1. Cost Reduction of Shock Application Project Overview for NSRP Panel Meeting July 16, 2019
Kristi Carroll and John Walks

2. Agenda Overview of Ingalls Shipbuilding and Introductions
Project Background/Overview
Project Management
Phase I Description (Tasks 1, 2 and 3)
Summary

3. Ingalls Shipbuilding
Building four classes of ships simultaneously— 10 ships currently under construction
Sole builder of the San Antonio-class (LPD 17) amphibious transport docks and the America- class (LHA 6) amphibious assault ships
One of two builders of DDG 51 Arleigh Burke- class destroyers
Sole builder of the Legend-class National Security Cutters for the U.S. Coast Guard
Largest private manufacturing employer in Mississippi – approximately 11,000 Employees
USCG National Security Cutter
DDG 51 Surface Combatants
LPD 17 Class Amphibious Transport
LHA 6 Amphibious Assault Ship

4. Team Members Ingalls Shipbuilding Newport News Shipbuilding
Mike Poslusny, Kristi Carroll, Sean Murphy, Parisa Ghandehari, Michael Thompson, John Walks
Newport News Shipbuilding
Mike Talley
Hi-Test Labs
Ashley Shumaker
NTS
Steven “Tucker” Thompson, Calvin Milam
ATI
Nick Laney, Project Manager
BAE Systems Southeast
Steve Cogswell, Program Technical Representative

5. Cost Reduction of Shock Application
The Big Idea
Leverage opportunities enabled by MIL-DTL-901E to expand less expensive methods of shock testing
Push old and new cost avoidance initiatives across the finish line and share results with the shock community through Navy documentation
Less expensive methods of shock testing
Deck Shock Simulating Machine (DSSM)
Medium Weight Shock Machine (MWSM)
Light Weight Shock Machine (LWSM)
Qualification by Inspection (Grade B items only)
Timeline
April 2019 through February 2021
Meeting shock requirements more cost effectively

6. Project Work Breakdown Structure (WBS)
Task 1: Project Initiation
Task 2: Validate Requirements with NAVSEA
Task 3: Design Standard Test Fixtures and Evaluate
25Hz Spring Tray
Task 4: Test Fixture and 25Hz Tray Characterization
Task 5: Shock Qualification Improvements
Task 6: Pursue NAVSEA Approvals
Task 7: Final Report and Final Project Workshop
Task 8: Program Management and Technology Transfer (both phases)
Phase I
Phase II

7. Team Member Roles Task Ingalls NNS Hi-Test NTS Project Initiation Lead
Support
Validate Requirements with NAVSEA
Design Standard Test Fixtures and Evaluate 25Hz Spring Tray
Test Fixture and 25Hz Tray Characterization
Co-Lead
Shock Qualification Improvements
Pursue NAVSEA Approvals
Final Report and Final Project Workshop
Program Management and Technology Transfer

8. Milestone Schedule – Phase I1
Project Management Plan
4/18/2019 2
Kickoff Meeting Minutes
5/31/2019 3
Quarterly Report 1
6/20/2019 4
Shock Test Requirements Summary Report
8/27/2019 5
Quarterly Meeting Minutes
8/30/2019 6
Quarterly Report 2
9/20/2019 7
11/27/2019 8
Initial Draft of Lightweight, Medium Weight and DSSM Standard Shock Test Fixture Design Documentation
12/13/2019 8a
Lightweight Fixture Design Documentation 8b
Medium Weight Fixture Design Documentation 8c
DSSM Fixture Design Documentation 9
Quarterly Report 3
12/20/2019 10
2/20/2020 11
End of Phase I Report
2/29/2020

9. Milestone Schedule – Phase II12
Quarterly Report 4
3/20/2020 13
Shock Test Plans
5/15/2020 14
Phase II Kickoff Meeting Minutes
5/29/2020 15
Quarterly Report 5
6/19/2020 16
Shock Test Reports
7/31/2020 17
Quarterly Meeting Minutes
8/28/2020 18
Draft Navy Certified Shock Engineer Requirements 19
Quarterly Report 6
9/18/2020 20
12/11/2020 21
Standard Shock Qualification Process for Low Risk Items
12/15/2020 22
Quarterly Report 7
12/18/2020 23
Suggested Changes to Navy Shock Qualification Documentation
2/15/2021 24
Final Project Report
2/24/2021 25
Final Project Workshop Materials
2/26/2021

10. Task 1 – Project Initiation
To kick off the project, Ingalls held a brainstorming session on 04/30/2019 to discuss old and new 901E cost avoidance project ideas with experts in the shock community
NAVSEA Attendees: Mike Campbell, Chris Merrill, Kurt Hartsough, Chris Wall and Dominic Urzillo
Discussed multiple project options:
Standard Deck Simulating Shock Machine (DSSM) Fixtures
Universal Medium Weight Test Fixture
Testing Class I Equipment on the DSSM (25Hz Spring Tray)
Expanded use of the Lightweight Machine
Update 901E Drawings (FSPs, DSF, Fixtures, etc.)
Streamline Shock CDRL Approvals
Universal Lightweight Test Fixture
Improve testing of mitigated deck and raft equipment
Mike Campbell (Technical Warrant Holder) directed us to select simple projects with the best chance of implementation

11. Task 1 – Project Initiation (Cont.)
Formal kickoff meeting was held on 05/29/2019
Technical discussion during the kickoff:
Presented details of the eight project options
Discussed pros/cons of each option
Determined potential road blocks
Determined which projects are the low hanging fruit
The team also brainstormed additional project ideas
A survey was sent to stakeholders to select the top four options

12. Task 2 – Validate Requirements with NAVSEA
Determine the best avenue for documenting results
Addendum to MIL-DTL-901E
NAVSEA Standard Drawings
Chris Merrill is evaluating the logistics of creating both types of documentation
Project deliverables will be in the proper format for NAVSEA to create official documentation
Standard test fixtures created under this NSRP project and documented by NAVSEA will eliminate the required test procedure approvals for DSSM, MW and LW testing

13. Task 3 – Design Std. Fixtures/Evaluate 25 Hz Spr. Tray
Results of Task 1 prioritization and Task 2 effort will flow into test fixture designs to be tested in Phase II
NAVSEA comments will be incorporated before test fixture design is considered complete
Test fixture designs will be built to enable testing early in Phase II

14. Summary The concept and plan is simple and straightforward
The team has the right experience and skills
We are fortunate to be building on some prior efforts
We will execute the plan and work to keep it simple