Spinnaker Systems Smoke Stack Re-design Steven Eck

Company Overview Spinnaker Systems is a Component of Southfork Industries Spinnaker Systems Produces Military Ships for the U.S. Air Force Spinnaker Systems Employs 15,000 People and has Annual Revenue of $4 Billion Southfork Industries is Defense Contractor that Employs 100,000 People With Annual Revenue of $10 Billion

Current Smoke Stack Design Current Design Contains Low Grade Structural Alloy With a Number of Circumferential Welds Material Was Chosen Primarily Because of Availability and Weight Quality of Welds is Inconsistent Throughout the Part Inspection Techniques for Evaluating Part are Inadequate

Service Failures Each of the First Five Smoke Stacks have Cracked in Service Cracks have been Analyzed with Poor Weld Quality Identified as Mode of Failure Part Experiences Vibration in Service Which Would Contribute to Cracking Improved Inspection Techniques Have Shown Additional Areas for Future Failures

Criteria for Part Re-design Repair of Part Requires Re-weld of the Part, Post-Process Inspection,and Forced Downtime of the Ship Welding and Inspection Costs are $10,000 per repair procedure Analysis of Cracked Part to be Performed to Determine if Unfixed Cracks Can Pose Safety Risk to Ship

Criteria for Re-design Re-design of Part Shall Keep Primary Components of Smoke Stack Constant –Curvature of Part –Overall Length and Diameter of Part –Weight of Part –Flatness Requirement of Mating Flange –Complete Non-recurring Portion of Project by End of Calendar Year 2002 –Select Design That Fits Within Project Budget

Funding Source for Project $100,000 IRAD Funding Available Funding Would Cover the Following: –Identification of Design Component Improvements –Selection of New Supplier –Non-recurring Tooling Costs Funding is Available Through End of Year

Selection Process Aim to Select Supplier That Can Provide Part With Identical Shape, Light Metal/Composite, Reduction in Quantity of Welds Talked With Prospective Suppliers and Provided Each With RFQ Received RFP from Suppliers Selected Optimal Design by August 1 to Allow for Tooling Construction Prior to Year’s End

Acquisition of First Part Supplier Will Manufacture Tooling for Part Spinnaker Will Create New Engineering Drawings Supplier Will Provide First Article for Testing Spinnaker Will Evaluate First Article Against Environmental and Functional Requirements Supplier Will Manufacture First Production Part for Spinnaker Spinnaker Will Install First Production Part on Ship by July 1, 2003