Watervliet Arsenal expands manufacturing capability through lights-out machining

WATERVLIET ARSENAL, N.Y. — Watervliet Arsenal is expanding its manufacturing capabilities through lights-out machining, using automation to increase available production capacity and strengthen its ability to respond to the Army’s evolving cannon requirements.

In one application, arsenal machinists have validated a 12.5-hour manufacturing process that requires approximately 2.5 hours of operator involvement, primarily for setup and other essential activities. Once underway, the machine completes the remaining 10 hours unattended, allowing skilled personnel to perform other tasks while equipment continues operating.

“Modernization at Watervliet Arsenal is not an abstract future goal—it is work being applied on the production floor today,” said Rob Cavanaugh, Watervliet Arsenal production manager. “By combining industry-proven automation with the expertise of our workforce, we are improving capacity, repeatability and responsiveness for the capabilities our soldiers depend on.”

Lights-out machining uses automated equipment and validated processes to perform manufacturing operations without continuous operator attendance. Arsenal teams have developed and tested these processes on production material for key components of the M109 Paladin 155-mm howitzer, clearing them for production use while maintaining established tooling, process and quality controls.

The effort builds on the expertise of the arsenal’s workforce. Production leaders have developed component-specific work instructions and completed preliminary personnel training, with additional instruction planned to expand advanced machining, monitoring and quality assurance capabilities.

The initiative is part of a broader modernization strategy that integrates technology, equipment, manufacturing processes and workforce development. By applying automation where it delivers operational value, the arsenal is improving its ability to use existing production resources and to adapt to changing requirements.

“Our responsibility is to deliver trusted manufacturing capability to the Army, today and in the future,” said Col. Danilo Green, Watervliet Arsenal commander. “Lights-out machining is one example of how our workforce is improving the way we produce critical components. We are building on the progress to create a more capable, flexible and responsive arsenal.”

These advancements strengthen the Army’s organic manufacturing capability and support a more responsive and resilient domestic industrial base.

Watervliet Arsenal is a U.S. Army-owned and operated manufacturing center specializing in the production of critical cannon, howitzer and mortar components. As part of the Army’s Organic Industrial Base, the arsenal combines precision manufacturing, specialized workforce expertise and advanced production technologies to deliver trusted capability in support of U.S. and allied military requirements.

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