Red River Army Depot

Written by Colonel Daniel Mitchell, Commander, Red River Army Depot

Originally, Red River was intended only as an ammunition storage depot. However, no sooner had the first trainloads of ammunition begun to arrive, than the demands of World War II caused top defense planners to take another look at the new installation. A good labor market, excellent transportation facilities, and the installation’s nearness to the great southwestern training areas and southern ports were reason enough to expand the depot mission to include general supply storage and tank repair facilities.

Throughout the years, the depot’s missions have evolved, and today Red River is engaged in activities ranging in scope from producing timber to recertification of the Hawk and Patriot missiles. Both the ammunition and supply missions remain but as tenants to the depot. One of the depot’s primary missions is still to supply posts, camps and stations, as well as National Guard and Reserve units with several types of military equipment. The depot accomplishes worldwide distribution to this country’s armed forces and to America’s allies through major ports.

The depot is host to 14 tenant organizations, with the largest being Defense Logistics Agency’s Distribution Depot that stores line items valued at over $6 billion. Weathering the Base Realignment and Closure (BRAC) laws of 1995, RRAD relinquished 765 acres of land and 106 buildings to Bowie County; however, Red River Defense Complex remains the largest single employer in the greater Texarkana area. Because of the installation’s prominence in the local area, very close ties exist between the depot and community.

Red River has received and maintained its registration as a globally recognized member of ISO 9000 and ISO 14001. These international registrations open global avenues for partnership opportunities with private industry. They are also a symbol of Red River’s ongoing commitment to its customers that RRAD will continue the process improvement quest to provide the customer the highest quality products available while continuing a respect for the environment.

Currently the depot is implementing the 2005 BRAC recommendations for realignment. The final recommendations include transfer of the missile recertification function to Letterkenny Army Depot, Pa. In addition, when the final actions are complete, several acres of depot property will be transferred to the local redevelopment authority.

RED RIVER TODAY

The mission flexibility and responsiveness of the work force, equipment and facilities provide Red River a competitive edge within the defense industry. RRAD is an ISO 9001:2000 registered industrial complex providing responsive and innovative solutions for the Department of Defense in repair, overhaul, recapitalization, remanufacture and conversion of combat systems and tactical vehicles. In 2008, RRAD achieved ISO 14001:2004 registration for Environmental Management Systems. Recognized as the Army’s Center of Industrial and Technical Excellence for tactical wheeled vehicles, bradley fighting vehicle systems and multiple launch rocket systems, Red River has the only DoD capability for recertification of Patriot and Hawk missiles as well as the remanufacture of road wheel and track. RRAD is the first location producing the safety certified HMMWV Egress Assistance Trainer (HEAT).

Along with providing a high quality product for each soldier, Red River also boasts an 88 percent decrease in recordable accidents. In 2007, the secretary of defense established the mine-resistant, ambush-protected program as the highest priority acquisition program. In support of MRAP, RRAD continues to deploy personnel to Southwest Asia and serve as the host site for MRAP University.

SOLDIER TRAINING PROGRAM

RRAD partnered with National Maintenance Training Center (NMTC) to support the component repair companies (CRC) with real-world hands-on training during annual training at the depot level. Soldiers are paired up with depot civilians to work depot level maintenance in accordance with MOS skills. For fiscal year 2008, six Reserve and National Guard Units conducted annual training at RRAD.

ANTITERRORISM PROGRAM

RRAD was recognized by the Army Materiel Command by being awarded two of four Antiterrorism (AT) Program Awards for FY08: Best AT Program for fixed Installations and Best AT Program Manager Awards. RRAD’s AT and chemical, biological, radiological, nuclear and explosive (CBRNE) plans were recognized by HQDA as model plans and adopted as the JPM Guardian’s installation protection program’s (IPP) model template for all IPP-fielding installations.

In addition RRAD was selected as “Department of the Army Best Antiterrorism Award Runner Up for 2008.” RRAD was second only to Fort Hood out of the entire Army.

FP is a combination of long-standing security and intelligence disciples. The overall concept of FP is an outgrowth of the Downing Commission’s in-depth study of the terrorist attack on Khobar Towers. The Downing Commission rendered 13 imperatives, which now serve as the basis for all standards for force protections guidance and regulations. In accordance with DoD and Department of Army regulations, AMC established an FP program encompassing supplemental regulations and performance-based evaluation. In 2005, AMC aligned their awards program with DoD and DA, establishing annual recognition of installations and individuals for excellence within several categories.

For the 2007 year, RRAD was awarded the Best Antiterrorism/ Force Protection Program for an installation. Director of Emergency Services Eric Foster accepted the award for the depot. The RRAD AT/FP program was recognized for the dramatic improvements over the past few years—to include 10 new projects that have been completed or are under way, each that significantly enhance physical and personnel security. Also recognized was the AT/FP exercise program that integrates local, state and federal civilian agencies. These efforts were recognized not just in answer to weaknesses identified during past assessments of the installation FP program, but were also forward-looking and exceeding minimum standards.

In addition for the 2007 year, Bill Pass was presented the Best Antiterrorism/Force Protection Program Manager award. To receive this award, the selected individual must have demonstrated both superior management and leadership skills and a level of commitment that has had a major impact on the overall program. Pass’ aggressiveness and futuristic outlook were instrumental in initiating procedural and programmatic improvements that have greatly enhanced the FP posture for RRAD.

MODEL-CENTRIC DESIGN

Red River Army Depot is working closely with the Army Research Laboratory initiative on model-centric design. The objective is to transition 3-D modeling work instructions into the sustainment of legacy systems. Many Fortune 500 companies use this technology, and RRAD is the first in the Army to develop this capability. Red River simulation team members have completed the product and process flow development and 3-D shop work instructions for the BFVS transmission and have started developing the BFVS 25 mm gun rebuild with plans to start on the BFVS turret drive system components in FY09.

PERSONNEL INNOVATION

RRAD is hosting approximately 20 soldiers and officers, both National Guard and Reservists, in the Personnel Innovation Program (PFI) this year. The military personnel are assigned in several areas throughout the depot to augment vacated positions. Several are working as quality inspectors on the production lines and serving as military police for the installation. In addition, two officers are working in the Business Management Office to coordinate and supervise the various military units performing their annual training on the depot; and two officers work in the Directorate of Contracting. Several PFI personnel are performing duties in the MRAP Division assisting as a rear detachment operation to coordinate the deployment and redeployment of several hundred DA forward MRAP operations in Kuwait, Iraq and Afghanistan.

MRAP

As part of the business development, RRAD opened communications with the program manager (PM) of MRAP in early June 2007. RRAD agreed based on a general statement of work provided by the program manager to deploy personnel with the mission to support the program manager of MRAP by deprocessing MRAP vehicles for issue, sustain MRAP vehicles in operation, and provide unit-embedded maintenance support teams. The number of personnel required by MRAP in theater continually changes, fluctuating between 1,000 and 500. RRAD’s deployment of personnel to support the mission continues to follow the MRAP mission changes in theater. From the inception of the program in the summer of 2007 to present, RRAD personnel have established three regional support areas (RSA) in Iraq, which serve as both sustainment and fielding sites, and four fielding sites.

In mid-December 2008, RRAD, at the request of the PM, has started to establish a new RSA in Kuwait with the purpose of refurbishing MRAPs in theater. RRAD personnel have never missed a fielding and have maintained an in-theater average operational readiness of 94 percent on the MRAP vehicles. During 2008, Red River, in conjunction with the MRAP Joint Program Office, initiated and now provides direct support for the MRAP University Training, training on average 150 personnel each week on site at RRAD prior to deployment into the CENTCOM AOR. Students include field support representatives, RRAD employees supporting MRAP forward repair and soldiers from all services. The curriculum includes operator level and field level maintenance on multiple MRAP OEM configurations. The mission will grow in FY09 by establishing the MRAP mobile training team mission. New facilities will be constructed on site at RRAD to provide home base repair and maintenance and instructor development. The facility will be the home station of 40 instructors who deploy along with MRAP vehicles to CONUS installations across all services to provide onsite training of troops.

HEAT

Before soldiers deploy, they are now being put through the “spin cycle” by the Department of the Army’s only vehicle rollover trainer. The HMMWV Egress Assistance Trainer, or HEAT, is able to realistically simulate a vehicle rollover in a safe environment. The trainer uses a rebuilt HMMWV body (predominantly 1114 configuration) mounted to pivots on a raised platform. An electric motor rotates the entire vehicle and simulates a rollover situation. This allows the trainers to familiarize soldiers with the critical 30-degree angle where one of these top-heavy up-armored vehicles will roll over. If the truck rolls beyond 30 degrees, vehicle crews are trained to anticipate the impending roll and immediately pull the turret gunner into the vehicle and restrain it. Practicing in the HEAT will save lives in the event of a rollover. To date, RRAD has produced 109 HEAT trainers of a total program quantity requirement of 239. The majority of the trainers have been fielded CONUS; however, units have been fielded to OCONUS sites such as Kuwait, Italy, Germany, Okinawa, Korea and Iraq for training. The Army AL&T has called the HEAT one of the top 10 greatest inventions for 2007.

MET

Due to a reduction of HMMWV rollover casualties attributed to “HEAT-trained” troops, the Army began development of the MRAP Egress Trainer (MET) in FY08. RRAD was once again designated as the production facility for the trainer production. In an effort to field the trainers as quickly as possible, RRAD was tasked to design and produce the first five “expedient” METs. These production models utilized MRAP cabs of five configurations. The cabs were selected from test vehicles located at Aberdeen Proving Ground, Md. All five trainers are projected to be completed by the end of January 2009 and ready for OCONUS fielding sites in February 2009.

In conjunction with the expedient trainers, RRAD also began production plans for the “Objective” METs to be fielded in FY09 at various OCONUS sites. To date there is a known requirement for a quantity of 43 trainers to be produced by RRAD during FY09. The MET, like the HEAT, teaches soldiers how to egress from the MRAP vehicles after a rollover occurs. This simulation helps the occupants defeat shock and gain “muscle memory” in knowing how to safely egress from an MRAP involved in a rollover situation.

ASV

The Armored Security Vehicle-150 (ASV-150) is an armored wheeled vehicle equipped with a turret and armament system designed to meet the security mission requirements of the Military Police Corps. The ASV-150 is a fourwheel drive vehicle equipped with a 260 horsepower diesel engine, six-speed automatic transmission and all-wheel independent suspension that offers a quality ride while providing superior mobility, agility and handling. The ASV-150 turret is equipped with an improved 40 mm MK 19 grenade launcher and 12.7 mm machine gun and can be traversed 360 degrees and the weapons elevated between -10 to +60 degrees. The vehicle features roll-on/roll-off C-130 transportability in the fully operational configuration. The ASV is a lightly armored, all-wheel drive vehicle that provides ballistic protection for the military police crew members against various threats. Protection is also required against anti-personnel mines and anti-tank mines up to an equivalent of 12 pounds of TNT.

TAJI NATIONAL DEPOT

RRAD provided the lead in establishing the first Iraqi Maintenance Depot. This project has been in process since 2005 in Taji, Iraq. In addition to establishing the facility, RRAD currently maintains a core team on site committed to oversee quality standards and capability for the full spectrum of weapons systems for the Iraqi military forces.

LSAC

In June of 2008, Tactical Vehicle Program Manager and the 402nd Army Field Support Brigade opened discussion with RRAD concerning the requirement to field low signature armored cabs on the family of medium tactical vehicles in Southwest Asia. RRAD competed for and won the mission. Deployments started in July 2008. RRAD also has the responsibility to order tools and equipment for the PM. Tools have been shipped to Iraq and have been received. Deployed personnel have been directed to both Kuwait and Iraq.

915 TRUCK

In June 2008 program managers for tactical vehicles and the 402nd AFSB opened discussion with RRAD concerning the requirement to field upgraded 915 cabs in SWA. RRAD competed for and won the mission. Deployments started in August 2008. RRAD also has the responsibility to order tools and equipment for the PM. Tools have been shipped to Iraq and have been received.

TRMD

For much of 2008, Theater Readiness Monitoring Directorate staffed a Kuwait facility (technical representative) who served as a liaison between the U.S. government, Raytheon and the Kuwait military. A team (equipment specialists, electronic mechanics and painter) also provided training to Kuwait soldiers manning the facility.

RRAD AND BAE SYSTEMS

RRAD began its partner relationship with BAE Systems in 2004 with the Army’s Program Management Combat Systems for the management, overhaul and upgrade of the Bradley fleet. In late 2006–early 2007, RRAD public-private partnership Team developed a groundbreaking relationship in implementing a public private-partnership between the U.S. Army and BAE Systems’ Ground Systems Division. The team implemented Lean Six Sigma remanufacturing lines for the Bradley transmission, 25 mm gun, turret drive system and power pack assembly, and the team also established a dedicated machine to mold Bradley road-wheels. In October 2007 BAE and RRAD signed a memorandum of intent for a partnership to support production of MRAP vehicles.

In addition to prior year partnerships/contract, the Red River public-private partnership office has successfully negotiated and signed teaming agreements with 30 contractors during 2008, and three more are in process and close to completion. The depot is working in partnership to develop a business case for rebuilding Caterpillar engines at RRAD backed by an original equipment manufacturer (OEM) warranty. The partnership started as a Lean Six Sigma project using the design, measure, analyze, improve and control (DMAIC) methodology approach to develop, test and analyze the rebuild process to provide the best value product to the warfighter.

Red River continues to negotiate contractual direct sales agreements and basic ordering agreements with OEMs and other contractors, and has received several substantial revenue-producing contract awards through direct sales/partnership initiatives during the past 12 months.

RECOGNITION

In 2008, Red River Army Depot became the first installation to achieve three Shingo Public Sector for Excellence in Manufacturing awards for two consecutive years by receiving a Silver medallion for the HEMTT Production Team and two Bronze medallions for the Tactical Trailer Processes and the Patriot Missile Team. NOR AND PAYOUTS

The NOR is profit and loss of the depot for the current fiscal year. The year ended with revenue of $948.6 million, expenses of $919.5 million, and a recoverable net operating result of $29 million. Each employee received an NOR payout of $2,000 as a bonus for their contribution to the depot’s financial success and outstanding safety record. ♦

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