Electronic Weld Record (eWR) for Pipe Welding Process Change

1. S2703 - Electronic Weld Record (eWR) - Pipe Process Change – Under Cognizance of Industry Ongoing Project Derek Hassell Newport News Shipbuilding NSRP Presentation March 13, 2019 DCN# 43-5036-19

2. Project Team (Organization Chart) Paul Huang – Program Officer PMS 450 Dale Orren – Deputy Director Warren Southerland – Project Manager Tim Wallace – Project Technical Representative Charles McNamara – PMS 450 Dave Hart – LCE Traci Jones – ManTech Project Manager Derek Hassell – Quality Manager (Project Lead) Ross Gambill – Prod Planning Sched Manager (Technical Lead) Joe Sabol – Director (Sponsor) Dale Bell – Quality Engineering Manager (Sponsor)

3. ManTech Project • Electronic Weld Record (eWR) - Replace paper-based pipe weld records with an Electronic Weld Record Application • Start Date/End Date: Nov 2016/Aug 2019 • Aligns with Newport News Shipbuilding Integrated Shipbuilding Strategy • Programs Targeted: VCS, Columbia, Aircraft Carriers (New Construction, Overhaul) • Estimated potential savings: • VCS: Estimated $1.5M per hull, per year $2.9M (based on working 9 VCS in-process hulls per year), and 5 years is $14.5M. • Carriers: Estimated $1.9M per new construction hull and $1.1M per carrier overhaul. Per year savings of $280K (for each carrier)

4. eWR – Overall Vision

5. Project Objectives/Benefits • The objective of this project is to develop an Electronic Weld Record System that will utilize the following electronic features throughout the welding value stream. • Signature, workflow, real time data access, certification, storage • eWR will provide process improvements that will eliminate/reduce the following for VCS/CVN pipe numbered weld joints: • Welding/NDT paper based forms (6 VCS/CVN Pipe Weld Records) • Routing and transporting forms for collecting signatures/data • Manual data input into ERS and SAP • Manual tracking/updates/review/status reporting • Printing paper forms and making copies • Paper record storage (boxes, file cabinets, warehouse) • Unnecessary fields and duplication of data • Editorial issues (e.g., missing, incorrect) caused by handwritten errors • Rework caused by loss of paper records • Time to hand deliver, certify, review, verify, monitor and track records

6. Interesting Project Data • Assumptions (in-process per year): • 9 VCS Hulls • 1 Carrier New Construction (X2) • 1 Carrier Overhaul • Project Data: • # of weld/NDT paper records currently used at NNS = over 25 (e.g, Nuc, Non-Nuc, Carrier, VCS, carrier, pipe) • Initial project focus = 6 pipe weld/NDT records (includes Nuc/Non-Nuc & VCS/Carriers) • Handwritten signatures & data entry per VCS/Carriers weld records = Signatures can be over 25 and data entry over 50 per record by 5 different departments • Record Review VCS 905 = each record can be reviewed by up to 5 different persons • # of records processed per year for 6 records = Est. 36,000 • # of pcs of paper printed per year for 6 records = Est 126,000 • Total time (in hours) per year spent processing 6 records = Est. 50,000 • # of non-value added process steps for VCS records = Est. 119

7. Current State Process Map

8. Project Schedule • Period of Performance: 12/07/2016 – 8/30/2019 3/13/2019

9. eWR Application • Uses SAP and eWICC (uses LX and Welder Work Assignment data) as data sources • Connects to SAP to read and write back • Allows users to enter data and sign at work location • Allows inspectors to accept/reject a weld joint • Allows record review to certify a joint • Allows work to progress to next step in process with signature • Can be used by desktop, laptop, tablet and/or phone (future) • User roles - fitter, welder, foreman, inspector, record review, general users

10. eWR Application – Fitter Screen

11. eWR Application – Fitter Screen

12. eWR Application – Fitter Screen

13. eWR Application – Welder Screen

14. eWR Application – Foreman/Inspector Screen

15. Transition / Implementation Status • Technology Transition Plan (TTP) • Original signed TTP completed (3/30/17) • Draft updated TTP based on changes to POP and NNS Management currently being routed for review/comments. • Implementation Status • The project is not implemented, as it is still in active development • An implementation plan will be developed during Phase II of the project (based upon research discoveries) and will be a deliverable of Task 9 • On the next slide is a table with the high level summary of known implementation requirements with place holders for unknown requirements

16. Implementation Plan - VCS

17. Implementation Plan - CVN

18. Near-Term Activities • Near-Term Milestones to be Addressed • Subtask 6 – Onsite deployment and configuration – Due 3/6/2019 (In-Process) • Risk Reduction Items to be Addressed • Continue heightened awareness of the schedule to minimize future delays • Implementation Actions to be Addressed • None; project is in active development