doing their business of managing traffic flow, as well Robert Shadlock, and to Joe Claus, the Arsenal director of
as visitors trying to gain access.                                      emergency services.
Page 9                                            Salvo                           April 30, 2012

                                         CPAC Corner
Did you know you can move your resume from Resumix to USAJobs? All you need to do is
follow the instructions below.

1.        Open a Word doc.
2.        Go to CPOL (www.cpol.army.mil) employment
–         Click “Build A resume/check Status”
–         Under Registered Users click “Login”
–         Click “Answer”
–         Click “View Resume”
–         Highlight the Resume
–         Right click “copy”                              If you have any questions,
–         Open word document
–         Right click “paste”                               contact the CPAC office
–         Click “File”
–         Click “Save As” to Desktop
                                                                       at
–         Name your resume                                         266-4058.
3.        Go to USAJobs (www.usajobs.gov)
–         Click “Resume”
–         Click “Upload resume”
–         Name your resume
–         Click “Browse”
–         Select the resume saved to desktop
–         Click “Upload”




                          Memorial Day Parades
                            Save The Dates
         The Arsenal is participating in the Village of Green Island parade on
         Thursday, May 24th and the City of Watervliet parade on Monday, May 28th.

         For the Village of Green Island parade, we plan to only provide the bob-tailed
         truck and lowboy trailer float. Need a Driver!!! The Arsenal commander will
         speak at the end of parade ceremony.

         For the City of Watervliet, we plan to provide the full parade contingent with
         marchers. The Arsenal commander will speak at the end of parade ceremony.

         Green Island Parade kicks off at 6 p.m.
         City of Watervliet Parade kicks off at 10 a.m.
Page 10                                                Salvo                                          April 30, 2012


                          Seven Wastes…plus one   By Karen Heiser




Processes add either value or waste to a product or service. Although products differ between factories, shop
and office wastes are usually similar. This article will introduce you to identification and elimination of waste
as the first step to increasing business success through lean management.

There are seven types of waste: overproduction, waiting, excess transportation, excess inventory, excess
processing, excess motion, defects and correction .

Overproduction is producing more, sooner, faster than required by the next process. It is costly because it
prohibits the smooth flow of materials and can actually degrade quality and productivity.

Waiting is employee or machine idle time. It results when goods are not moving or being processed. Over
90% of a product’s lead time in traditional batch-and-queue manufacture is spent waiting for the next thing to
happen.

Excess transportation is product movement that adds cost but no value to the customer. Excessive movement
and handling can also cause damage and provide an opportunity for quality to deteriorate.

Excess inventory is raw material, work in process (WIP), or finished goods in excess of requirements for an
on-time delivery to the next process, or to the customer. It consumes productive floor space and hides problems
because it generates an alternative to investigating the root cause of the problem.

Excess processing is doing more work than necessary that adds no value. This includes change orders, extra
operations such as rework, reprocessing, handling or storage that occurs due to defects, overproduction or
excess inventory. Any work that goes beyond the customer’s needs is excess.

Excess motion occurs when extra steps are taken by employees and equipment to make up for inefficient
process layout, poor use of technology, defects, reprocessing, overproduction or excess inventory.

Defects and corrections result in scrap, repair and rework and are an excess cost to the customer. Impacts
include capacity loss, quarantining inventory, re-inspecting, rescheduling.

The eighth waste is your time and skills. When employees are losing time dealing with the seven traditional
wastes, they, and the organization are not reaching their potential. And the customer is paying for it.

At Watervliet Arsenal we are justifiably proud of our quality to the customer. As COL Migaleddi often says,
“We are too good to be ignored.” Global competition, economic constraints, and technological innovations
have driven other good companies to become world-class organizations through lean management. As world-
class organizations realize, customers will pay for value-added work, but not for waste.
Page 11                                             Salvo                                         April 30, 2012



 The SWARM is coming ... huh?
                                            By Maj. Donald Freer

    Experienced safety professionals often seem to have a sixth sense – they walk onto a production floor or
into an office and immediately know what is going on. This sixth sense is “situational awareness” developed
gradually over several years of working in the safety profession.
    Any employee can quickly develop situational awareness by learning to focus your attention on specific
facets of what is happening around you in an orderly and disciplined way. It takes concentration, practice and
patience, but you can do it. Remember that safety begins with you!
    To help you focus on safety checks and inspection areas the safety office is introducing a new mnemonic
aid called SWARMED. A mnemonic aid is simply a learning technique makes memorization easier. Commonly
encountered mnemonics are often verbal, such as a very short poem or a special word used to help a person
remember something, particularly lists.
    Mnemonics rely on associations between easy-to-remember constructs which can be related back to the
data that are to be remembered. Here is the breakdown of our safety mnemonic:

S = Signs and barricades in place
(Ensure all emergency egress, restricted areas, & barricades are posted and functional)
W = Wear PPE properly
(Ensure all building inhabitants are wearing required PPE)
A = Administrative controls (labels)
(Ensure all safety labels, placards, and JSA’s are posted and readable)
R = Risk free walking/working surfaces
(Ensure proper housekeeping and keep working areas clean and clear)
M = Machine guarding
(Ensure machine guards are in place and operational)
E = Energy hazard controls
(Ensure all lockout-tag out procedures are followed)
D = Disposal of chemicals
(Ensure chemicals are properly labeled, stored, and disposed of)




                                                              Always something new
                                                                at the Arsenal's
                                                                   AAFES PX.

                                                              Remember...a portion
                                                                of the profits is
                                                              returned back to the
                                                               Arsenal to support
                                                               MWR facilities and
                                                                     events
Page 12                                Salvo                              April 30, 2012


   Arsenal Appreciation Night with the ValleyCats
                      Saturday, 18 August SA
                 egin                       VE
          l es B           at 7 p.m.           THE
    et Sa a     y                                  D                          ATE
Tick 30 M




      Contact                                                        Contact
    John Snyder                                                    John Snyder
    at 266-5055                                                    at 266-5055
          or                                                             or
    in Room 102                                                    in Room 102
     Building 10                                                    Building 10
    for tickets!!!                                                 for tickets!!!




 •	 The Arsenal has coordinated with the Tri-City ValleyCats baseball organi-
    zation for the 4th Annual Arsenal Appreciation Night.
 •	 Game is on Saturday, 18 August, at 7 p.m. (Fireworks Night)
 •	 Department of the Army Civilians and Arsenal family members may pur-
    chase a "Reserved Box" ticket for only $5.50 (42% discount). These are
    better	seats	than	what	we	had	in	the	past	(Section	230).		And,	for	the	first	
    time, if you want to save a few bucks, you may purchase Grandstand
    tickets for only $4 (38% discount). Yes, a price for everyone.
 •	 Even though we have better seats, All Arsenal Military Veterans will still
    receive a free ticket.
 •	 You may also purchase a reduced meal voucher for only $3.50 This
    voucher is good for one hot dog, small soda, and bag of chips.

 •	 For	tickets	and	information,	contact	John	Snyder,	room	102,	Bldg.	10.

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Watervliet Arsenal's Newsletter: Salvo 30 April 2012

  • 1. S ALVO “Service to the Line, On the Line, On Time” Vol. 12, No. 4 U.S. Army Watervliet Arsenal, Watervliet, NY April 30, 2012 Honors students turn labs into classrooms Photos by John B. Snyder Steve Smith, the acting branch chief for Benét Labs fatigue fracture analysis group, prepares the group for a live firing. Fifteen hon- ors students, who were all high school seniors, helped turn many of Benét’s labs into classrooms on April 25th. By John B. Snyder on the Watervliet Arsenal, shifted several of its op- erations into science classrooms for 15 local high High school honors students, who are enrolled school honors students who are enrolled in the New in a college-preparatory science program called Visions’ Science, Technology, Engineering, and New Visions, helped turn Army laboratories at the Math program that is administered in Rensselaer, Watervliet Arsenal into classrooms April 25. The Greene, and Columbia counties. purpose of the visit was to give students a firsthand The students were from Troy, Tamarac, Maple look at the role science and technology has in the de- Hill, Taconic Hill, Averill Park, Berlin, Hoosic Val- velopment of military weapon systems. The Army’s Benét Laboratories, which is located Story continues on page 3, see Students Commanders Column Boiler Plant Test Take Your Child to Work Visitors’ Center Page 2 Page 5 Page 6 Page 8
  • 2. Page 2 Salvo April 30, 2012 Commander’s Corner I was outside my quarters the other day doing some spring cleaning when the sound of bees caused me to put in our environment that we move into a safety trap because off that cleaning until maybe … next fall. All kidding everything was fine the last time we drove on that road or aside, you may not hear the sound of bees at the Arsenal worked on that machine that we become blind to the trap before you become SWARMED. I’m talking about our before it closes on us. new safety awareness program. To give you a sense of how big a problem overlooking Our safety gurus have come up with an innovative way safety is, I took a look at Google news for just a 24-hour to remember a safety process, commonly called an acro- period leading into the drafting of this column and there nym in the military, which should add a new dimension to were more than 11,000 stories posted. Many of these sto- our safety program. I know, some of you are thinking that ries involved death, such as a jury recommending that any- this is just what we need … something else to memorize. one involved in felling trees should wear a safety helmet So, don’t memorize it. Convert it into a checklist. following the tragic death of a father-of-five. Another story involved the death of a worker due to his company failing SWARMED to use energy control, or “lockout/tagout,” procedures prior  Signs and barricades in place to allowing the employee to enter the machine’s danger  Where PPE properly area.  Administrative Controls in place Wow, more than 11,000 safety accident stories in 24  Risk free walking/working space hours. As much as I like getting the Arsenal into the news,  Machine Guarding in place this is not one story that I want my public affairs officer to  Energy hazard controls in place and functional have to write.  Disposal of chemicals...properly Although you may get SWARMED at work, please do not become complacent this coming summer as you venture SWARMED is just part to help you LOOK FOR IT, more outside. You are too important to the Arsenal — too FIND IT, AND FIX IT! But keep in mind that safety is important to your family — to have you injured for some- more than a cute tagline or acronym. Our success in pro- thing that could have been prevented. tecting the workforce, on and off duty, must be a conscious part of our thought process every hour, by leaders and the workforce. Mark F. Migaleddi Some of you may believe that injury or loss of life due Commanding to an unsafe act won’t happen to you. After all, it is al- ways someone else. But sometimes, we get so comfortable Manufacturer 6 Commander, Col. Mark F. Migaleddi The Arsenal Salvo is an authorized monthly publication for members of the Department Public 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, or Photographer: 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: john.b.snyder.civ@mail.mil. The editor reserves the right to edit all information submitted for publication.
  • 3. Page 3 Salvo April 30, 2012 Students cont. ley, and Cohoes high schools, said Tammie Bor- land, the New Visions teacher who coordinated the visit. “This is a special program for high school seniors who want to concentrate in science and engineering in preparation for college,” Borland said. “What is great about the New Visions program is that we live and breathe hands-on education Photos by John B. Snyder and that is why we like to vis- Top: New Vision honor students it such places as the Army’s check out the weight difference Benét Labs.” between steel and composite base Sara Makowiec, an elec- plates. The composite was most favored, something Benét would tronics engineer with Benét like to hear from the Army. Labs, coordinated with Bor- Left: Students, with great restraint land for the visit. After all, by not touching, get a close look at some of the Benét fatigue lab work. who better than Makowiec to know what the students would like given that she had Strang said. “I was most gone through the same New impressed, however, at how Visions program five years the many fields of science are ago. brought together to achieve “This was great for us to a common purpose at the Ar- interact with students who senal.” have interest in the type of Most of the students have science and technology that never visited the Watervliet we work with at Benét,” Arsenal. But if Strang’s fel- Makowiec said. “For me, I low students left the Arsenal still remember how exciting feeling the same way as he it was going through the New Visions program five did, then Benét Labs did a lot more than simply shar- years ago because the program gave me great insight ing their work with high school students — they also into a wide variety of scientific fields of study.” educated some of America’s future science and engi- But it is often easy to please teachers and Arsenal neering experts about the value of military manufac- workers who like to share their knowledge with folks turing. outside of the Arsenal fence line and so, the value of According to the New Visions website, the STEM the visit truly rested with the students. program is located at Rensselaer Polytechnic Insti- If one could measure the body language, such as tute (RPI) in Troy, N.Y., and is part of the Questar III the smiles and looks of inquiring interest, then the program that is sponsored by the New York Board visit was a success for Benét Labs and for the New of Cooperative Educational Services. As part of the Visions program. But better than body language were curriculum, students interact with more than 80 pro- the comments from Robert Strang, a Troy High School fessionals each year, including researchers from Rens- senior. selaer, as well as technology organizations such as “This was my first time visiting the Watervliet Ar- General Electric and Benét Labs. This program is an senal and I was surprised at how much science and ideal choice for students who want to know what it re- technology is used to manufacture weapon systems,” ally means to be an engineer or scientist.
  • 4. Page 4 Salvo April 30, 2012 Albany Devils Military Appreciation Game April 14, 2012 Photos by John B. Snyder
  • 5. Page 5 Salvo April 30, 2012 Sweating test results in the boiler room? new technology on a similar boiler burning natural gas would By John B. Snyder have an expected annual fuel savings of $125,000, and for a boiler using oil, the annual savings would be nearly $140,000.” Do you remember the old test days when you were in The digitally-controlled prototype added a computerized school? You may not have been able to eat or sleep, and for system that continuously monitored the concentrations of oxy- others, they sometimes developed strange rashes and other ail- gen and carbon dioxide in the exhaust fumes to optimally ad- ments that we won’t go into. Suffice it to say that tests were just the amount of fuel and air fed to the boiler, thus improving very stressful to many of us. its efficiency, Poncia said. But what may have been more stressful than taking a test? But the results of this test may have a far greater conse- Finding out the results. quences than simply improving the efficiency and environment Well, the Arsenal has been undergo- at the Watervliet Arsenal. ing a nearly $250,000 test for the past Dr. Jim Galvin, the ESTCP Energy year and this month the results were in. & Water program manager who was in But for once, the Arsenal didn’t have to attendance when UTRC rolled out its sweat it. results, said “The Department of De- “United Technologies Research Cen- fense is seeking ways to reduce its $4 ter, out of Connecticut, installed a digi- billion-a-year energy costs at military tally-controlled prototype system on one installations. Watervliet Arsenal served of our steam boilers last year that trans- a critical role as an energy test bed for formed 1970s technology into a state-of- the Department of Defense to find in- the-art system,” said Richard Hoshko, novative ways to enhance boiler plant the Arsenal boiler plant supervisor. efficiencies.” The Arsenal site was selected primar- “To replace boiler systems through- ily due to its close proximity to UTRC out the Department of Defense is too and to Fireye, which is a division of costly,” Galvin added. “But if we can United Technologies’ Climate, Controls find a cost effective way to improve & Security Systems and is located in boiler efficiency, which saves energy New Hampshire. Fireye supported and reduces the production of green- UTRC in the development and instal- lation of the prototype device. An- Photo by John B. Snyder house gases, and do so with a relatively other strong consideration as to why the UTRC, briefs the results of the test to members short investment payback period, then Dr. Guido Poncia, c, who is the project leader at Arsenal site was selected speaks to the that process or modification may have who represented such organizations as the Army Arsenal leadership’s willingness to sup- Corps of Engineers and DoD’s Environmental Se- great utility for the Department of De- port testing of advanced technologies that curity Technology Certification Program office. fense. This technology demonstration at may benefit the Army and the Depart- the Army’s Watervliet Arsenal appears to ment of Defense. be meeting all those objectives.” But the main selling point to the Arsenal leadership in al- According to Poncia, the estimated potential of savings lowing this test to occur was that the test came at no cost to the across DoD, based on the demonstration at the Arsenal, indi- Arsenal. The Department of Defense’s Environmental Secu- cates a nearly $56 million annual fuel cost reduction and the rity Technology Certification Program (ESTCP) fully funded avoidance of approximately 600,000 tons of CO2 going into the test. the environment each year. Dr. Guido Poncia, who is the project leader at UTRC, said The Arsenal has four main boilers that provide heat and that when his company installed the new control module they limited power. Some of these boilers were installed as far back anticipated the Arsenal would attain better efficiency in its as the 1950s and therefore, lack computer controls that would boiler operations, as well as a significant reduction in green- enhance the efficiency, as well as the environment. The boiler house gasses. undergoing testing was installed in the 1978, Hoshko said. So, with a sense of excitement and hope for solid test re- The demonstration would not have been possible without sults, the Arsenal and UTRC waited … and waited until this the constant support of the Watervliet Arsenal, who hosted the month. demonstration, Poncia said. “During a one-year testing campaign between February “We acknowledge the amazing help we received from Rich 2011 and March 2012, the new system demonstrated a fuel Hoshko, the Arsenal’s Boiler Plant Manager, and to Vanessa savings of about 4 percent and a corresponding reduction of Duenas, the Arsenal’s Energy Manager of Watervliet Arsenal, CO2 emissions,” Poncia highlighted. “The investment in the for supporting and enabling the demonstration,” Poncia said.
  • 6. Page 6 Salvo April 30, 2012 Watervliet Arsenal: A place where children inspire 198 years of pride By John B. Snyder gram was dusted off last year to gauge interest. The Working in the historic feedback from the kids, Watervliet Arsenal has giv- their parents, and from the en nearly eight generations workforce who provided of workers a sense of pride demonstrations was so that may be rarely equaled positive that the Arsenal anywhere in the Army. But leadership decided to con- give it to children, who tinue the program. participated in the Arsenal’s The kids ranged from Take Your Child to Work 5th to 12th grade, and the Day on April 12, to take that ratio of males to females sense of pride to a higher was balanced. But wheth- level. er they were 12 or 17, the The Arsenal, with sup- smiles were universal. port from the Army’s Benét Eight grade student Laboratories, opened its Daniel J. Whelan IV said manufacturing operations that he never knew much to nearly 30 children of the about where his mother Arsenal’s workforce and worked. Photo by John B. Snyder showed them the work of Eight grade student Daniel J. Whelan IV said that he never knew “It was really cool,” skilled artisans and engi- much about where his mother worked until the Take Your Child Daniel said. “Although to Work Day. Daniel is standing in front of a 155mm tube that was I liked all the demonstra- neers who develop, manu- just forged. facture, and sustain our tions, my highlight of the nation’s military with large caliber tubes and cannons. day was seeing a cannon tube go through the forge.” This was an opportunity that is rarely shared with the Although the importance of what the Arsenal public. workforce does has never been lost, it sometimes “This was no small undertaking as more than 20 takes people from outside of the Arsenal fence line, workers, from machinists to firefighters to engineers, in this case children, for the workforce to know that provided presentations and demonstrations throughout after nearly 200 years of providing military hardware the day,” said Howard Kindell, the Arsenal’s Equal to our nation’s warfighters that what they do is still Employment Opportunity Officer who oversaw the “cool.” event. The kids weren’t the only ones “Our goal was to strengthen who got something out of the the bonds between the Arsenal day. and the Arsenal’s family mem- “The questions asked bers,” Kindell said. “And if showed a true interest in the you could measure success by science and technology and I the excitement shown on the think I saw one or two of my kids faces, then we achieved replacements in that crowd,” tremendous success.” said Timothy O’Connor, an en- For many years, the Arsenal Photo by John B. Snyder gineering technician at Benét Matthew Woelfersheim, a mechanical engineer who did not conduct a Take Your works in Benét Labs, points out some of the capabilities Labs who provided a presenta- Child to Work Day, but the pro- of an Abrams Tank. tion in laser scanning.
  • 7. Page 7 Salvo April 30, 2012 Making sense of historic photos By Mark Koziol Arsenal Museum The Watervliet Arsenal Museum, like many other institutions, has thousands of unique photographs in its collections. Unfortunately, incomplete captions are Photo provided by Arsenal Museum a common problem when collecting old photographs. The Arsenal Museum has a fairly large library of historic photos, such This said, last year the museum was fortunate to receive as this one with former Arsenal Commander Brig. Gen. Alexander G. a thoughtful gift of six photos from a local donor where Gillespie who commanded the Arsenal during World War II. each photo was captioned with the names of the people one published here along with the date of the party: June seen in each image. 16, 1942. Glued onto the same page as the photo was a The photograph included in this month’s SALVO copy of the June 17, 1942 Troy Record newspaper article newsletter was taken during World War II and depicts about the celebration: Arsenal Commander Brig. Gen. Alexander G. Gillespie standing alongside four Arsenal employees who, at the “A surprise party was given for Gen. Gillespie time, had 40 years or more of employment: in the R. W. Building, to celebrate his 40th anni- Left to Right: Wilmot H. Roblin, George Tofte, versary of entering the army. The 20 Year Club Ernest R. Oathout and Edward P. King. The occasion for was invited, along with the department heads the photo was a party at the Arsenal celebrating the 40th and all the officers on the post. A keg of beer anniversary of Gillespie entering the West Point Military was on hand as well as plenty of cold cuts and Academy in 1902. Unfortunately, the exact date of the sandwiches. There was community singing event was missing. and a great time was had by all 100 present.” After doing a little detective work, we located in the museum’s archives a scrapbook for the Watervliet Arse- The museum is continuing its research for more informa- nal 20th Anniversary Club, 1919-1952. After checking tion about the lives of the four men standing alongside the entries for 1942, we discovered a similar photo to the Gillespie. Speaking of photos.... It is amazing the type of stuff sent to the public affairs officer. One of these two cuties has worked at the Arsenal since World War II or so it seems. Suffice it to say...a very long time. A Free Arsenal T- Shirt to the 1st person who not only guess- es the name of the person in the picture, but also who picks the correct twin. Call the humble public affairs officer at x5055.
  • 8. Page 8 Salvo April 30, 2012 Improving force protection, first impressions By John B. Snyder “In regards to our force protection at the south gate, we have been like Soldiers since 9/11 in that we, too, have had The old adage about first impressions cannot be under- to improve our foxholes,” said Robert Shadlock, the Arse- stated and for those who have in recent years ventured into nal’s senior facility engineer. the south gate guard building of the Arsenal know firsthand Shadlock said that in the past 11 years, the Arsenal kept the value of a recent and significant change to how visitors tweaking the south gate operations to not only add more now enter the Arsenal. force protection obstacles, but also to improve safety in and The Arsenal’s main gate used to be the historic entry around the south gate. point on Broadway in the city of Watervliet where since “Because of limited funding through the years, we have 1813 workers and visitors yet to build the ideal solution gained access to the Army post. for worker and visitor ac- The attacks on 9/11 forever cess,” Shadlock said. “Nev- changed not only the fabric of ertheless, we have done quite American life as we once knew well with the resources we it; those attacks also changed had and this month’s opening the Arsenal. of a new Visitors Center is The Broadway main gate no just one example.” longer offered an entry point Just behind the south that would mitigate or elimi- gate guard building is a new nate a forced, illegal entry. $250,000 Visitors Center that After a quick, but thorough began operations this month. security analysis, the Arsenal The new center greatly im- leadership moved its main en- The south gate guard building in the foreground once handled the proves safety and is support- Photo by John B. Snyder try point to its south gate off of flow of traffic, as well as processing visitors. Those two opera- ive to those with disabilities, tions are now separate as all visitors are now processed through Shadlock said. rd 3 Avenue in Watervliet. Three significant things the Visitors’ Center in the background. As part of the Visitor happened as a result of that decision in 2001. Center cost, there was also a First, the Arsenal has steadily made improvements to its significant upgrade to the electrical system that provides force protection by making it very difficult for an attacker power to the south gate area. to gain rapid, unimpeded access to the Arsenal. Such “We more than doubled the amount of the transformer things as concrete protection barriers commonly called capability, as well as installed underground power for the “Jersey Barriers” to pop-up barriers to a vehicle inspection force protection lift gates,” said Benjamin Dedjoe, the Ar- area have been put in place during the last 11 years. senal’s electrical engineer. The second outcome from the relocation of the main But probably one of the most obvious changes is a visi- gate deals with a false perception by many from outside of tor’s first impression. the fence line. When the Arsenal used the original main Arsenal Security Officer Mike Valle commented that in gate, thousands of travelers driving along I-787 could see the former south gate access point, the lines of people try- the flow of vehicular traffic into and out of the Arsenal ing to get an access badge would often run out the door. every day. With the relocation to a side street, interstate “This was a very unsafe condition as we had people run- drivers no longer could see any movement into or out of the ning back in and forth in front of cars entering the Arsenal Arsenal, which gave many a false impression that maybe all trying to vie for space in a small building,” Valle said. the Arsenal had closed. “Now, all visitor traffic is away from the gate and visitors Finally, the guard post at the south entry gate was never enter a very nice facility that enhances their first impres- intended to be a main entry point. The small structure, sions of the Arsenal.” which doubled as a visitors center, was not conducive to This addition was so significant to the Arsenal’s access logging in and out visitors, and had a degree of safety risk operations that during a recent visit to the Arsenal by the as visitors had to park their cars and then crossover the en- Army Materiel Command’s Commanding General, Gen. try lane to get into the south gate to sign in. Once inside, Ann E. Dunwoody, she awarded her commander’s coins the small building became rather crowded with security of- for excellence to Al Columbus, chief of Arsenal security, ficers doing their business of managing traffic flow, as well Robert Shadlock, and to Joe Claus, the Arsenal director of as visitors trying to gain access. emergency services.
  • 9. Page 9 Salvo April 30, 2012 CPAC Corner Did you know you can move your resume from Resumix to USAJobs? All you need to do is follow the instructions below. 1. Open a Word doc. 2. Go to CPOL (www.cpol.army.mil) employment – Click “Build A resume/check Status” – Under Registered Users click “Login” – Click “Answer” – Click “View Resume” – Highlight the Resume – Right click “copy” If you have any questions, – Open word document – Right click “paste” contact the CPAC office – Click “File” – Click “Save As” to Desktop at – Name your resume 266-4058. 3. Go to USAJobs (www.usajobs.gov) – Click “Resume” – Click “Upload resume” – Name your resume – Click “Browse” – Select the resume saved to desktop – Click “Upload” Memorial Day Parades Save The Dates The Arsenal is participating in the Village of Green Island parade on Thursday, May 24th and the City of Watervliet parade on Monday, May 28th. For the Village of Green Island parade, we plan to only provide the bob-tailed truck and lowboy trailer float. Need a Driver!!! The Arsenal commander will speak at the end of parade ceremony. For the City of Watervliet, we plan to provide the full parade contingent with marchers. The Arsenal commander will speak at the end of parade ceremony. Green Island Parade kicks off at 6 p.m. City of Watervliet Parade kicks off at 10 a.m.
  • 10. Page 10 Salvo April 30, 2012 Seven Wastes…plus one By Karen Heiser Processes add either value or waste to a product or service. Although products differ between factories, shop and office wastes are usually similar. This article will introduce you to identification and elimination of waste as the first step to increasing business success through lean management. There are seven types of waste: overproduction, waiting, excess transportation, excess inventory, excess processing, excess motion, defects and correction . Overproduction is producing more, sooner, faster than required by the next process. It is costly because it prohibits the smooth flow of materials and can actually degrade quality and productivity. Waiting is employee or machine idle time. It results when goods are not moving or being processed. Over 90% of a product’s lead time in traditional batch-and-queue manufacture is spent waiting for the next thing to happen. Excess transportation is product movement that adds cost but no value to the customer. Excessive movement and handling can also cause damage and provide an opportunity for quality to deteriorate. Excess inventory is raw material, work in process (WIP), or finished goods in excess of requirements for an on-time delivery to the next process, or to the customer. It consumes productive floor space and hides problems because it generates an alternative to investigating the root cause of the problem. Excess processing is doing more work than necessary that adds no value. This includes change orders, extra operations such as rework, reprocessing, handling or storage that occurs due to defects, overproduction or excess inventory. Any work that goes beyond the customer’s needs is excess. Excess motion occurs when extra steps are taken by employees and equipment to make up for inefficient process layout, poor use of technology, defects, reprocessing, overproduction or excess inventory. Defects and corrections result in scrap, repair and rework and are an excess cost to the customer. Impacts include capacity loss, quarantining inventory, re-inspecting, rescheduling. The eighth waste is your time and skills. When employees are losing time dealing with the seven traditional wastes, they, and the organization are not reaching their potential. And the customer is paying for it. At Watervliet Arsenal we are justifiably proud of our quality to the customer. As COL Migaleddi often says, “We are too good to be ignored.” Global competition, economic constraints, and technological innovations have driven other good companies to become world-class organizations through lean management. As world- class organizations realize, customers will pay for value-added work, but not for waste.
  • 11. Page 11 Salvo April 30, 2012 The SWARM is coming ... huh? By Maj. Donald Freer Experienced safety professionals often seem to have a sixth sense – they walk onto a production floor or into an office and immediately know what is going on. This sixth sense is “situational awareness” developed gradually over several years of working in the safety profession. Any employee can quickly develop situational awareness by learning to focus your attention on specific facets of what is happening around you in an orderly and disciplined way. It takes concentration, practice and patience, but you can do it. Remember that safety begins with you! To help you focus on safety checks and inspection areas the safety office is introducing a new mnemonic aid called SWARMED. A mnemonic aid is simply a learning technique makes memorization easier. Commonly encountered mnemonics are often verbal, such as a very short poem or a special word used to help a person remember something, particularly lists. Mnemonics rely on associations between easy-to-remember constructs which can be related back to the data that are to be remembered. Here is the breakdown of our safety mnemonic: S = Signs and barricades in place (Ensure all emergency egress, restricted areas, & barricades are posted and functional) W = Wear PPE properly (Ensure all building inhabitants are wearing required PPE) A = Administrative controls (labels) (Ensure all safety labels, placards, and JSA’s are posted and readable) R = Risk free walking/working surfaces (Ensure proper housekeeping and keep working areas clean and clear) M = Machine guarding (Ensure machine guards are in place and operational) E = Energy hazard controls (Ensure all lockout-tag out procedures are followed) D = Disposal of chemicals (Ensure chemicals are properly labeled, stored, and disposed of) Always something new at the Arsenal's AAFES PX. Remember...a portion of the profits is returned back to the Arsenal to support MWR facilities and events
  • 12. Page 12 Salvo April 30, 2012 Arsenal Appreciation Night with the ValleyCats Saturday, 18 August SA egin VE l es B at 7 p.m. THE et Sa a y D ATE Tick 30 M Contact Contact John Snyder John Snyder at 266-5055 at 266-5055 or or in Room 102 in Room 102 Building 10 Building 10 for tickets!!! for tickets!!! • The Arsenal has coordinated with the Tri-City ValleyCats baseball organi- zation for the 4th Annual Arsenal Appreciation Night. • Game is on Saturday, 18 August, at 7 p.m. (Fireworks Night) • Department of the Army Civilians and Arsenal family members may pur- chase a "Reserved Box" ticket for only $5.50 (42% discount). These are better seats than what we had in the past (Section 230). And, for the first time, if you want to save a few bucks, you may purchase Grandstand tickets for only $4 (38% discount). Yes, a price for everyone. • Even though we have better seats, All Arsenal Military Veterans will still receive a free ticket. • You may also purchase a reduced meal voucher for only $3.50 This voucher is good for one hot dog, small soda, and bag of chips. • For tickets and information, contact John Snyder, room 102, Bldg. 10.