Challenges in Shell Production Hinder U.S. Army Objectives
As the U.S. Army strives to meet an ambitious ammunition production goal, it faces significant obstacles that could derail its efforts. A recent Pentagon report highlights the difficulties in boosting the output of 155-mm howitzer shells, essential for military operations.
Although the Army set a target to manufacture 100,000 shells monthly by October 2025, a report from the Department of Defense Inspector General reveals that production only reached 36,000 shells per month by March 2026. The report underscores that the primary hurdle is the production of projectile metal parts, which are crucial for assembling these artillery rounds.
Production of these shells involves two main steps: creating the projectile at a metal parts plant and then filling the shell with explosives at another site. The report clarifies, “projectile metal part production is the limiting factor for reaching the 100,000 round-per-month goal for 155-mm artillery rounds.”
A critical issue is the inability to produce sufficient metal parts at a facility in Mesquite, Texas. “At a contractor-owned, contractor-operated facility in Mesquite, Texas, the contractor has been unable to produce any projectile metal parts that meet contract specifications,” the report states.
In 2024, the Army invested $469 million to establish the Universal Artillery Projectile Lines factory in Mesquite, operated by General Dynamics Ordnance and Tactical Systems. The facility was intended to utilize advanced manufacturing technologies to produce large-caliber metal parts efficiently. However, challenges in adapting existing equipment have hampered progress.
The Army’s Capability Program Executive Ammunition & Energetics (CPE A&E) admitted to taking a risk by purchasing unproven production equipment. According to the Inspector General’s report, CPE A&E “issued the contract and accepted the risk associated with purchasing and adapting unique production equipment which had not been proven to meet U.S. specifications.”
Attempts to modify production lines initially designed for the older M107 shell, dating back to 1958, instead of the modern M795, have not resolved the issues. The report notes, “CPE A&E accepted the risk associated with the contractor’s plan to purchase and adapt M107 metal part production equipment to produce a newer variant of the 155-mm projectile metal parts at different specifications.”
Concerns have also been raised about an older ammunition facility in Scranton, Pennsylvania. There are issues with contractor responsiveness and equipment maintenance, leading to apprehensions about the lack of competition in the Mesquite contract award.
The Mesquite facility’s bottleneck leaves existing production plants in Scranton, Wilkes-Barre, Pennsylvania, and Ingersoll, Canada, to compensate for the shortfall.
In response to Ukraine’s rapid consumption of 155-mm rounds, the Department of Defense outlined a plan in 2022 to revamp artillery shell production. The 2025 National Defense Industrialization Strategy Implementation Plan aims to produce 100,000 shells monthly by October 2025.
Progress has been made, with production increasing from 14,000 to 36,000 shells per month. Future expansions, including modernizing the Iowa Army Ammunition Plant and establishing new facilities in Kansas and Arkansas, aim to achieve a monthly output of 140,000 shells by December 2027.
The Inspector General suggests reviewing the Mesquite facility’s contract to assess expenditure and potential fund recovery. The report recommends, “determine whether the Mesquite contract was appropriately issued.”
