Implementation of NAVWELD Software to Support Electronic Welding Procedures AWS Shipbuilding Conference May 11, 2011 Paul Hebert Manager, Welding Engineering

Procedure of Tomorrow (POT) Overview Strategy/Implementation Objectives Advantages Software Selection Challenges Procedure of Tomorrow (POT)

#1 - Electronic Only #2 - All Inclusive #3 – User Friendly: Objectives - Finding Procedure - Navigating Comprehension

Develop MIL-STD Specific Software Software Selection => Commercial Standards (i.e. ASME) => MIL Standards (i.e. MIL-STD-248) Develop MIL-STD Specific Software

Software Selection Development Team Members NAVSEA NSWC - Carderock NGSB-NN GDEB NMC Weld QC 2003 2004 2005 2006 2007 2008 2009 SBIR Phase I SBIR - Phase II MANTECH NavWeld Web-based software application & database that assists the user in developing welding procedures according to NAVSEA requirements.

Software Selection NavWeld Modules Procedure Qualification Record (PQR) Essential Elements NDE Tests Destructive Tests & Number of Samples Qualified Ranges Fabrication Document Requirements Welding/Brazing Procedure Specification (WPS) Welder/Brazer Performance Qualification (WPQR) Tracks Welder History

Software Selection NavWeld – Processes and Documents Qualification Documents Fabrication Documents Arc TP248 ABS/NVR - 2007 TP278 TP1688 MIL-STD-1689A Stud Resistance AWS D17.2 Brazing (Piping) 0900-LP-001-7000

Strategy / Implementation Engineers Revisions 40+ Years NAVSEAs PQRs SOSs 248s Grandfather Fab Docs Interpretations Issues Engineer Historian Evolution of Legacy Procedures Fortune Teller Clean Up for POT All Inclusive Review = Specifications / PQR’s / History Document for Each WPS

Strategy / Implementation Welding Parameters Base Metal Preheat Cleaning Specification Legacy Procedures – Information in Multiple Locations Consolidate for POT Procedure = Handful of Pages = All Requirements = Certified = Approved Hand to the welder to use

Strategy / Implementation Generic Legacy Procedures – Given Material / Process Multiple Filler Metals Special Exceptions Subtle Differences Multiple Joint Designs Make POT More Specific One filler = limited joint designs = minimal notes / exceptions One Technique in Legacy Procedure = 3 or 4 or 5 in POT (dbase – who cares?)

Strategy / Implementation Legacy Procedure Revisions User to ID Changes => 800+ Pg. Procedure POT Revisions – Clear and Visible Revision Record - First Page of Each WTN = What + When + Why Changed

Advantages Creating PQR / WPS Once PQR created - Print Qualified Range Report to ID procedure ranges

Advantages Creating PQR / WPS Enables and Disables Fields Based on Inputs ***If you select ceramic backing you have to enter manufacturer and type***

Advantages Creating PQR / WPS Bounces input against the spec and flags incomplete info ***Missing Minimum Travel Speed***

Advantages Creating PQR / WPS Prompts user where to go in spec for rule

Advantages Real Time Revisions Old System: Make change in MS Word + send to QA + QA send to repro + QA make distribution + recipients make changes to paper copy = Weeks NAVWELD System: Make Change in Dbase + Validate electronically + Revised Procedure ready for use = Minutes Real Time Revision = Double Edged Sword Person looks at procedure – we make change afterwards – he is using an outdated procedure. Caution Solution: Adding something no big deal – anytime Taking something away – we need to take the action to let user know.

Advantages Procedures Easy To Find

Advantages Consistent Format

Advantages Procedure Stand-Alone Printed Out

Advantages Green SSPs = 16 Proc X 500 pgs each X 50 copies = 400,000 pages (not counting revisions) SOPs = 91 Proc X 20 pgs each X 5 copies = 9100 pages (not counting revisions) Not counting electricity to create and copy + fuel to distribute Paper = .0038” thk. X 409,100 pgs. = 130 feet high stack

Advantages Electronic Data Kiosk on shop floor / ship PDA – Foremen to carry procedure with them Weld Procedure Data Welder Qual data Eng Data User Job Assignment

Challenges A B C Computer Literacy – What about those who aren’t proficient with computers? - Ease of Use - Training Reliability - What happens if the computer crashes? Back-Up Paper Copy Back-Up PDF Copy Resistance to Change – Why can’t you leave the procedures the way they’ve always been? Involve users in the process Stress the advantages Listen Tenacity

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