1. NSRP Presentation March 13, 2019 DCN# 43-5036-19
S Electronic Weld Record (eWR) - Pipe
Process Change – Under Cognizance of Industry
Ongoing Project
Derek Hassell
Newport News Shipbuilding
NSRP Presentation
March 13, 2019
DCN#

2. Project Team (Organization Chart)
Paul Huang – Program Officer
Dale Orren – Deputy Director
Warren Southerland – Project Manager
Tim Wallace – Project Technical Representative
Charles McNamara – PMS 450
PMS 450
Dave Hart – LCE
1/23/17: Warren – Traci, revise to ManTech Project Manager - Complete
Traci Jones – ManTech Project Manager
Derek Hassell – Quality Manager (Project Lead)
Ross Gambill – Prod Planning Sched Manager (Technical Lead)
Joe Sabol – Director (Sponsor)
Dale Bell – Quality Engineering Manager (Sponsor)

3. ManTech Project
Electronic Weld Record (eWR) - Replace paper-based pipe weld records with an Electronic Weld Record Application
Start Date/End Date: Nov 2016/Aug 2019
Aligns with Newport News Shipbuilding Integrated Shipbuilding Strategy
Programs Targeted: VCS, Columbia, Aircraft Carriers (New Construction, Overhaul)
Estimated potential savings:
VCS: Estimated $1.5M per hull, per year $2.9M (based on working 9 VCS in-process hulls per year), and 5 years is $14.5M.
Carriers: Estimated $1.9M per new construction hull and $1.1M per carrier overhaul. Per year savings of $280K (for each carrier)

4. eWR – Overall Vision

5. Project Objectives/Benefits
The objective of this project is to develop an Electronic Weld Record System that will utilize the following electronic features throughout the welding value stream.
Signature, workflow, real time data access, certification, storage
eWR will provide process improvements that will eliminate/reduce the following for VCS/CVN pipe numbered weld joints:
Welding/NDT paper based forms (6 VCS/CVN Pipe Weld Records)
Routing and transporting forms for collecting signatures/data
Manual data input into ERS and SAP
Manual tracking/updates/review/status reporting
Printing paper forms and making copies
Paper record storage (boxes, file cabinets, warehouse)
Unnecessary fields and duplication of data
Editorial issues (e.g., missing, incorrect) caused by handwritten errors
Rework caused by loss of paper records
Time to hand deliver, certify, review, verify, monitor and track records

6. Interesting Project Data
Assumptions (in-process per year):
9 VCS Hulls
1 Carrier New Construction (X2)
1 Carrier Overhaul
Project Data:
# of weld/NDT paper records currently used at NNS = over 25 (e.g, Nuc, Non-Nuc, Carrier, VCS, carrier, pipe)
Initial project focus = 6 pipe weld/NDT records (includes Nuc/Non-Nuc & VCS/Carriers)
Handwritten signatures & data entry per VCS/Carriers weld records = Signatures can be over 25 and data entry over 50 per record by 5 different departments
Record Review VCS 905 = each record can be reviewed by up to 5 different persons
# of records processed per year for 6 records = Est. 36,000
# of pcs of paper printed per year for 6 records = Est 126,000
Total time (in hours) per year spent processing 6 records = Est. 50,000
# of non-value added process steps for VCS records = Est. 119

7. Current State Process Map

8. Project Schedule Period of Performance: 12/07/2016 – 8/30/2019
3/13/2019
Period of Performance: 12/07/2016 – 8/30/2019

9. eWR Application
Uses SAP and eWICC (uses LX and Welder Work Assignment data) as data sources
Connects to SAP to read and write back
Allows users to enter data and sign at work location
Allows inspectors to accept/reject a weld joint
Allows record review to certify a joint
Allows work to progress to next step in process with signature
Can be used by desktop, laptop, tablet and/or phone (future)
User roles - fitter, welder, foreman, inspector, record review, general users

10. eWR Application – Fitter Screen

11. eWR Application – Fitter Screen

12. eWR Application – Fitter Screen

13. eWR Application – Welder Screen

14. eWR Application – Foreman/Inspector Screen

15. Transition / Implementation Status
Technology Transition Plan (TTP)
Original signed TTP completed (3/30/17)
Draft updated TTP based on changes to POP and NNS Management currently being routed for review/comments.
Implementation Status
The project is not implemented, as it is still in active development
An implementation plan will be developed during Phase II of the project (based upon research discoveries) and will be a deliverable of Task 9
On the next slide is a table with the high level summary of known implementation requirements with place holders for unknown requirements

16. Implementation Plan - VCS
Requirement
Responsibility
(Name, Title, Role)
Resource Commitment
(funding amount, estimates)
Equipment/Material
Tablets/Kiosks
Tim Sweitzer, Director of Digital Shipbuilding
$172.5K (Capital)
Wi-Fi
Bharat Amin, VP Information Technology
Network Infrastructure
Training
Develop training courses
Xavier Beale – VP Trades Operations
$25K (Overhead)
Procedures/Work Instructions
Update/create shipyard procedures
Gary Zimak – Director of Quality
IT Enhancements
IT Production Implementation
Bob Schatzel – Shop Manufacturing Director
Rob Check – VCS Program Director
Chandra McCulley-Hooker – VCS Trades Director
$50K (Overhead)
IT EB Installation
K2 Software License
$25K (250 $100 per license)
Database Enhancements/Improvements
$15K per year (Overhead)
Approvals (Mandatory)
Ron Murray – VP Quality

17. Implementation Plan - CVN
Requirement
Responsibility
(Name, Title, Role)
Resource Commitment
(funding amount, estimates)
Equipment/Material
Tablets/Kiosks
Tim Sweitzer, Director of Digital Shipbuilding
$172.5K (Capital)
Wi-Fi
Bharat Amin, VP Information Technology
Network Infrastructure
Training
Develop training courses
Xavier Beale – VP Trades Operations
$25K (Overhead)
Procedures/Work Instructions
Update/create shipyard procedures
Gary Zimak – Director of Quality
IT Enhancements
K2 Software License
Bob Schatzel – Shop Manufacturing Director
Todd West – Director ISCVN Program
Joe Dvorak - Director of CVN78 Production
$25K (250 $100 per license)
Database Enhancements/Improvements
$15K per year (Overhead)
Approvals (Mandatory)
Ron Murray – VP Quality

18. Near-Term Activities Near-Term Milestones to be Addressed
Subtask 6 – Onsite deployment and configuration – Due 3/6/2019 (In-Process)
Risk Reduction Items to be Addressed
Continue heightened awareness of the schedule to minimize future delays
Implementation Actions to be Addressed
None; project is in active development