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

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

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

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

5. 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.

6. 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

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

8. 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

9. 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

10. 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?)

11. 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

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

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

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

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

16. 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.

17. Advantages Procedures Easy To Find

18. Advantages Consistent Format

19. Advantages Procedure Stand-Alone Printed Out

20. 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

21. 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

22. 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

23. ??????