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STAFFORDSHIRE UNIVERSITY FACULTY OF COMPUTING, ENGINEERING AND TECHNOLOGY

NEGOTIATED FINAL PROJECT BEng (Mechanical)

Project Report

Fitter Truck Storage Solution

British Army MAN SV 6T truck (Think Defence 2014)

A project to investigate current and possible improved solutions for the carriage of tools and repair facilities on the Army MAN SV truck, used as part of deployed Equipment Support (ES)

Student Graeme Wilcock W022700FProject Tutor Mr Chris Wayman

February 2016

Abstract

Create and design an adaptable and modular storage system for the carriage of tools and repair assets on the Army MAN Support Vehicle, used as part of deployed Equipment Support (ES).

When deployed out of barracks ES personnel need to store tools, special test equipment and spares on the MAN Support Vehicle (SV). There is currently no standard storage unit for this and local modifications for storage are proving time-consuming to implement, potentially unsafe and unable to accommodate all items securely.

In order to understand the situation this project first established a customer requirement of equipment to be carried. This was achieved through a customer survey of 150 personnel from across the Land ES environment. From this a Product Design Specification (PDS) was created with a list of items and criteria deemed essential. Research into current storage solutions, civilian modular systems and complete ISO container based systems was conducted with the findings assisting in the creation of a self-designed storage system.

This design was based around the dimensions of standard NATO storage boxes and vehicle mechanic toolboxes. By utilising Computer Aided Drawing (CAD) software a technical design specification was created for a storage unit based around 4 main pillars of box section steel combined with 3 shelving units that can be moved up and down the pillars to accommodate different storage requirements. The pillars also allowed for further shelves to be used to extend the storage unit lengthways thereby creating a modular system. A securing bracket was designed to mount onto the truck bed to which the storage unit could sit on and mathematical calculations proved the integrity of the design.

A concept prototype was built to prove the practicality of building the design within local unit capabilities, although achievable it ultimately highlighted the high degree of accuracy and time required and was therefore deemed unfeasible to manufacture within local unit capabilities, and full production should be sought through civilian industry. Further CAD modelling was instead used to prove the storage capability of the design.

This report concludes that to provide deployable storage for ES equipment across a range of customer bases, while maintaining the crucial ability to quickly remove it, an adaptable and modular system such as the one this project has designed offers the best solution. Despite the manufacturing requirements this solution is both practical and achievable whilst at a greatly reduced cost when compared with containerised solutions.

Acknowledgements

This project would not have been possible without the support and help of the following persons:

1.Mr Daniel Errington from DE&S. Senior manager for the MAN vehicle for initial project assistance.

2.Mr Gary Daniels. Manager for all Deployable Machine Repair Solutions for information on ISO container based systems.

3.Mr Chris Wayman. Project tutor from Staffordshire University for continual assistance and guidance.

4.Captain Chris Marsh (REME). My line manager and senior officer within my workshop for his authorisation of the use of Army facilities.

5.Members of 6 RLC LAD. The authors peer group who were instrumental in synthesising ideas.

6.Members of the ES Land environment. For their time and effort in completing the customer surveys without which no specification couldve been created.

ContentsChapter PageAbbreviationsiv1. Introduction1-12. Project Management2-13. Identifying the Required Change3-14. Designing the Change4-15. Produce the items to effect the change5-16. Implement the Change6-17. Monitor the Effect7-18. Conclusion and Recommendations7-4Bibliography7-6

AnnexesA Project Analysis TableA-1B Initial Gantt Chart A-2C Updated ChartA-3D Fitter truck storage data requirementsA-4E Technical Design SolutionA-5F Storage Unit CalculationsA-6G Securing Frame CalculationsA-7Appendix 1 to Annex G&H Data TablesA-8

iv

Abbreviations

AESPArmy Equipment Support Publication

ASMArtificer Sergeant Major

CCMConfiguration Change Management

CADComputer Aided Design

CD CSSCapability Director Combat Service Support

CESCambridge Engineering Selector

COTSComercial Of The Shelf

DE&SDefence Equipment and Support

DMSDeployed Machine Shop

DMRSDeployable Mechanical Repair Systems

DTSSDeployable Technical Support Solutions

ESEquipment Support i.e. maintenance, inspection and repair

JSP Joint Service Publication

LADLight Aid Detachment

MODMinistry Of Defence

NATONorth Atlantic Treaty Organisation

PMEPump Mounted Equipment

POLPetroleum, Oil and Lubricants

PTProject Team

REMERoyal Electrical and Mechanical Engineers

RMRoyal Marines

TC OPOTransportable Container Operational

TDUTrials and Development Unit

SVSupport Vehicle

VMVehicle Mechanic

Chapter 1.Introduction

1.1Background 1.2Project Selection1.3Selection of a project1.4Fitter Truck1.5Project Aim 1.6Objectives 1.7Success Calculation

1.1Background

As a vehicle artificer in the Armys Royal Electrical and Mechanical Engineers (REME) the author chose a project based on land equipment as this is relevant to his career and interest. Three potential projects were initially investigated and these were found through the authors experience, discussion with colleagues and advice from the MOD Defence Equipment and Support (DE&S) Project Teams who manage all equipment for the MOD.

1.2Project Selection

Three options were considered:1.Quad bike loading. Investigate a means for safely loading and unloading quad bikes (fig 1) from flatbed trucks without the use of a crane in order to reduce the logistics burden for quad bikes.2.Recovery vehicle winch snapping. Investigate the reasons for failure of the winch fairlead shackle on the MAN SV recovery vehicle (fig 2). 3.Repair section fitter truck. Investigate current and possible improved solutions for the carriage of tools, POL, repair facilities and specialist items on the MAN SV truck in support of deployed operations.

Fig 1. Quad bikeFig 2. MAN SV Recovery(British Army n.d Crown Copyright) (Defence update n.d)1.3Selection of a project

The technique of SWOT analysis was used to help choose between the options. This highlighted the Strengths, Weaknesses, Opportunities and Threats to each one as shown in the authors proposal document. The threats identified during this analysis resulted in options 1 and 2 being discounted.

In consultation with Staffordshire University project tutor for advice on suitability it was decided to go forward with option 3, hereafter known as the fitter truck storage project detailed below. This is relevant to the authors career and interest, has the required supporting information freely available and access to the equipment.

1.4Fitter Truck Storage

Army equipment is maintained and repaired by REME sections from Light Aid Detachments (LADs) attached to each Army unit. When deployed out of barracks they carry all tools and repair equipment on their vehicles, and in armoured units there are special armoured repair vehicles available with built-in storage and repair facilities. However in non-armoured units they use standard issue flatbed trucks such as the MAN Support Vehicle (SV) 6t (Fig 3.) and convert the back of them in an ad hoc manner to use as repair trucks with tool storage, spares, vices and drills etc.

Fig 3. MAN SV 6t (CST) (Think defence 2014)

This conversion is done by placing workbenches and storage units on the load bed secured by ratchet straps, correct securing angles and tensions are difficult to achieve which results in the equipment moving around during cross-country driving (fig 4) which can lead to damage. The storage units are also heavy and cannot be moved by hand which leads to excessive time to set up the repair truck.

Fig 6. Evidence of items moving around during transport. (Wilcock 2015)

Project Analysis

Project analysis was conducted to look to at the issues, implications and deductions for this project and this can be seen at Annex A. The project aimed to firstly establish what the exact requirement for repair trucks was from the Land environment[footnoteRef:1]. It then investigated current and alternative solutions before designing and evaluating a self-designed system. The intent was to design a solution that is easily removable and modular in nature. [1: Defence terminology meaning users operating on the ground, in this case referring to Army and Royal Marine units ES units.]

1.5Project Aim

Create and design an adaptable and modular storage system for the carriage of tools and repair assets on the MAN SV truck, used as part of deployed Equipment Support (ES).

1.6Objectives

To complete this project the following objectives have been set:

1.Create a Product Design Specification (PDS) based on feedback f