URO-MRC 003 Process Lean Event Out-brief Trident Refit Facility

1. URO-MRC 003 ProcessLean Event Out-briefTrident Refit Facility For Commanding Officer Presenters: Lean Team 19 August 05

2. Project Objectives • Have the work completed (including preservation) prior to the FMA Work Complete Date. • Minimize the number of required URO-MRC related Departure-From-Specifications (DFSs). • Identify any waste (non-value added activities) in the process, and eliminate or minimize them. • Communicate work progress and responsibilities to ensure # 1 happens.

3. Project Team • Rick Munn (413) • John Stephens (Georgia Tech) • Ernie Schwach (413) • Bob Thran (401) • Jaime Ordaz (441) • Michael Hebert (424) • John Parsons (11A) • Dennis Kapparis (11A) • George Banks (303) • Norman Boissonneault (11A) • Randy Mixson (304) • Brett Mounsey (303)

4. URO Program • NAVSEA managed program: • Established in 1973 • Identify material condition of hull integrity boundary • Maintain submarines certified to design test depth • Minimize possibility of undetected degradation of materials • Unrestricted Operations (URO) Maintenance Requirements Cards (MRCs)

5. Structural URO MRCs • 001 -- NDT Surveillance Inspection of Selected Hull Welds • 002 -- Inspection of Fwd and Aft Stern Tube • 003 -- Hull Structural Survey • 004 -- Statistical Ultrasonic Sampling Inspection of Hull Welds • 005 -- Ultrasonic Monitoring Inspection of Known Discontinuities • 035 -- Inspection of Tubes and Cylinders thru Pressure Hull

6. Process Definition • Initial Code 413 Inspection to Final Code 413 Inspection • Excludes: • Initial Tank Opening Process • Technical Work Document development Process • Work Packaging and Control Process • Preservation and Tank Closeout Process • Command requires a standard tracking process for completion of action items from LEAN Value Stream Mapping (VSM) projects

7. Inspection/Repair Process Engineering Inspection Additional Cleaning, When Necessary NDT Inspection, When Necessary Engineering Evaluation of NDT Results Engineering Re-inspection & Repair Instructions, When Necessary Repair Final Engineering Inspection/ Acceptance Open, Gas Free, Clean, Stage, Light Tank TWD Development Prepare, Paint, QA, Cure, Close Tank Work Packaging And Control

8. Typical Inspection Results C/413 Inspect Yes No Sat ? SUBSAFE ? 70% 30% No 70% Yes 30% 70% 21% 9% No ESR Required Non-Controlled CWP

9. URO MRC 003 EGL • Pressure Hull • Non-Pressure Hull • Superstructure/Sail • Bilges • Internal tanks • External tanks • Control Surfaces • Penetrations • Shortest Inspection – as little as one day • Longest Inspection/Repair – as much as 3 weeks (21 days) • Typical internal tank – Depth Control Tank (DCT) – 9-10 days for inspection and repair.

10. VA vs. NVA • Value Added Activities (VA) • Activities that transform materials into the finished product • Customer willing to pay for • Non-Value Added Activities (NVA) • Activities that take time and resources (Waste) • Customer is NOT willing to pay for • Need to eliminate or minimize

11. Product Family Current State Map Future State Map Plan and Implement Value Stream Map How the process currently operates The foundation of the future state Designing a lean flow

13. Brainstorming • Brainstorming produced 120+ ideas • These were sorted into major categories • Each idea was analyzed • The process resulted in 14 final recommendations some of which included more than one initial idea

14. Recommendations • Schedule and prioritize URO inspections as part of the A-45 Meeting and monitor all critical path jobs throughout refit. • Adjust refit schedules based on critical path(s). • Monitor WPC process to validate reduction of 1st line supervisor workload.

15. Recommendations • Define roles, responsibilities and duties of all personnel involved in the URO process (similar to Preservation IPI). • Schedule and conduct group (11A, AWC, 413, NDT, SF, etc.) URO Process training.

16. Recommendations • Create URO Work Team • Engineering support for swing shift

17. Recommendations • Evaluate current workforce mix and restructure billets to overloaded shops to support URO inspection and repair workload.

18. Recommendations • AWRs revised to provide job-specific assist work center (AWC) duties (as defined in proposed IPI). • Authorize non-controlled repairs as “contingency repairs” in WKJC AWRs.

19. Recommendations • Develop standard procedures (Planning Department Memorandums (PDMs)) for routine repairs (i.e., doubler plates, incremental grinding). • Establish permanent civilian tank coordinator positions.

20. Recommendations • Evaluate “bundling” of 11A miscellaneous structural inspection, URO inspection, touch-up/full preservation, and zinc replacement JCNs into a single AWR.

21. Recommendations • Leverage technology used for information workflow in process (e.g., PDF scanners for ESRs and NDT reports sent between multiple codes/shops).

23. Calendar Time Savings • Current State Map WorkWaitTotal Hours • Inspection SAT (70%) 41 79 120 • Non-CWP Repairs (21%) 65 152 217 • CWP Repairs (9%) 65 152 217 • Future State Map WorkWaitTotal Hours% Red • Inspection SAT (70%) 41 23 64 47% • Non-CWP Repairs (21%) 65 34 99 54% • CWP Repairs (9%) 65 96 161 26%

24. Recommendations for Follow Up • Code 401 responsible for coordinating implementation

25. End of Presentation