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SHOP 67H Buoy Maintenance Trident Refit Facility

SHOP 67H Buoy Maintenance Trident Refit Facility. Presenters: VSM Team 28 SEPTEMBER 2006. Team. Ltjg Lofton– Code 720/730 Division Officer David Bliton – Code 730 General Foreman Craig Graham – Code 730 2 nd Shift Supervisor David McIntyre – Code 741 Technical Support

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SHOP 67H Buoy Maintenance Trident Refit Facility

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  1. SHOP 67HBuoy MaintenanceTrident Refit Facility Presenters: VSM Team 28 SEPTEMBER 2006

  2. Team • Ltjg Lofton– Code 720/730 Division Officer • David Bliton – Code 730 General Foreman • Craig Graham – Code 730 2nd Shift Supervisor • David McIntyre – Code 741 Technical Support • David Dobson – Shop 67H Supervisor • ETC Corkin – Weapons Ship Superintendent • PO1 McAtee – Work Processing Group • Robert Nevers – Shop 57B • John Stephens (Georgia Tech)

  3. Project Description • Objective: • Enhance the efficiency of buoy maintenance. • Decrease the delay time between buoy evolutions • Implement a scheduling aid for buoy maintenance • Implement the use of non classified scheduling tool available on the TRF LAN • Scope: • All units undergoing repairs at TRIDENT Refit Facility, Kings Bay

  4. Customer focused Teamwork Equal input Be flexible Respectfully disagree Stay positive One conversation at a time Team Ground Rules

  5. The Buoy

  6. Buoy Nest

  7. CURRENT SCHEDULE • Start between refit day 3 & 8 • Finish by refit day 25 • Preservation • 9 refit days • PMRs • 11 working days (~15 refit days) • Refit day 27 (w/o TRF OT) • PMRs + Tow cable replacement • 14 working days (~18 refit days) • Refit day 30 (w/o TRF OT)

  8. CURRENT STATE

  9. 8hrs 6hrs 8hrs 8hrs 8hrs Off-Load Buoy #2 Arrival Inspection RF&D Buoy #2 RF&D Buoy #1 Inboard Electrical Tension S/F slack Tow Cable Hang tags Fresh water Wash 3 4 3 3 2 4 3 C/T C/T C/T C/T C/T C/T C/T 4 6 1 2 8 2 2 AWC None AWC None AWC None AWC 72A AWC None AWC None AWC 02A 8hrs 6hrs 4hrs 2hrs 2hrs 2hrs 1hr TOT Generates WAF TOT Submits WAF To LWC for Approval LWC approves WAF TOT Delivers WAF to S/F S/F generates TO TOT approves TO Duty Chief Reviews TO LWC requests WAF WAF is delivered to LWC TOT Opens WAF Duty Officer Opens WAF TOT Verifies tags 2nd person verifies tags 1st person Hangs tags Duty Officer Approves TO Crane Delay

  10. TOT Generates WAF TOT Submits WAF To LWC for Approval LWC approves WAF TOT Delivers WAF to S/F S/F generates TO TOT approves TO Duty Chief Reviews TO WAF is delivered to LWC TOT Opens WAF Duty Officer Opens WAF TOT Verifies tags 2nd person verifies tags 1st person Hangs tags Duty Officer Approves TO 8hrs 6hrs 8hrs 8hrs Buoy Nest Release For Preservation Cable Cut Off-Load Buoy #1 Buoy Lube Off-Load Buoy #2 Continued Arrival Inspection 3 4 3 3 3 In Shop Buoy Repairs/ Testing C/T C/T C/T C/T C/T 1 2 1 4 6 AWC None AWC None AWC None AWC 02A AWC 02A 9 Days Includes 2 weekends 1hr 6hrs 4hrs 2hrs LWC requests WAF Crane Delay 68 hrs 38 hrs

  11. Tow Cable Replacement

  12. TOT Generates WAF TOT Submits WAF To LWC for Approval LWC approves WAF TOT Delivers WAF to S/F S/F generates TO TOT approves TO Duty Chief Reviews TO WAF is delivered to LWC TOT Opens WAF Duty Officer Opens WAF TOT Verifies tags 2nd person verifies tags 1st person Hangs tags Duty Officer Approves TO 6 8hrs 8hrs 8hrs 6hrs 6hrs 8 Off-Load Reeling Machine Load new Tow cable box Off-load Empty tow Cable box Install new Tow cable Remove Tow Cable Route New tow cable Load Reeling Machine Breakaway 3 3 3 3 3 3 3 C/T C/T C/T C/T C/T C/T C/T .5 1 .5 2 2 4 2 AWC 02A AWC None AWC None AWC None AWC 02A AWC None AWC 02A .5hr 2 hrs 2 hrs 2hrs .5hr 4hrs 1hr LWC requests WAF Crane Delay Crane Delay Crane Delay 50 12

  13. Post Preservation

  14. TOT Generates WAF TOT Submits WAF To LWC for Approval LWC approves WAF TOT Delivers WAF to S/F S/F generates TO TOT approves TO Duty Chief Reviews TO WAF is delivered to LWC TOT Opens WAF Duty Officer Opens WAF TOT Verifies tags 2nd person verifies tags 1st person Hangs tags Duty Officer Approves TO 8hrs 8hrs 14hrs 8hrs 6hrs 14hrs Buoy Fly/ Door Timing RF&D Buoy #1 Load Buoy #1 RF & D Buoy #2 Load Buoy #2 3 3 3 4 6 C/T C/T C/T C/T C/T 2 2 2 2 2 AWC None AWC 02A AWC None AWC 02A AWC None 126 / 176 58 hrs 2hrs 2hrs 2hrs 2hrs 2hrs 48 / 60 10 hrs LWC requests WAF Crane Delay Crane Delay Crane Delay FMA Work Complete

  15. Current state does not include any shipboard corrective maintenance or other external interference. • Ships Drills • PET • Weather delays • Access to waterfront is secured during electrical storm warnings which secures the waterfront gates • Cranes shut down • Tours

  16. BRR-6/6B RELIABILITY

  17. PROJECTS

  18. Buoy Event Schedule • 2 months to implement • Both buoy doors open • Bangor does this now • Remove both linkage pins • Manufacture alignment pin for reassembly • 2 weeks for ESR/AWR approval

  19. Non-Classified Key Event Schedule • Permits ready access to a real time schedule on the LAN • 2 weeks to implement • Readdress Fast Start priority • WAF’s other than those necessary for Fast Start are being delivered to boat with the Fast Start • A separate Lean process is addressing WPCG

  20. Post buoy on-load RF Test • Bite test only if RF&D was accomplished up front • 2 weeks for Naval Surface Warfare Center, Cardrock Division (NSWCCD) memo • Route AWRs/WAF to 67H (Bldg 5060) vice CCS • Shop spare MAMs Kit for BRR-6/6B • Inventory and Purchase • Requesting funds for FY07 • Readdress buoy hydro procedure • 4 months for NSWCCD to evaluate procedure • 9 hours to 6 hours

  21. Early paint inspection • 2 weeks to implement • Completed by Refit Day 5 • S/F, contractor, etc. and shop conduct inspections together • Controlled evolutions • Allows swapping doors without WAF revision (similar to buoy fly) • NSWCCD PA currently evaluating CDM revision • Approval - 6 months

  22. Modified 2W1 cable assembly • Increases buoy reliability • Hydrostatic test pending • 6 months for NSWCCD approval following hydrostatic testing • Beneficial suggestion accepted locally. Waiting acceptance from NSWCCD concurrence • Readdress door gag (horse shoe or door linkage) • Both buoy doors can be opened at the same time. • Gag installed to prevent doors from closing • 6 months for ESR approval

  23. Rotatable Assets • Cost – Purchase $1.28 million over 4 years (2 BRR-6, 2 BRR-6B) • Cost – Build at TRF $580k over 2years (requires mold from NUWC) • USS Alaska buoys available while in shipyard • USS Tennessee buoys become available following • Pull buoys only when necessary (Future State #2) • S/F resistant to removing an operational buoy • NSWCCD prefers leaving operational buoy shipboard (consistent with Bangor process) • Approval – 1 year

  24. FUTURESTATE 1

  25. Inboard Electrical Off-Load Buoy #2 Open Buoy Door #1 Buoy Nest Release For Preservation Tension Buoy Lube Open Buoy Door #2 RF&D Buoy #1 Arrival Inspection Off-Load Buoy #1 RF&D Buoy #2 Cable Cut 3 3 3 3 3 4 3 3 3 4 3 3 In Shop Buoy Repairs/ Testing C/T C/T C/T C/T C/T C/T C/T C/T C/T C/T C/T C/T 8 2 1 2 8 6 2 4 2 4 1 2 AWC 72A AWC 72A AWC None AWC 72A AWC None AWC None AWC None AWC None AWC None AWC None AWC None AWC None .5 .5 2 8 8 8 9 Days Includes 2 weekends 2 1 8 2 2 4 6 2 8 2 4 1 Future State 1 Door pins removed w/Controlled Evolution S/F slack Tow Cable Hang tags Fresh water Wash Crane Delay 27 42

  26. Tow Cable Replacement

  27. TOT Generates WAF TOT Submits WAF To LWC for Approval LWC approves WAF TOT Delivers WAF to S/F S/F generates TO TOT approves TO Duty Chief Reviews TO WAF is delivered to LWC TOT Opens WAF Duty Officer Opens WAF TOT Verifies tags 2nd person verifies tags 1st person Hangs tags Duty Officer Approves TO 2 8hrs 8hrs 8hrs 2hrs 2hrs 8 Off-Load Reeling Machine Load new Tow cable box Off-load Empty tow Cable box Load new Tow cable Off-Load Tow Cable Route New tow cable Load Reeling Machine Breakaway 3 3 3 3 3 3 3 C/T C/T C/T C/T C/T C/T C/T .5 1 .5 2 2 4 2 AWC None AWC None AWC None AWC None AWC None AWC None AWC None .5hr 2 hrs 2 hrs 2hrs .5hr 4hrs 1hr LWC requests WAF Crane Delay Crane Delay Crane Delay 38 12

  28. Close Buoy Door #1 Close Buoy Door #2 Fly Load Buoy #2 Bite Test 3 6 3 3 3 3 C/T C/T C/T C/T C/T C/T 1 1 4 2 2 2 AWC None AWC 72A AWC 72A AWC None AWC 72A AWC None 2 8 .5 2 4 2 1 2 2 1 Future State 1 Door pins removed w/Controlled Evolution Load Buoy #1 39.5 54 Current State 126 / 176 48 / 60 174 / 236 Future State #1 39.5 / 77.5 54 / 66 93.5 / 143.5

  29. FUTURESTATE 2

  30. Inboard Electrical Cable Cut Buoy Nest Release For Preservation Open Buoy Door #1 Tension RF&D Buoy #1 Close Buoy Door #2 Bite Test Buoy Lube Fly RF&D Buoy #2 Arrival Inspection Open Buoy Door #2 Close Buoy Door #1 3 3 4 3 3 6 3 3 3 3 3 3 3 3 In Shop Buoy Repairs/ Testing C/T C/T C/T C/T C/T C/T C/T C/T C/T C/T C/T C/T C/T C/T 6 2 2 8 4 8 2 2 4 2 4 2 2 2 AWC None AWC None AWC None AWC None AWC None AWC None AWC 72A AWC None AWC None AWC 72A AWC None AWC None AWC None AWC None .5 8 2 8 8 .5 8 .5 9 Days Includes 2 weekends 2 4 8 2 2 6 2 2 8 2 2 2 4 4 Future State 2 Door pins removed, Controlled evolution, Buoys not removed S/F slack Tow Cable Hang tags Fresh water Wash 35.5 50

  31. Current State 126 / 176 48 / 60 174 / 236 10.75 Working Days (16 hour days) 9 refit days preservation Refit Day 27 / 30 Future State #1 39.5 / 77.5 54 / 66 93.5 / 143.5 5.84 Working Days (16 hour days) 9 refit days preservation Refit Day 19 / 22 Future State #2 35.5 50 85.5 5.34 Working Days (16 hour days) (work is complete prior to preservation) 9 refit days preservation Refit Day 18

  32. Future State 1 Reduce delays Fewer WAF’s/WAF revisions/Tagouts Better crane lift coordination Saves 8 days compared to Current State Cost savings by reducing/minimizing OT Potential increase for buoy reliability (2w1) Streamline the process Provide more time for potential corrective maintenance BENEFITS

  33. Future State 2 Eliminate buoy removal BENEFITS

  34. Benefits Annual Savings ~$40,000 Due to reduction in overtime 67H and assist work centers

  35. Thank you

  36. PROJECTS

  37. PROJECTS

  38. PROJECTS

  39. Buoy Event Schedule • 2 months to implement • Both buoy doors open • Bangor does this now • Remove both linkage pins • Manufacture alignment pin for reassembly • 2 weeks for ESR/AWR approval • Non-Classified Key Event Schedule • Permits ready access to a real time schedule on the LAN • 2 weeks to implement • Readdress Fast Start priority • WAF’s other than those necessary for Fast Start are being delivered to boat with the Fast Start • A separate Lean process is addressing WPCG

  40. Post buoy on-load RF Test • Bite test only if RF&D was accomplished up front • 2 weeks for Naval Surface Warfare Center, Cardrock Division (NSWCCD) memo • Route AWRs/WAF to 67H (Bldg 5060) vice CCS • Shop spare MAMs Kit for BRR-6/6B • Inventory and Purchase • Requesting funds for FY07 • Readdress buoy hydro procedure • 4 months for NSWCCD to evaluate procedure • 9 hours to 6 hours

  41. Early paint inspection • 2 weeks to implement • Completed by Refit Day 5 • S/F, contractor, etc. and shop conduct inspections together • Controlled evolutions • Allows swapping doors without WAF revision (similar to buoy fly) • NSWCCD PA currently evaluating CDM revision • Approval - 6 months

  42. Modified 2W1 cable assembly • Increases buoy reliability • Hydrostatic test pending • 6 months for NSWCCD approval following hydrostatic testing • Beneficial suggestion accepted locally. Waiting acceptance from NSWCCD concurrence • Readdress door gag (horse shoe or door linkage) • Both buoy doors can be opened at the same time. • Gag installed to prevent doors from closing • 6 months for ESR approval

  43. Rotatable Assets • Cost – Purchase $1.28 million over 4 years (2 BRR-6, 2 BRR-6B) • Cost – Build at TRF $580k over 2years (requires mold from NUWC) • USS Alaska buoys available while in shipyard • USS Tennessee buoys become available following • Pull buoys only when necessary (Future State #2) • S/F resistant to removing an operational buoy • NSWCCD prefers leaving operational buoy shipboard (consistent with Bangor process) • Approval – 1 year

  44. Past State Arrival In shop RF&D can be done shipboard POST PRESERVATION Inboard Electrical RF&D Tension Lube Cable Cut FLY Current State Inboard Electrical RF&D Arrival Tension Lube Cable Cut In shop RF&D can be done shipboard POST PRESERVATION RF&D FLY Required Testing

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