In preparing for its Joint-Air-to-Surface Standoff Missiles (JASSM) project, Lockheed Martin Missiles and Fire Control had to determine the best method to move missiles out of the production area and into a testing chamber -- a material handling problem that presented quite a challenge even to Michael P. Goeb, a Lockheed Martin veteran of over 25 years. Pflow Industries, a manufacturer of vertical lifts and conveyors, solved the problem.
Lockheed Martin Missiles and Fire Control, an operating element of Lockheed Martin Systems Integration business unit, develops, manufactures, and supports advanced weapon systems. Lockheed Martin Corp, headquartered in Bethesda, MD, is a highly diversified global enterprise principally engaged in research, design, development, manufacture, and integration of advanced technology systems, products, and services. Lockheed Martin''s customers include the U.S. Army, Navy, Air Force and Marine Corps; and foreign nations approved by the U.S. Department of State.
Lockheed Martin Missiles and Fire Control employs about 8,500 people in 10 facilities, one of them Alabama-based Pike County Operations. Here final assembly, testing operations, and storage of anti-armor missiles such as the helicopter-launched Hellfire II, the shoulder-fired Javelin, and the radar-guided Longbow Hellfire take place. The facility also assembled the famed Patriot air defense missile and the medium-range Air-to-Ground AGM-142 missile used by Air Force B-52 bombers and allied forces during Desert Storm.
A Material Handling Challenge
In August 1999, Pike County Operations started performing final missile assembly and testing of JASSM, a long range, conventional, air-to-ground precision missile designed to destroy well-defended high-value targets. Michael P. Goeb, director of major projects for Lockheed Martin Missiles and Fire Control, oversees construction operations and has been active in the design of the Pike County Operations facility. Goeb had to determine the best method to move missiles out of the production area and into a testing chamber -- a material handling problem that presented quite a challenge, even for someone with his years of experience.
"We needed to develop a method to move missiles out of production and into a chamber for testing," recalls Goeb. "Initially, our plan was to move the missiles horizontally into the chamber with an overhead crane. Then, the missile would be placed on a lift that would move it vertically to a designated testing station. The initial concept, however, proved to be too costly and inefficient." Goeb and his team then began to design a more cost effective, practical and safer solution. During that time, he contacted Pflow Industries, a manufacturer of vertical lifts in Milwaukee, WI.
Working with Pflow engineers, Lockheed Martin developed a new concept for moving the missiles. Safety was a primary design objective, given the sensitive nature of the product that was being transported. The end result was a highly specialized material handling platform designed to move a missile horizontally into the chamber and then vertically to the designated test station. The final concept required approximately four months to develop.
Lockheed Martin requirements meant that the Pflow system had to be extremely stable, safe, and capable of accurately positioning the missile for critical testing procedures. In addition, the platform had to accommodate repetitive points of loading and unloading with fractions of an inch variation. Vertical and horizontal control tolerances were critical.
Specialized System Solves the Problem
To transport the missile, Pflow designed a 6,500 lb capacity work platform that travels laterally on 18 in. wheels via a gear and pinion line shaft drive. The platform measures approximately 20 ft x 20 ft and weighs over 28,000 lb. A rail system, recessed into the floor, provides a method for the platform to travel to and from the testing chamber. The Pflow platform was designed to meet all OSHA and Lockheed Martin safety standards associated with handling explosive devices, as well as for personnel safety while riding the platform.
When a missile comes out of production, it is placed on the Pflow work platform. The platform then moves horizontally on the recessed rails into the test chamber. Once inside the chamber, the platform and missile are raised vertically 20 ft to a designated testing station. Vertical travel is controlled via screw lifts mounted inside the platform columns. All services including power, communications, and data are provided to the platform utilizing retractable wheels. After missile testing is completed, the platform is lowered and backed out of the chamber. Horizontal and vertical positioning of the Pflow platform is accurate to within 1/8 in.
Goeb claims that a specialized material handling system had to be developed to move the missiles. "You cannot do it with manpower -- by hand -- and you can''t do it with standard material handling equipment," said Goeb. "This was a one-of-a-kind operation, the first of its kind. The Pflow system provided a safe, efficient solution."
Pflow also reacted quickly to meet the Lockheed Martin delivery schedule. "Pflow developed the concept and had the unit operational within six months," said Goeb. "The platform was installed in a new facility that was being constructed at the time. We had a delivery schedule and Pflow beat the schedule. We were very satisfied."