48th Fighter Wing Airmen Develop Innovative Technology to Streamline Munitions Loading

A Groundbreaking Innovation at RAF Lakenheath: Enhancing Munitions Handling with Smart Solutions

Introduction to a Smart Solution

At RAF Lakenheath in England, creativity and resourcefulness are more than just buzzwords—they’re vital to mission success. Senior Airman Devon Word has recently taken strides to enhance the efficiency of the 48th Fighter Wing, potentially saving the U.S. Air Force over 750 man-hours annually. As a conventional crew chief with the 48th Munitions Squadron, Word identified a pressing issue: the frequent jamming of 20 mm ammunition replenisher tables, which caused significant delays and posed safety risks to operators.

Recognizing a Persistent Problem

The jamming of ammunition tables created a bottleneck during operations, requiring repeated manual interventions that not only wasted time but also introduced the risk of injury. Word’s observations were rooted in the real-world experiences of those on the front lines, where inefficiencies could directly impact mission readiness. "It was frustrating to see the team losing time and resources to repeatedly fix the same problem," Word recounted. This frustration was the catalyst for innovation—a realization that something must be done to streamline the process.

Collaboration for Innovation

Word’s ingenuity was complemented by the collaboration of Staff Sgt. Bethany Levi, who serves as the non-commissioned officer in charge of the Air Force Repair Enhancement Program for the 48th Maintenance Group. Together, they conceptualized a practical solution: a simple yet effective insert designed to improve the function of the ammunition replenisher table. Their teamwork exemplified how frontline Airmen, equipped with insights from hands-on experience, can address operational challenges in ways that may not be apparent to higher levels of management.

A Design for Safety and Efficiency

The design flaw in the existing replenisher table allowed multiple rounds to fall simultaneously onto the loader instead of one, which led to frequent jams requiring around 15 minutes of troubleshooting each time. Word’s innovative insert compensates for this flawed design, thereby minimizing jams during the loading process and significantly reducing overall operation times. Lt. Col. Jonathan Tolman, the commander of the 48th Munitions Squadron, praised the initiative, stating, “The military’s willingness to embrace and implement ideas from frontline Airmen demonstrates adaptability, which is crucial in rapidly changing operational environments.”

Innovation in Action: Prototyping and Testing

To bring their idea to fruition, Levi, alongside Senior Airman Joshuah Fontena, a metals technology journeyman from the 48th Equipment Maintenance Squadron, embarked on a rigorous prototyping process, utilizing 3D printing technology to create 11 prototypes. After six rounds of trials on the load table, adjustments were made until the insert was perfected. This hands-on approach not only fostered a culture of innovation but also highlighted the importance of collaboration among Airmen with diverse skill sets.

Results: A Significant Impact on Operations

Following months of testing and modifications, the insert has been adopted for regular use within the squadron, resulting in a remarkable reduction in machine malfunctions. During fiscal year 2023, there were a staggering 319 operations that averaged 957 jams on the replenisher table, consuming about 798 man-hours due to the need for multiple personnel on-site during these occurrences. With the time saved by utilizing Word’s innovation, Airmen can now redirect their efforts to other critical tasks, optimizing their overall mission capability.

Recognition of Team Efforts

Word attributes the success of this project to the collective effort of his fellow Airmen and the support of leadership, stating, “I couldn’t have done it without the support of my fellow Airmen and leadership. This is the product of our shared commitment to improving the way we work.” This sentiment reinforces the idea that innovation within the military relies heavily on collaboration, creativity, and a willingness to improve existing processes.

Future Implications: Expanding Innovation Across the Air Force

The impact of Word’s invention extends beyond the 48th Munitions Squadron. The team is currently pursuing a patent for the design and aims to share it with other munitions squadrons within the Air Force. By doing so, they hope to significantly enhance operational readiness and efficiency for all munitions Airmen grappling with similar issues. This initiative not only sets a precedent for innovation in munitions handling but also serves as a testament to the potential of grassroots, ground-level problem-solving within the military.

In essence, this story at RAF Lakenheath illustrates the incredible capacity of Airmen to innovate and adapt, helping to shape the future of military operations through practical and effective solutions.