Kratos helps supports Zumwalt Class Destroyer for the Navy
Beginning in 2006, Kratos, thought its Gichner subsidiary, was awarded contracts for the design, engineering and production of Electronic Modular Enclosures (EMEs) from Wenzlau Engineering and Raytheon Integrated Defense Systems in support of the U.S. Navy DDG 1000 Zumwalt Class Destroyer and Self Defense Test Ship programs.
Situational Overview
Under the U.S. Navy's DDG 1000 Detail Design and Integration contract awarded in 2005, Raytheon Integrated Defense Systems (IDS) serves as the prime mission systems equipment integrator for all of the leading-edge electronic and combat systems for the Zumwalt-class destroyer program. Working with the Navy and a team of industry leaders, IDS is leading the effort to transform the Navy's ship requirements to reality. Raytheon IDS was tasked with providing new cost-effective innovations to modernize the approach to shipbuilding and mission equipment integration. As a subcontractor to IDS, Kratos was selected to provide design, engineering, manufacturing and technical support for the development of Electronic Modular Enclosures, which enable reductions in ship integration costs by streamlining shipboard combat system installation, integration and testing.
DDG 1000 Zumwalt Class Destroyer
Kratos was tasked with:
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Developing enclosures that efficiently package the shock mitigation, electromagnetic interference protection, thermal conditioning, security and vibration isolation for commercial off-the-shelf electronics integrated inside.
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Providing Engineering and technical support including finite element analysis.
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Conducting testing and equipment operational verification.
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Maintaining a quality assurance program approved by Raytheon IDS.
The Kratos team has been instrumental in providing services and resources to support program goals and budgetary requirements.
Kratos Solution
Because of its expertise in design and production of tactical military enclosures, Kratos was able to provide the following design, production, testing and support services for the DDG 1000 program:
- Design and production of large custom built EMEs that measure close to 35-feet long, 8-feet high and 12-feet wide.
- Conduct EMI/RFI shielding effectiveness testing to ensure proper electromagnetic interference protection.
- Design, layout and installation of electrical and signal wiring allowing increased efficiency in the installation of electronics.
- Kratos supported concurrent EME production of this design to manufacturing program by assigning a dedicated program team that included program management, mechanical and manufacturing engineering, quality and test engineering, production and in-process inspection. This team supported the dedicated production line developed specifically for the DDG EME product line.
Empowering Benefits
Kratos’ quality engineering services, production and technical support have contributed to the innovations and efficiencies inherent in this design approach for DDG 1000, including:
- Superior System Protection: The EMEs provide isolation for shock, vibration, and electromagnetic interference in addition to supplying power, cooling, and security allowing the use of Commercial-Off-The-Shelf (COTS)-based Mission System Equipment.
- Reduced Ship Production Times: This Electronic Modular Enclosure approach to ship building provides substantial savings in electronics packaging, shipbuilding, and shipboard integration and reduces shipyard production cycle times.
- Reduced Costs: The EMEs are a lower cost approach in shipbuilding that enables over 200 individual COTS electronics cabinets to be fully integrated and tested as sub-systems before being delivered as stand-alone EMEs to the shipyard.
Kratos worked with Raytheon engineering and program management to minimize cost growth during the complex design to manufacturing transition and throughout the manufacturing program by implementing continuous improvement initiatives. These initiatives were successful in minimizing production, test and delivery schedule delays.