Project Implementation
Design for Production (Process Improvement, Knowledge Tools, Seamless Delivery, Design Alternatives)
Successfully developed a process and procedure for DfP implementation within the design and engineering communities at General Dynamics Electric Boat's Groton shipyard facility
System: VIRGINIA-Class Submarine program, commencing with SSN-784
Payoff: $5.175M/hull
Hull Fairness & Accuracy Control
Investigated and now implementing the expanded use of metrology instrumentation to support hull section fabrication requirements at Northrop Grumman Shipbuilding-Gulf Coast
Systems: LPD, LHA, DDG, and NSC
Payoff: $3.8M total savings
Internal Supply Chain
Developed a new material management system process to optimize Marinette Marine Corporation's internal supply chain
System: LCS
Payoff: $3.1M/hull
Laser Image Projection
Implemented new methodologies for locating attachments and penetrations on VCS hulls at EB's Quonset Point, RI shipyard facility
System: VIRGINIA-Class Submarine program, commencing with SSN-782
Payoff: $530K/hull; anticipate $15.5M over 31-hull construction program
Metrology for Automated Hull Layout
Implemented new metrology technologies (Laser Tracker, Total Stations, Romer Arm and Scanner) to streamline manufacturing component layout and interfacing operations at EB's Quonset Point, RI Shipyard Facility
System: VIRGINIA-Class Submarine program, commencing with SSN-784
Payoff: $475K/hull; anticipate $14.7M over 31-hull construction program
Nested Material Manufacturing Improvement
Developed an automated planning and control system- Pipe Shop Management System (PSMS) at NASSCO
System: T-AKE
Payoff: $1.34M/year; $5.5M cost avoidance over five year period
Outfitting Process Improvement
Evaluated and enhanced construction processes and improved production tools used during the VCS hull outfitting stages. Implemented improvements in GDEB Facilities at Groton and Quonset Point shipbuilding sites.
System: VIRGINIA-Class Submarine program, commencing with SSN-786
Payoff: $1.8M/hull; anticipate as much as $5M/hull
Product Centric
Re-engineered the structural fabrication processes of the total enterprise that affects the building of major structural assemblies at EB
System: VIRGINIA-Class Submarine program, commencing with SSN-784
Payoff: $925K/hull
Small Weldments
Predicted and validated resultant reduction in cost and increase in throughput for given equipment purchases and process change through the use of a computer-simulated model that analyzes process flow, varying work and grouping, tooling, labor skill mix and volume at NGSB-Newport News
System: VIRGINIA-Class Submarine program, commencing with SSN-784
Payoff: $440K/hull
Smart Manufacturing Methods
Successfully used resin flow modeling and simulation software to predict resin flow behavior and determine optimal production parameters at NGSB-Gulf Coast
System: DDG-1000
Payoff: $778K/hull
Technical Training and Data Collection
Developed a comprehensive technical and data collection program for structural welders and fitters which is being used at NGSB- Gulf Coast
System: DDG-1000
Payoff: $300K/hull
VCS Material Management
Established a world-class material flow system at EB’s Quonset Point, RI shipyard facility.
System: VIRGINIA-Class Submarine program, commencing with SSN-786
Payoff: $5.4M/hull
Weld Distortion
Successfully produced a tool for optimizing thick plate, multi-pass weld joints and their associated processes at NGSB-Newport News
System: CVN 21
Payoff: Reduction of construction costs and cost avoidance of 1/3 to 1/2 labor hours
