1. Norfolk Naval Shipyard Any Ship, Any Time, Any Where 1

2. Norfolk Naval Shipyard Any Ship, Any Time, Any Where AGENDA TOPICS  INTRODUCTION T FLEET READINESS CONSTRUCT T USS GEORGE WASHINGTON TLEAN APPROACH TCAPSTONE SHIPALT T WRAP-UP 2

3. Norfolk Naval Shipyard Any Ship, Any Time, Any Where NAVY ENTERPRISE CONSTRUCT 3

4. Norfolk Naval Shipyard Any Ship, Any Time, Any Where 4

5. Norfolk Naval Shipyard Any Ship, Any Time, Any Where January 22 nd, 2007, visit to NNSY to see LEAN in action. Takeaways from visit: Process improvement needs to be senior manager driven Requires employee engagement & enthusiasm PI focus on bottom line – ROI Aggressive pursuit of process consistency and knowledge sharing CFFC “BOOTS ON THE GROUND” CFFC, NAVSEA, SUBFOR, AIRLANT, SURFLANT, CFFC N43, SEA04, & MARMC attended. 5

6. Norfolk Naval Shipyard Any Ship, Any Time, Any Where NAVSEA LEAN APPROACH 6

7. Norfolk Naval Shipyard Any Ship, Any Time, Any Where

8. Norfolk Naval Shipyard Any Ship, Any Time, Any Where 8

9. Norfolk Naval Shipyard Any Ship, Any Time, Any Where CAPSTONE - OVERVIEW CAPSTONE - Group of 13 Ship Alts that include: Main mast replacement (Mast Correction SHIPALT)Main mast replacement (Mast Correction SHIPALT) Installation of new weapon, radar, & C 2 systemsInstallation of new weapon, radar, & C 2 systems –Improvement of CVN self-defense capabilities Core Capstone Self-Defense System comprises: Ship Self Defense System (SSDS Mk2 Mod 1) Ship Self Defense System (SSDS Mk2 Mod 1) Cooperative Engagement Capability (CEC) Cooperative Engagement Capability (CEC) AN/SPQ-9B, AN/SPS-49A, & AN/SPS-48E radars AN/SPQ-9B, AN/SPS-49A, & AN/SPS-48E radars Rolling Airframe Missile (RAM) Rolling Airframe Missile (RAM) NATO Sea Sparrow Missile System re-architecture NATO Sea Sparrow Missile System re-architecture Enhanced Sea Sparrow Missile (ESSM) Enhanced Sea Sparrow Missile (ESSM) 5th CAPSTONE Install – 3rd In-Service 9

10. Norfolk Naval Shipyard Any Ship, Any Time, Any Where MAIN MAST REPLACEMENT Requirements for CAPSTONE Alteration: Larger stronger mastLarger stronger mast –CAPSTONE mast 112K lbs, old mast 89K lbs Allows for running cabling inside mastAllows for running cabling inside mast Remove / Reinstall Legacy Antennas & EquipmentRemove / Reinstall Legacy Antennas & Equipment New mast installed in two sections (Base and entire Mast)New mast installed in two sections (Base and entire Mast) New mast supports future upgrades and has reduced maintenance requirements. 10

11. Norfolk Naval Shipyard Any Ship, Any Time, Any Where CAPSTONE MAIN MAST 11

12. Norfolk Naval Shipyard Any Ship, Any Time, Any Where SCOPE OF AIT WORK 12 Alteration Installation Teams (AIT)12 Alteration Installation Teams (AIT) Upgrade and or installation of 12 Combat SystemsUpgrade and or installation of 12 Combat Systems 63 affected spaces63 affected spaces Extensive work in CDC, IFF Equipment Room, BFTT Equipment Room, NSSMS Launcher RoomsExtensive work in CDC, IFF Equipment Room, BFTT Equipment Room, NSSMS Launcher Rooms 12

13. Norfolk Naval Shipyard Any Ship, Any Time, Any Where CVN 73 CAPSTONE APPROACH Problem: NNSY to accomplish CAPSTONE install during an 11 month availability NNSY to accomplish CAPSTONE install during an 11 month availability – Benchmark was 13 months by PSNS on CVN-74 Solution (two parts): Main MastMain Mast –Implement LEAN processes for the planning, fabrication, and replacement of the mast AIT work (Island and below)AIT work (Island and below) –Incorporate and utilize lessons learned from NGNN and PSNS into production and testing implementation 13

14. Norfolk Naval Shipyard Any Ship, Any Time, Any Where MAST REPLACEMENT LEAN IMPLEMENTATION MAST REPLACEMENT LEAN IMPLEMENTATION Joint pre-fab effort between PSNS and NNSY –Mast assembled at PSNS and shipped to NNSY –Designed & established inside shop fab cell for yardarms & platforms –Established Dock-side assembly area Old Mast removed in one pieceOld Mast removed in one piece – – CVN-74 mast removed in 10 pieces New mast installed in one pieceNew mast installed in one piece – CVN-74 mast installed in 3 pieces Equipment and Cable installationEquipment and Cable installation – Detailed integrated schedule for work sequence and cable installation Substantial savings: schedule (35 days) & cost (2.5K MDs or 13%) 14

15. Norfolk Naval Shipyard Any Ship, Any Time, Any Where AIT INSTALL LESSONS LEARNED NNSY involved early in co-yard Capstone lessons learned NSWC-PHD implementation of lessons learned: – –Formulated Installation Coordination Team (ICT) – –Integrated production schedule & testing schedule of CAPSTONE alts – –Port Hueneme POC actively involved in AIT activities – –Dedicated personnel: Main Mast APS, AIT Coordinator, and two CCTCs – –Weekly teleconferences & space deconfliction meetings – –Walkthroughs at 25%, 50%, 75% point for each alt Combat Systems Trials Rehearsal (CSTR) – –Live aircraft test runs performed pierside, vice at-sea » »Reduces sea trials by 3 days Production efficiencies coupled with program level oversight enabled 28 day reduction in Combat Systems Testing! 15

16. Norfolk Naval Shipyard Any Ship, Any Time, Any Where WRAP-UP WRAP-UP Still marching to the same drumbeat Enterprise/LEAN approach – – Standardized, disciplined, and holistic – – CVN-73 CAPSTONE is an example Build the fleet of the future 16

17. Norfolk Naval Shipyard Any Ship, Any Time, Any Where Questions? 17