Senior Airman Devon Word, a conventional munitions crew chief from the U.S. Air Force’s 48th Munitions Squadron, solved a perennial ammunition handling issue faced by the 48th Fighter Wing at RAF Lakenheath, U.K., which often saw 20 mm rounds jamming while moving from the replenisher table to the ammunition loader. The frequent  jamming makes manual intervention necessary, with “15 minutes of troubleshooting per jam” required which “may also cause injury to the operator.”

In fiscal year 2023, according to the press release, there were 319 operations resulting in an average of 957 instances of jams using the replenisher table. These accounted for approximately 798 man-hours due to the need for at least four personnel during operations.

Word developed a specially designed 3D-printed insert that addressed the old design issue causing the stoppages – a gap between the rounds and the top of the replenisher table. The unit-level innovation could save the 48th FW and U.S. Air Force over 750 man-hours annually, the unit said.

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