bluuebunny/crossref_metadata_2025 huggingface dataset:
Application of Zone Logic and Outfit Planning Concepts to Overhaul, Modernization, and Repair of U.S. Navy Ships
Authors: Moen Dennis
Published: January 2021

This paper presents the experience of Puget Sound Naval Shipyard in applying zone logic and outfit planning concepts to the overhaul, modernization, and repair of an aircraft carrier, three cruisers, and a submarine. Procedures were developed to involve design, production, testing, and material personnel in the overhaul process from preplanning through completion of the production phase, with the resulting synergism and open communication. The systems approach was replaced with zone by stage sequenced work packaging with as much work as possible done off the ship. Computer Aided Design (CAD) and photogrammetry were applied to enhance preplanning and off-ship work. Puget Sound Naval Shipyard's application of zone logic is drawn from the research managed by the Maritime Administration's National Shipbuilding Research Program which has introduced the highly successful scientific shipbuilding systems developed in Japan. In brief, this concept represents a shift in logic from system to zone orientation.
Zone Outfitting in a Canadian Great Lakes Shipyard: The First Four Years
Authors: Telfer Alan J.
Published: January 2021

This paper traces the introduction of zone outfitting and outfit modules in a Canadian Great Lakes shipyard following ideas put forward at a Washington, D.C. seminar in 1981. Advances made during construction of five 736-ft bulk carriers are presented, showing the increase in outfit material incorporated in steel units before erection and the rapid increase in size of machinery modules from 3 to 4 tons to some of 40 tons. The different attitudes to these changes by senior management, production supervisors, drawing office personnel and mechanics are briefly examined. Some of the problems encountered are discussed along with the benefits gained by different departments in the yard. The paper examines problems which have yet to be overcome with a look at new advances planned for future ships. The advantages of zone outfitting for a yard with only a medium-sized technical department and a small planning department, but with a willingness to accept change, are reported. Although all of the techniques available to larger yards cannot be adopted by smaller yards, the author's experience with zone outfitting during the past four years provides valuable lessons for the industry at large.
Technological Changes and Worker Participation in the Japanese Shipbuilding Industry
Authors: Okamoto Hideaki
Published: January 2021

The Japanese shipbuilding industry as a socio-technical system is examined in terms of the interaction of technological changes and worker commitment. The high level of employee suggestions is discussed along with general background factors that helped establish Japan's reputation as a world leader in shipbuilding, which became a model for other industries. Innovations such as multiskill targeting are described as well as the components of Japanese on-the-job training in the industry. Finally, there is a discussion of possible problems in the future, and of current ideas on rebuilding the industry, which has suffered a severe decline in recent years due to the worldwide slump in orders.
Computer Optimizing of Bevel Angles for Welded Pipe Joints
Authors: Mergler H. W.
Published: January 2021

There is a direct relationship between pipe joint welding times and applied weld volume. This paper gives the computations necessary to define the locus for the branch saddle as a function of certain variables and of the optimized bevel angle. Joint configurations were studied for weld area variations for both fixed and optimized bevel angle configurations. Results demonstrated a considerable reduction in weld volume when the optimized volume was compared with the volume obtained using a fixed bevel angle.
Evaluation of the Usability and Benefits of Twist Wire GMAW and FCAW Narrow Gap Welding: 1984-1985
Authors: Mortvedt Derek H.
Published: January 2021

This paper is an interim report for the Puget Sound Naval Shipyard on the usability and benefits of twist wire narrow gap welding in the shipbuilding industry covering the period 1984 to 1985. It includes both the gas metal arc (GMAW) and flux cored arc (FCAW) welding processes. Various types of weld defects are discussed in terms of causes and effects. The ability of the twist wire process to produce high quality welds, with desired mechanical properties, over a wide range of gap widths and using a wide range of welding parameters, is also examined. The equipment used in this process is described.
Factors in the Selection of Drydocking Systems for Shipyards
Authors: Salzer J. Richard
Published: January 2021

This general paper discusses the principal types of launcher/recovery systems for ships, the sizes of ship for which each system is presently applicable, the size limitations that are projected for each system, and a comparison of other factors to be considered in the selection of a system for a new or modernized shipyard.
Theodore Roosevelt (CVN 71) Construction Schedule Compression
Authors: Halper Irving D.
Published: January 2021

This paper examines the environment in which improvements in ship construction can occur and looks at the type of planning that must be done to ensure benefits are realized. The Navy is now the major customer of the U.S. shipbuilding industry, and even with the increased emphasis on competitive procurement, by necessity, contracts for a significant amount of sole-source ship construction will exist due to technical or facility constraints. For these contracts, as well as many others, the shipbuilder has a limited incentive to accept the increases in risk inherent in changing his business strategy and existing industrial processes. Recognizing this problem, the Navy began, successfully, to change the environment for aircraft carrier construction. This paper describes the Navy's efforts.
A New Shipbuilding Measurement Tool—Photogrammetry for Measuring Circularity of Submarine Hulls
Authors: Jacobsen L. R. , Biondo P. N.
Published: January 2021

Photogrammetry is the art, science, and technology used in the interpretation of coordinate data about physical objects by the measurement and analysis of photographic images. This paper is concerned with the use of photogrammetry to measure the as-built circularity (out-of-roundness) of the Trident Class submarine pressure hull cylinders Various other mechanical methods have been used in the past for measuring hull circularities, but the unique features and capabilities of photogrammetry have proved themselves well in meeting demanding shipyard needs. The large, awkward shape of submarine pressure hull cylinders, m combination with the flexibility and ease of the use of the photogrammetric technique, makes photogrammetry a productive tool in support of submarine construction.
The Use of Statistical Methods in Dimensional Process Control
Authors: Krajcsik Stephen
Published: January 2021

In shipbuilding, the stage of construction which lends itself to the most time and cost reduction is unit erection in the basin or on the ways. This requires all units to be complete and accurately assembled in order to eliminate costly rework during and after erection. To achieve this high degree of unit accuracy, the author's company has undertaken a pilot dimensional control program that has set the guidelines for systematically monitoring each stage of the production process prior to erection. Through the collection and analysis of data, steps can be taken to control each process and insure achievement of the desired degree of accuracy. The cumulative effects of "fine tuning" each individual work process will ultimately lead to improvement in the dimensional accuracy of completed units. This paper discusses the company's experience in applying statistical methods in the collection and interpretation of dimensional data on automatic burning machines. The results obtained and the benefits derived from the pilot program have proved that statistical process control, as applied successfully in Japanese shipyards, is a viable method for improving productivity in the shipbuilding industry.
Benefits of the National Shipbuilding Research Program to the Navy and the Industrial Base: Part 3—Navy Perspective
Authors: Christensen W. L.
Published: January 2021

This paper reviews the benefits of the National Shipbuilding Research Program (NSRP) to the shipbuilding industry, and more specifically, its benefits to the Navy and the shipbuilding and ship repair mobilization base. The paper also identifies significant additional benefits that the Navy can gain in the next few years if the NSRP continues not only on its present course of solving productivity problems in building new ships, but also addresses additional targets of opportunity in solving productivity problems in the overhaul, repair and modernization of Navy ships. The labor part here appears to be an even larger budget item than the labor part of new ship construction.
Shipyard Facilities—New and Old Closures for Dry Docks
Authors: Hassani Jay J.
Published: January 2021

Among the many old and new shipyard facilities, this paper depicts three types of closures for dry docks, one old and the other two new, and discusses them from the standpoint of operation, capital investment, life cycle costs, and adaptability to specific sites. The first is a sliding caisson, used in the 40's, the second an innovative double keel caisson, and the third is a seldom-used cantilever-type flap gate, which appears to have great potential. In addition, a recently installed intermediate dock gate is presented.
The Automatic Cutting, Marking, and Processing of Structural Sections
Authors: Wilkens Gunter C. , Kalogerakis John M.
Published: January 2021

Structural sections used in the offshore and shipbuilding industries require a wide range of cutouts, end-cut configurations and edge preparations. Such shapes are currently sketched, layed-off, and cut with manual and/or semi-automatic methods. This paper describes the development of a high-throughput automated (computer numerical control) shape cutting line that incorporates all of the activities from the planning stage through to the finished workpiece. For the more complex shapes, a flexible automation (robotic) cutting system is described that includes an off-line programming capability. Two practical application examples are also detailed. It is concluded that section preparation is now an area that can be automated, with robotics being a feasible and flexible solution.
Ship Design for Production—Some U.K. Experience
Authors: Bruce George J.
Published: January 2021

Ship design for production is widely accepted in principle. Its successful establishment depends on the shipbuilders having a well-defined shipbuilding policy, available to the designer, the establishment of a realistic and agreed schedule, and adequately trained personnel. Key production engineering techniques include spatial analysis, process analysis, and standardization. The advent of powerful and inexpensive computer software has created new opportunities for producibility to be incorporated from the earliest stages of the design process. Significant progress has been made in recent years in the development of design methods and in their application
Investigation of Tubular Electrodes Designed for Submerged Arc Welding Applications
Authors: Whannell R. A. , Halverson B. H.
Published: January 2021

This paper reports on an investigation into the benefits of using new-generation flux-cored electrodes in the submerged arc welding process. The validity of manufacturers' claims of improved physical properties and economies of welds produced with the new electrode is examined by comparison with standard solid electrode performance. The tests are based on application of weld metal to four different grades of steel common to both commercial and naval ship construction. The authors conclude that for some, but not all, applications, the flux-cored—or tubular—electrode is a marked improvement.
Rework Management: A Current Perspective
Authors: Fenton Paul H.
Published: January 2021

Rework occurs in all management and industrial environments. This has always been acknowledged, but quantifying the amount and identifying the underlying problems are recent efforts that are beginning to pay dividends. This paper discusses the efforts of the Norfolk Naval Shipyard Production Department to identify, quantify, analyze, and solve basic rework problems. Key to the effectiveness of the program is the organization developed to manage this process. A discussion of significant successes is included
High-Strength Steels Produced by Advanced Metallurgical Processes
Authors: Stern I. L. , Wheatcroft M. , Ku D. Y. , Waite R. F. , Hanzalek W.
Published: January 2021

Advanced metallurgical processes have made possible the manufacture of steels that—in addition to possessing high strength and toughness characteristics—maintain modest carbon equivalents for good weldabiiity results. These steels show promise of application in the marine industry because of their potential relative insensitivity to heat input and hardening and their potential for reduced requirements for preheat. This paper reviews several candidate steels, their composition, metallurgy and mechanical properties, and analyzes the results of a series of weldabiiity and toughness tests.
Development of an Intelligent System for Flame Straightening Panel Structures—Devices and Algorithms to be Used with Robots
Authors: Masubuchi Koichi , Imakita Akihiko , Miyachi Hiroshi , Miyake Masayasu
Published: January 2021

Distortions which occur during the assembly of steel panel structures can be removed by flame straightening—a technique that has been used for a number of years in the shipbuilding industry. Correct skill to perform this technique is acquired by many years of experience. The industry is concerned now about the decreasing number of skilled workers. What is needed to improve the situation is to develop a robot capable of not necessarily replacing a human worker, but helping a human worker. This paper discusses results obtained thus far in a research program of which the ultimate objective is to develop an intelligent machine capable of performing flame straightening on a deck of a ship superstructure. Discussions are given on (a) a concept of an algorithm to determine heating conditions, and (£>) sensors needed for "in-process" sensing and controlling the robot movements.
Streamlining in a Competitive Environment
Authors: Piersall Charles H. , Sinche Charles J.
Published: January 2021

The push for streamlining the acquisition process has been complicated by legislation such as the Competition in Contracting Act. Acquisition strategy decisions are often influenced by the real and perceived incompatibility between legislative actions. There are courses of action that can be taken to satisfy both sets of requirements and keep risks to a reasonable level.
Overcoating Inorganic Zinc Primers for Underwater Service
Authors: Gehring G. A. , Ellor J. A.
Published: January 2021

During ship construction, steel hull plate is normally protected with an inorganic zinc preconstruction primer. For the underwater portion of the hull, conventional practice is to remove the primer by abrasive blasting before final coating of the hull. If the requirement for removing the preconstruction primer could be eliminated, there would be a significant cost savings. As a result, a laboratory study was undertaken to investigate the performance of selected marine coatings when applied over inorganic zinc primers in underwater service. In general, the results of the study suggest that there are inorganic zinc preconstruction primers that can be overcoated for underwater service. The results encourage further tests to investigate the parameters affecting compatibility.
Increasing Efficiency Through Outfit Planning
Authors: Murphy Catherine M.
Published: January 2021

Outfit planning provides a means to increase productivity and schedule enhancements through zone outfitting, group technology, and prefabrication. Puget Sound Naval Shipyard has gained an understanding of outfit planning through publications by the Maritime Administration's National Shipbuilding Research Program. In an attempt to increase efficiency, Puget Sound Naval Shipyard is using outfit planning methods to overhaul, alter, and repair U.S. naval ships. One project targeted for outfit planning is the forward-end electronic package on submarines. This paper describes Puget Sound's efforts to use outfit planning concepts in developing work packages for the forward end ship alterations.
Shop and Zone Administration and Management: The Transition to Zone Outfitting in Repair and Overhaul at Puget Sound Naval Shipyard
Authors: Sterns Anthony A.
Published: January 2021

This paper discusses Puget Sound Naval Shipyard's implementation of Zone Outfitting in Repair and Overhaul (ZORO). Four problems are responsible for past poor performance: funding by system, planning using key-operations which are too broad, scheduling by event, and inflating cost by inaccurate historical expenditure records. These problems are discussed and addressed. Several preliminary studies have also been released which show significant gains as a result of ZORO. A study of man-hour comparisons between identical work, prior to the use of work packaging and after, shows a decrease of 30 percent. Comparison of the man-hours required for planning versus man-hours saved shows a savings of 54 percent. Although these results are very preliminary, they indicate an extensive potential for improvement in both efficiency of production and effectiveness of work packaging.
Submarine Tank Repair Using Outfit Planning
Authors: Dunford Charles P. , Blackler Keith D.
Published: January 2021

Outfit planning and zone logic methods have been implemented in the shipbuilding industry in response to the need for increased efficiency in the construction of new ships. Efforts have been underway at Puget Sound Naval Shipyard to use outfit planning principles to plan and execute ship alterations on operational ships. The next logical step is to use these same principles to plan and execute overhaul and refurbishment work. This paper addresses efforts at Puget Sound Naval Shipyard to apply outfit planning principles to the repair of submarine tanks.
Electroslag Surfacing: A Potential Process for the Rebuilding and Restoration of Ship Components
Authors: Yu D. W. , Devletian J.H.
Published: January 2021

With construction of new commercial ships in U.S. shipyards at an all-time low and Congressional appropriations insufficient to maintain a U.S. Navy fleet of 600 ships, the priorities of the surviving U.S. shipyards are changing from that of shipbuilding to ship rebuilding, restoration, and repair. This paper presents a review of the international literature on the most recent developments in thick section surfacing by electroslag surfacing (ESS) using strip or wire electrodes. The advantages of this newly developed technique from Japan are explained in comparison with the conventional surfacing processes, such as submerged arc surfacing (SAS). A number of innovations and applications in this area are introduced to emphasize the substantial economical advantage of strip ESS for ship repair and manufacturing. ESS with strip electrodes is capable of overlaying a wide variety of corrosion and/or wear-resistant deposits on structural ship components with half the dilution level and twice the deposition rate of its closest competitor, SAS. Because of its significant economical merits, strip ESS has already become the dominant thick-section surfacing process in many industrialized countries, particularly in Japan, the Soviet Union and parts of Europe.
Formal Manufacturing Approaches to Modern Shipbuilding
Authors: Powell Paul C. , Zigelman Charles I.
Published: January 2021

This paper describes how a formal manufacturing environment, as defined by the American Production and Inventory Control Society (APICS), compares with modern shipbuilding techniques. Formal manufacturing, through a product-based build strategy, provides a framework for integrating contract scheduling, design development, material purchasing, inventory control, production capacity planning, and production control. An understanding of formal manufacturing provides a foundation for understanding modern shipbuilding techniques.
Revitalization of Industrial Engineering in the Naval Shipyards
Authors: MacGregor Roy M.
Published: January 2021

Recent developments in the ship repair industry have focused attention on the operation of the naval shipyards. The loss of commercial ship construction work to foreign nations and the declining commercial ship repair work market have resulted in aggressive competition among private shipyards for naval ship repair work. The naval shipyards have come under increasing pressure and scrutiny to become more productive and cost effective. This paper examines the impact of these factors on the naval shipyards, specifically with respect to the industrial engineering functions. It describes the initiatives taken to revitalize industrial engineering in the naval shipyards and summarizes some of the successes achieved in reducing costs. The paper concludes with a prognosis for the future and describes efforts to institutionalize the strengthened role of industrial engineering.
Affordable Technologies for Small Shipyards
Authors: Lane Kenneth R. , Siburg Mark W. , Waterhouse John W.
Published: January 2021

This paper attempts to recast some large shipyard production technologies in light of the needs of small yards. The importance of small shipyards to the nation's marine economy is addressed and three methods are offered as affordable ways of increasing yard productivity. These are operations management, numerical lofting, and zone outfitting. The paper concludes with a call for increased attention to the problems of small yards.
A Group Technology Approach to Master Scheduling of Shipbuilding Projects
Authors: Gribskov Jon
Published: January 2021

This paper describes the current Master Scheduling approach used at National Steel and Shipbuilding Company (NASSCO) in San Diego. Master schedules at NASSCO focus on key interim products involved in ship construction: units, blocks, (on-board) zones, and tests. Network scheduling algorithms (that is, Critical Path) are used. Each interim product has an associated subnet. Categorization by type is used to simplify the task of developing and maintaining activity lists, dependencies (predecessor/successor relationships) and durations for the thousands of activities. Manual level-loading of critical resources is incorporated into and supported by the overall scheduling process. The paper includes some discussion of problems encountered in the implementation of this scheduling approach.
Navy Acquisition of Ships to Commercial Standards Using a Circular of Requirements
Authors: White David D. , Croyle Carlton R.
Published: January 2021

A variety of ship acquisition procedures have been used by the Naval Sea Systems Command (NAVSEA) in recent years. Every new design uses some variant on the basic design process. There are in-house designs and contracted-out designs and a variety of gradations in between. This paper addresses the acquisition of ships designed and built to commercial standards using the two-step procurement method. Both the two-step approach and the use of commercial standards have created a degree of controversy and confusion within NAVSEA. A less rigorous degree of control is exerted by NAVSEA over these designs without a corresponding decrease in responsibility. This paper explores the advantages and the pitfalls of the Navy's commercial acquisition approach, from the perspective of both the project manager and the technical codes. The mechanics of the approach are described and compared with the conventional Navy acquisition process. Finally, "lessons learned" and possible future acquisition strategies are presented.
NIDDESC: Meeting the Data Exchange Challenge Through a Cooperative Effort
Authors: Kloetzli John , Billingsley Dan
Published: January 2021

The application of computer-aided design (CAD) and manufacturing (CAM) techniques in the marine industry has increased significantly in recent years. With more individual designers and shipyards using CAD within their organizations, the pressure to transfer CAD data between organizations has also increased. The Navy/Industry Digital Data Exchange Standards Committee (NIDDESC) provides a mechanism for public and private organizations to cooperate in the development of digital data transfer techniques. Organizationally, NIDDESC is a cost-sharing venture between private firms and government organizations. This effort arose from the Naval Sea Systems Command (NAVSEA) in cooperation with the National Shipbuilding Research Program. The members include leading professionals in the marine industry from several major design firms, private shipyards, naval shipyards, and government laboratories. All members are directly involved in CAD/CAM in their organizations and together represent a broad spectrum of experience and perspectives. NIDDESC has many subcommittees devoted to specific areas of digital data transfer. The basic objective is to develop an industry-wide consensus on product data models for ship structure and distribution systems. Efforts include contributions to the Initial Graphics Exchange Standard, the Product Data Exchange Standard, preparation of a Recommended Practices Manual and the analysis of ship production data flows. NIDDESC has made contributions to the development of CALS standards, including MIL-STD-1840, DOD-IGES, SGML, and MIL-D-28000.
Methods of Incorporating Design-for-Production Considerations into Concept Design Investigations
Authors: Bong H. S. , Hills William , Caldwell John B.
Published: January 2021

The paper describes a method of incorporating knowledge and data of the production process into a concept design model in a way which provides a flexible and powerful structural design tool. Interactive graphics is shown to be a useful design aid when defining geometry and scantlings particularly when combined with a database of information on standardization, build methods and production technology. An effective method of assessing work content is presented in which man-hours are assessed for each phase in the construction process, that is, preparation, fabrication and erection. The total build cost, including labor, material and overhead, is used as the criterion in a series of studies which demonstrate the application of the method to concept design and which show the sensitivity of total cost to changes in various parameters of design and production.
Model Testing of an Oval-Shaped Seal for Sealing of Large Gaps Between Mating Surfaces
Authors: Eutizzi Nick F.
Published: January 2021

A pressure chamber was designed and manufactured in two parts, which were clamped together at their flanges using a clamping ring. An "O" ring seal was used for sealing the gap between the mating surfaces. The clamping ring held the two flanges together while the chamber was pressurized with mixed gas. The internal chamber pressure caused the gap to widen (unseat with pressure), resulting in a final gap in which the O-ring could no longer maintain an adequate seal. The O-ring seal groove was designed with an undercut or dove-tail groove to capture the O-ring. The dovetail groove cross-sectional area was designed to accept 100 percent of the O-ring area. The pressure chamber could not be taken out of service to redesign the mating connection and to accomplish the related production work. To solve this problem, an oval-shaped seal was designed to fit into the existing dovetail groove, but with a greater standoff height to allow for the larger gap (Fig. 1).Fig. 1Pressure chamber assembly
Liability for Hazardous Wastes Produced During the Course of Ship Repair
Authors: Wittenborn John L. , Guerry William M.
Published: January 2021

Many common ship repair tasks result in the production of quantities of various hazardous wastes. These wastes, regardless of volume, present difficult burdens for shipyards and the U.S. Navy. Under federal environmental laws, the responsibility for handling hazardous wastes and the liability for their ultimate disposal rests with the person or persons who create the wastes and who arrange for their disposal. Oftentimes, however, the responsibility and liability for handling and disposing of these wastes is unclear. This is especially true when naval ships are repaired in contractor facilities and wastes are produced by the activities of ships' force, contractor personnel, or some combination of the two. Further complicating the web of liability is the divergent source of the wastes. Some wastes are produced as a direct result of required maintenance work on ship systems. Other wastes may be produced in the yard by activities which are largely discretionary with the contractor. Ultimately, these wastes from all sources must be identified, packaged, stored, treated, transported, and disposed. Potential future liability may arise at each step in this process. This paper reviews briefly the structure and function of two principal federal hazardous waste statutes and explains how their myriad complex responsibilities and liabilities are applied in the context of a typical ship repair2
Producibility in Ship Design
Authors: Kraine Gilbert L. , Ingvason Sigurdur
Published: January 2021

Much attention has been given in recent years to the problem of reducing ship construction costs. This has primarily emphasized the improvement of production techniques, processes and management controls. There is a great deal that can be accomplished in reducing ship construction costs, however, by improving the producibility of the design of the ship. The design of a more producible ship requires concurrent product and process design. Various principles and techniques can be applied throughout the design process in order to reduce the construction man-hours required by ensuring that the manufacturing attributes are considered. This paper identifies some of the key principles involved and describes the techniques for applying the principles. A practical approach to estimating the cost benefit of alternative designs by estimating the labor input differential between the designs is also presented. Finally, specific examples of the application of the producibility techniques to several recent ship designs are included.
A Study of the Causes of Man-Hour Variance of Naval Shipyard Work Standards
Authors: Bunch Howard M.
Published: January 2021

This paper presents the results of a study conducted at a U.S. Navy shipyard during 1987 concerning the relationship between engineering standards and the variances that were occurring in production budget and charged man-hours. The ten engineering standards having the greatest man-hour variances were examined. These standards, as a group, accounted for about 62 percent of the man-hour variance that was reported during the first nine months of 1987. The study indicated that, with one exception, all of the standards were "generic" in their application, that is, they can be applied over a wide range of job orders. The study also concluded that engineered standards are only partially responsible for the production variance.
Manufacturing Lead Time—A Factor to Consider During Planning and Acquisition of Navy Ships
Authors: Ennis William V. , Speth Harry F. , Mieskolainen Albert
Published: January 2021

Philadelphia's NAVSEA Shipbuilding Support Office provides current Manufacturing Lead Time information to Navy planners, designers and acquisition managers responsible for the timely procurement of the latest design Navy ships. Lead time information is critical to effective budgeting and on-time delivery of basic material, hull, mechanical and electrical components and combat systems. This paper addresses the methodology for solicitation, statistical consolidation and final assessment of information provided by over 1300 domestic primary and secondary manufacturers. Early detection of lead time change provides a basis for remedial action whereby critical paths may be selected, schedules altered, or substitutions provided. The paper further addresses the status of the U.S. industrial base capacity to provide these materials, components and systems and compares the current industrial base with its status five and ten years ago. Loss of domestic capacity has resulted in sole or single-source procurement and in some cases sole dependence upon a foreign source for critical subcomponents. The ability of U.S. manufacturers to respond to peacetime programs and potential surge or mobilization requirements is also examined.
Modeling and Transfer of Product Model Digital Data for DDG 51 Class Destroyer Program
Authors: Schmidt William R. , Vander Schaaf James R. , Shields Richard V.
Published: January 2021

The significant benefits achieved by the Navy from application of a CAD/CAM modeling technique to the Aegis Destroyer Construction Program are described. Building a computer model of the ship—the Arleigh Burke Class (DDG 51)—prior to construction reduces interferences and improves design accuracy and completeness. Major challenges addressed by the paper are the translation to CAD of an existing paper design and the transfer of three-dimensional CAD product models in order to permit construction of the ship at two different yards. This ongoing project represents a major cooperative effort between the Navy, design agencies, weapons systems manufacturers, and two private shipyards.
Photogrammetry as an Advanced Planning Tool for Naval Shipyards
Authors: Ingram Harold , Dudeck Felicia K.
Published: January 2021

Photogrammetric technology captures dimensional data on systems' existing configurations. Photogrammetry is useful for determining the dimensional attributes of a system whose configuration has been modified and/or not recorded or updated. Knowing before execution of work begins the as-built structural conditions of systems on which work will be performed increases the shipyard's ability to plan a job efficiently, allowing the job to be completed in a timely cost-effective manner. This can assure the elimination of millions of dollars' worth of rework and trial-and-error fit-ups, and can provide enhanced product quality. This paper presents several case studies in which naval shipyards have used photogrammetry prior to execution of work in order to effectively plan and accomplish the work more efficiently. Successes realized through the use of photogrammetric technology can be shared among all of the naval shipyards with great cost savings potential to the Navy.
Composite Materials and Naval Surface Combatants: The Integrated Technology Deckhouse Project
Authors: Cahill Pat
Published: January 2021

Composite materials, particularly fiberglass, have created a revolution in commercial marine design and construction over the past 20 to 30 years. The U.S. Navy, however, has been slow in recognizing the value of composite materials and implementing their use. The current construction of a fiberglass minesweeper will introduce composites into the auxiliary Navy, but major surface combatants have yet to take advantage of their unique material properties. The Integrated Technology Deckhouse (ITD) Project has been steadily progressing toward the goal of constructing naval combatant deckhouses out of an integrated system of steel and composites. The approach of the ITD Project has resolved problems and issues in phases, with each phase becoming progressively narrower in scope and greater in detail. The first phase of the project was primarily a materials and structural concepts trade-off study. Material properties were reviewed for a variety of fiberglass composites and design concepts, resulting in a tradeoff matrix. The second phase included a shipyard producibility study. Issues associated with working with composites in a modular, steel construction environment were addressed. Recommendations from this study were then addressed in detail in a follow-on producibility study. In the most recently completed study, the producibility issues associated with the design and construction of the DDG-51 Class forward Close In Weapons System (CIWS) maintenance enclosure were addressed. This paper reviews the progress to date in the ITD project, highlighting the significant issues and explaining why some of the major decisions were made. Emphasis is placed on the most recent phase of the project, which concentrated on a specific ship unit.
Maintaining the Shipbuilding Technology Base—Looking at Other Markets
Authors: Bongiorni H. Bruce
Published: January 2021

This paper introduces for discussion the need and opportunities for shipyards to diversify into new areas of business. The need for diversification results from reductions in defense spending and the difficulties U.S. shipbuilders are having in gaining new orders. Shipyards have unique abilities that can be competitive strengths in other markets. Among these strengths are the ability to handle large, complex projects, the range of skills among their workforce, and their proximity to water transportation facilities. Examples of shipyard participation in new markets demonstrates these strengths. Other markets addressed in this paper serve the utility and process industries, and the opportunities to participate in energy resource research and development.
Infrastructure Study in Shipbuilding: A Systems Analysis of U.S. Commercial Shipbuilding Practices
Authors: Wade Michael , Karaszewski Zbigniew J.
Published: January 2021

This paper documents the results of the first phase of the Infrastructure Study in Shipbuilding (ISIS). The purpose of the first phase was to accurately document the current processes used to build commercial ships in the United States. These results have provided an increased understanding of the commercial shipbuilding process and have also provided a strategic planning tool capable of determining the length of time required to market, design, build, and deliver a typical merchant ship in the United States. The methodology used to document the shipbuilding process was IDEF0. The resulting product was an IDEF0 function model composed of 272 interrelated activities. A subset of 70 of these functions was analyzed with critical path methodology to produce a Gantt chart representing an atypical merchant ship acquisition program. Data were taken from a recently completed merchant ship program used to establish an overall process duration for these functions.
Breaking the Chains of Tradition and Fantasy—A Revolutionary Approach to the Constraints on Productivity
Authors: Rogness James
Published: January 2021

Productivity improvement is becoming an evermore crucial agenda item for the U.S. shipbuilding industry. Initiatives to improve productivity in U.S. shipyards have traditionally taken the form of piecemeal efforts to increase capability and capacity through technological upgrades of production methods, facilities, tooling, and machinery. In spite of the fact that those initiatives have been successful in eliminating many of the physical constraints of productivity, a broadening productivity gap with foreign competitors places U.S. shipbuilding in a noncompetitive position in the international commercial market. The continuing failure of technological initiatives to narrow the productivity gap does more than suggest that additional measures need to be taken. It strongly indicates the presence of productivity constraints which exist beyond the realm of technology. In fact, one of the most valuable opportunities currently available to U.S. shipbuilders may exist in the realization that many of the constraints limiting productivity in shipbuilding are actually self-imposed, arising from traditional management and organizational policies which run counter to the new and changing realities of modern industry.
Maquiladora Operations for Shipbuilding
Authors: Laughlin Gary , Gomez Guillermo
Published: January 2021

The maquiladora program was established by the Mexican Government to encourage foreign investment and promote industrial growth. The success of the program encourages more and more participation each year. The low cost of labor in Mexico has attracted U.S. companies in all types of manufacturing with the exception of shipbuilding. With the focus on the domestic shipbuilding market over the past 25 years, U.S. shipyards have lacked the impetus to establish a maquiladora operation. The world market for shipbuilding has been steadily improving, while the U.S. domestic market has been steadily decreasing. The opportunities for U.S. shipyards to focus their strategies on the world market may not get any better. By understanding the complexities of establishing a maquiladora operation and then integrating the operation into its overall production plan, a shipbuilder can begin to realize that large labor cost savings are possible.
Areal Coverage Using Friction Surfacing
Authors: Lambrineas Peter , Jewsbury Peter
Published: January 2021

Areal coatings of 304 and 316 marine grade stainless steel were made on flat mild steel substrates using a low-pressure friction surfacing technique and various deposition configurations. The maximum through-thickness tensile bond strength obtained for such coatings was 890 MPa (1.3 × 105 psi). Gaps or cracks or both between strips of deposited material were not eliminated completely during the manufacture of these coatings. Consequently, the overlay coatings described in this paper, which were made using a range of overlapping and non-overlapping deposition configurations, are primarily suitable for applications in noncorrosive environments.
Portable Arc Welding Robots—A Practical Shipbuilding Tool?
Authors: Williams Peter , Orrick Peter
Published: January 2021

An overview of the application of portable welding robots in shipbuilding is given, with particular reference to a pilot project undertaken at a British shipyard. A general basis for cost justification is outlined, and applications and limitations of the robot system are discussed. Particular attention is drawn to the requirements imposed on other shipyard systems when using robots.
Ship Conversion Project Monitoring—From the Customer’s Viewpoint
Authors: Karlson Edward S.
Published: January 2021

Over the past ten years, the Maritime Administration (MARAD) has awarded and administered contracts for the major conversion of 15 vessels. Each of these projects involved vessel reactivation as well as conversion, and each contract was awarded on a fixed price basis. The combination of fixed pricing and vessel conversion/reactivation creates a challenge to shipyards bidding for the contract in that price competition is intense while, at the same time, an unknown level of growth work can be expected in the vessel reactivation portion of the project. Moreover, the project being bid, inclusive of anticipated growth work, must be integrated into the overall orderbook within the shipyard. The need for careful planning by the shipyard from the beginning of bid preparation through the end of the performance period is clearly evident. This SNAME paper, however, addresses not shipyard planning but continuing project monitoring and progress evaluation by the shipyard's customer. Such monitoring includes ongoing comparisons between the shipyard's planned and actual performance with respect to resource application and schedule adherence. From a technical standpoint, it involves compliance with contract and specification requirements. And finally, from a financial standpoint, it includes project progressing to provide the basis for periodic payments to the shipyard for completed work.
Reducing the Construction Contract Cycle for Naval Auxiliary Ships
Authors: Spicknall Mark H. , Wade Michael
Published: January 2021

A Mid-Term Fast Sealift Technology Development Program producibility study was undertaken by the Manufacturing Systems Division (Code 125) of the Naval Surface Warfare Center, Carderock Division for the Naval Sea Systems Command Computer Aided Engineering Division, Ship Design and Engineering Directorate, SEA 507. The producibility project team was initially tasked to identify and evaluate possible design improvements with regard to their potential impact upon the cost of construction for the Baseline 0a rough-order-of-magnitude geared-diesel option. This particular design variant is a 30-knot twin-screw, 289 m (948 ft) roll-on/roll-off vessel with four 18 PC4.2V medium-speed diesels producing 85 619 kW (114 817 hp) of installed power. The construction cost estimate developed by NAVSEA for the variant is $385 million per ship. In addition to the NAVSEA-assigned task, the team reviewed the producibility aspects of the Navy auxiliary ship procurement process with regard to finding methods that would facilitate major reductions in the construction contract cycle, as time is now recognized as a major cost driver in ship procurement. The construction contract cycle is defined as the amount of time from construction contract award to delivery, and was estimated by NAVSEA to be 42 months for the subject ship.
Strip Cladding of Propeller Shafts with Nickel Alloy 625 by Electroslag Surfacing
Authors: Devletian J. H. , Gao Y. P. , Zhao Q. H. , Wood W. E.
Published: January 2021

A comprehensive comparison between electroslag surfacing (ESS) and submerged arc surfacing (SAS) using 30-mm-wide (1.2 in.) χ 0.5-mm-thick (0.020 in.) nickel alloy 625 strip was conducted in both the as-deposited and stress relieved (at 650°C [1200°F]) conditions. In most cases, exactly duplicate cladding conditions were used to best compare ESS with SAS. Nickel alloy 625 strip was deposited on 10-cm-thick (4 in.) flat plates and 64-cm-diameter (25 in.) shafting (both MIL-S-23284 Class 1 steel) using optimized ESS and SAS processes. Tension and face and side bend tests were performed on as-welded and stress-relieved cladding at room temperature. Microstructural analyses of the clad specimens were performed using optical and electron microscopy. Cladding parameters were found to affect the dilution, deposition rate, and penetration. Although ESS and SAS cladding possessed similar strength levels, the cladding deposited by ESS was shown to have greater ductility than that by SAS. Also, the resistance to solidification cracking of cladding by ESS was superior to SAS because of the reduced silicon, carbon, oxygen, and impurity levels which promote interdendritic Laves phase, niobium-rich MC carbides and inclusions. Compared with SAS, the ESS method proved to be not only more metallurgically favorable but also cost-effective.
Evolution of Cost/Schedule Control (Direct Labor) in Naval Shipyards
Authors: Gessis Scott N.
Published: January 2021

The evolution of a cost/schedule control system (C/SCS) for direct labor in naval shipyards can be traced from the cost/schedule control concept used in the Air Force in the 1960s as an initiative toward more reliable data. Subsequent C/SCS programs were initiated across the Department of Defense (DoD) in the late 1960s and early 1970s. As private shipyards came under what is known as cost/ schedule control system criteria (C/SCSC), and its validation requirements, the issue of C/SCS in naval shipyards rose to the surface. In 1984, the Naval Sea Systems Command (NAVSEA) issued a directive which called for C/SCS implementation in naval shipyards. Expanded use and standardization has followed. This paper reviews basic C/SCS principles, how naval shipyards have used C/SCS in improving performance, and how it has been standardized while still retaining a degree of flexibility.