Advances in manufacturing of helix traveling wave tubes

Summary form only given. Even though the advanced helix traveling wave tube (TWT) used in the microwave power module (MPM) enables, to a large extent, the compact size and high performance of the MPM, it currently represents greater than 40% of the cost. Unlike solid state devices, which are manufactured using highly automated methods, TWTs are fabricated using more traditional methods that often rely on highly skilled laborers. Phase II of a Navy ManTech program is underway at Northrop Grumman to apply lean manufacturing methodologies to the production of helix TWTs with a targeted cost reduction of 30-40%. The initial stages of this program involved baseline assessment, followed by a phase of opportunity assessment. Specific areas for manufacturability enhancement that are addressed include subassembly design, subassembly processing, fixturing, and automated measurement and test. These enhancements are aimed toward increased commonality, simplified assembly and processing, rapid verification, and increased yield. Implementation of "Lean manufacturing" principals using value streaming techniques were investigated and implemented. A commodity design team involving suppliers early in the design phase was formed which led to a supplier conference. Some goals of the supplier conference were to form teaming agreements with our supplier partners, long term forecasting of projected production volumes and creating unique solutions to lowering supplier/customer cycle times and costs.