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HUNTINGTON INGALLS INDUSTRIES PRIVATE/PROPRIETARY LEVEL I Implementation of NAVWELD Software to Support Electronic Welding Procedures May 11, 2011 Paul.

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Presentation on theme: "HUNTINGTON INGALLS INDUSTRIES PRIVATE/PROPRIETARY LEVEL I Implementation of NAVWELD Software to Support Electronic Welding Procedures May 11, 2011 Paul."— Presentation transcript:

1 HUNTINGTON INGALLS INDUSTRIES PRIVATE/PROPRIETARY LEVEL I Implementation of NAVWELD Software to Support Electronic Welding Procedures May 11, 2011 Paul Hebert Manager, Welding Engineering AWS Shipbuilding Conference

2 HUNTINGTON INGALLS INDUSTRIES PRIVATE/PROPRIETARY LEVEL I Overview 2 Advantages Challenges Software Selection Strategy/Implementation Procedure of Tomorrow (POT) Objectives

3 HUNTINGTON INGALLS INDUSTRIES PRIVATE/PROPRIETARY LEVEL I Objectives 3 #1 - Electronic Only #2 - All Inclusive #3 – User Friendly: - Finding Procedure - Navigating - Comprehension

4 HUNTINGTON INGALLS INDUSTRIES PRIVATE/PROPRIETARY LEVEL I Software Selection 4 => Commercial Standards (i.e. ASME) => MIL Standards (i.e. MIL-STD-248) Develop MIL-STD Specific Software

5 HUNTINGTON INGALLS INDUSTRIES PRIVATE/PROPRIETARY LEVEL I Software Selection Development SBIR Phase I SBIR - Phase II MANTECH NAVSEA NSWC - Carderock NMC Weld QC Team Members NGSB-NN GDEB NavWeld Web-based software application & database that assists the user in developing welding procedures according to NAVSEA requirements.

6 HUNTINGTON INGALLS INDUSTRIES PRIVATE/PROPRIETARY LEVEL I Software Selection NavWeld Modules 6  Procedure Qualification Record (PQR) Essential Elements NDE Tests Destructive Tests & Number of Samples Qualified Ranges Fabrication Document Requirements  Welding/Brazing Procedure Specification (WPS) Essential Elements Fabrication Document Requirements  Welder/Brazer Performance Qualification (WPQR) Essential Elements NDE Tests Destructive Tests & Number of Samples Qualified Ranges Tracks Welder History

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

8 HUNTINGTON INGALLS INDUSTRIES PRIVATE/PROPRIETARY LEVEL I Strategy / Implementation 8 Engineers Revisions 40+ Years NAVSEAs PQRs SOS s 248s Grandfather Fab Docs Interpretations Issues All Inclusive Review = Specifications / PQR’s / History Document for Each WPS Evolution of Legacy Procedures Engineer Historian Fortune Teller Clean Up for POT

9 HUNTINGTON INGALLS INDUSTRIES PRIVATE/PROPRIETARY LEVEL I Strategy / Implementation 9 Procedure = Handful of Pages = All Requirements = Certified = Approved Hand to the welder to use Welding Parameters Base Metal Preheat Cleaning Specification Legacy Procedures – Information in Multiple Locations Consolidate for POT

10 HUNTINGTON INGALLS INDUSTRIES PRIVATE/PROPRIETARY LEVEL I Strategy / Implementation 10 Generic Legacy Procedures – Given Material / Process One filler = limited joint designs = minimal notes / exceptions One Technique in Legacy Procedure = 3 or 4 or 5 in POT (dbase – who cares?) Multiple Filler Metals Subtle Differences Special Exceptions Make POT More Specific Multiple Joint Designs

11 HUNTINGTON INGALLS INDUSTRIES PRIVATE/PROPRIETARY LEVEL I Strategy / Implementation 11 User to ID Changes => 800+ Pg. Procedure Revision Record - First Page of Each WTN = What + When + Why Changed Legacy Procedure Revisions POT Revisions – Clear and Visible

12 HUNTINGTON INGALLS INDUSTRIES PRIVATE/PROPRIETARY LEVEL I Advantages Creating PQR / WPS 12 Once PQR created - Print Qualified Range Report to ID procedure ranges

13 HUNTINGTON INGALLS INDUSTRIES PRIVATE/PROPRIETARY LEVEL I Advantages Creating PQR / WPS 13 Enables and Disables Fields Based on Inputs ***If you select ceramic backing you have to enter manufacturer and type***

14 HUNTINGTON INGALLS INDUSTRIES PRIVATE/PROPRIETARY LEVEL I Advantages Creating PQR / WPS 14 Bounces input against the spec and flags incomplete info ***Missing Minimum Travel Speed***

15 HUNTINGTON INGALLS INDUSTRIES PRIVATE/PROPRIETARY LEVEL I Advantages Creating PQR / WPS 15 Prompts user where to go in spec for rule

16 HUNTINGTON INGALLS INDUSTRIES PRIVATE/PROPRIETARY LEVEL I Advantages Real Time Revisions 16 Real Time Revision = Double Edged Sword Person looks at procedure – we make change afterwards – he is using an outdated procedure. Solution: Adding something no big deal – anytime Taking something away – we need to take the action to let user know. NAVWELD System: Make Change in Dbase + Validate electronically + Revised Procedure ready for use = Minutes Old System: Make change in MS Word + send to QA + QA send to repro + QA make distribution + recipients make changes to paper copy = Weeks Caution

17 HUNTINGTON INGALLS INDUSTRIES PRIVATE/PROPRIETARY LEVEL I Advantages Procedures Easy To Find 17

18 HUNTINGTON INGALLS INDUSTRIES PRIVATE/PROPRIETARY LEVEL I Advantages Consistent Format 18

19 HUNTINGTON INGALLS INDUSTRIES PRIVATE/PROPRIETARY LEVEL I Advantages Procedure Stand-Alone Printed Out 19

20 HUNTINGTON INGALLS INDUSTRIES PRIVATE/PROPRIETARY LEVEL I Advantages Green 20 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 HUNTINGTON INGALLS INDUSTRIES PRIVATE/PROPRIETARY LEVEL I Advantages Electronic Data 21 Kiosk on shop floor / shipPDA – Foremen to carry procedure with them Eng Data Weld Procedure Data Welder Qual data User Job Assignment

22 HUNTINGTON INGALLS INDUSTRIES PRIVATE/PROPRIETARY LEVEL I Challenges 22 A B C Computer Literacy – What about those who aren’t proficient with computers? Reliability - What happens if the computer crashes? Resistance to Change – Why can’t you leave the procedures the way they’ve always been? - Ease of Use - Training - Back-Up Paper Copy - Back-Up PDF Copy - Involve users in the process - Stress the advantages - Listen - Tenacity

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