Focus on safety - Ingalls Shipbuilding - Huntington Ingalls Industries

June 2012
<strong>Focus</strong> on
safety
Ingalls Shipbuilding/A Division of Huntington Ingalls Industries

President's Message
Vol. 2, Number 5 • June 2012
At Ingalls, we encourage and empower
our shipbuilders to find a better way to
do their jobs. A lot of our folks have good
ideas about improving work processes
– how to do it right and do it better – and
overcome some really tough challenges.
Every year a few stand out. The annual
President’s Award recognizes individual
shipbuilders and teams for extraordinary
performance and leadership.
Last month, we honored six outstanding
teams and two exceptional shipbuilders
with the Ingalls President’s Award. By
taking ownership of their work and being
accountable for identifying areas that can
be improved, and by using innovation,
technology and sometimes just sheer
determination and tenacity, they lived up
to our “Hard Stuff, Done Right” reputation.
In this issue of The Anchor, we recognize
this year’s President’s Award winners (see
pages 4-5).
All the teams and individuals who
won the President’s Award – and those
nominated as well – have some things
in common. These folks care about
our shipyard, our shipbuilders and our
customers. They personify leadership and
engagement. They are Ingalls Shipbuilders
and I am proud of each and every one.
And each year, I’m impressed by
both the number of nominations and
the great things those nominees have
accomplished. The folks we honor with
the President’s Award represent the best
of our best. James Bertrand said, “Once
we rid ourselves of traditional thinking, we
can get on with creating the future.” The
teams and individuals who earned this
prestigious award are recognized for doing
just that. Through their achievements, they
take on the challenge and set an example
of how we will create our future.
The Ingalls President’s Award and
the nomination process highlights
shipbuilders that are stepping up and
taking responsibility. But while we
celebrated a group of President’s Award
winners last month, a lot of shipbuilders
did a lot of great things to make our first
year as a new 75-year-old company
successful. In the tough market conditions
we’ll face in the coming years, this is the
kind of leadership and behavior that will
sustain us and allow us to grow.
The President’s Award is a way of
recognizing shipbuilders who are keeping
us focused on our top priorities – safety,
quality, cost and schedule. Thanks to the
winners and nominees and thanks to all of
you for all you do to build great ships.
Debbi McCallam
Director, Ingalls Shipbuilding Communications
Lance Davis
Manager, Employee Communications
Michael Duhe
Editor
Shane Scara, Ed Winter
Contributors
Pat Toney
Graphic Designer
Steve Blount, Lance Davis, Michael Duhe,
Ron Elias
Photographs
The Anchor is published 10 times a year for
the employees of Ingalls Shipbuilding.
Comments, questions, story ideas and
suggestions are encouraged and welcomed.
Please direct feedback to:
Michael.Duhe@hii-ingalls.com
228-935-0799
1000 Jerry St. Pe Hwy
Pascagoula, MS 39567
Emergency Information
Phone Line:
1-877-871-2058
• Press 2 for Ingalls Shipbuilding
Press 1 for Pascagoula
Press 2 for Gulfport
Press 3 for AMSEC
Press 4 for CMSD
Press 5 for Avondale
Editor's Notes
There will be no July issue of The Anchor. The August edition will feature Ingalls
shipbuilders and the children of shipbuilders who recently graduated from college
or high school. See the current issue of Centerline for a submission form.
Do you like HII? Do you Tweet? Here’s your invitation to join HII on social media
and engage in the online conversation. Connecting with HII on Facebook, Twitter,
YouTube and Flickr makes it easy to keep up with what’s going on in the company
and share the news, photos and videos that are highlighted on the company social
media pages with your friends and family. Here’s how:
www.facebook.com/HuntingtonIngallsIndustries
www.twitter.com/HIIndustries
www.youtube.com/HuntingtonIngalls
www.flickr.com/huntingtoningalls/
Employees are reminded that taking personal photos at work is prohibited.
On the cover
Tameka Campbell,
shipfitter helper
apprentice, wears new
safety eyewear while
grinding a beam that will
be a part of LPD 26. See
page 14 for a story about
the new safety glasses.
Photo by Lance Davis
On the Web
http://www.huntingtoningalls.com
Stay Connected...
2

Vol. 2, Number 5 • June 2012
LPD 26 mast built
with quality at Gulfport
6 8 14
LPD 22 commissioned
in San Diego
New eyewear keeps
focus on safety
Avondale shipbuilder earns Ingalls Security All Star Award
Security, like safety, is everyone’s responsibility at Ingalls
Shipbuilding.
Mike Madere, LPD Test and Trials superintendent, takes
that responsibility personally. For his outstanding attention to
security, he was recently presented the Ingalls Shipbuilding
Security All Star Award.
“I believe shipyard security, and especially ship security, is
extremely important,” Madere said. “We have government
and classified information onboard the LPD ships, as well as
advanced technology and the instructions on how to operate it,
and all these things require protection and security."
“Mike Madere is very deserving of this recognition,”
Rick Graham, Ingalls Security director, said at a brief award
ceremony at Avondale recently.
The Ingalls Security All Star Award is presented bi-annually to
an Ingalls Shipbuilding employee who contributes significantly
to company security. Employees from Pascagoula, Gulfport
and Avondale can be nominated for this recognition and Ingalls
Security coordinates the evaluation process.
“Significant among Madere’s attributes is his ability to
communicate clearly, openly and accurately,” Graham added.
“He meets potential problems head-on and resolves issues
before they can get out of hand, and that’s a sign of a true
leader.”
According to Graham, Madere voluntarily assumed the
security responsibilities as supervisor for all closed areas and
custodians on the LPD ships at Avondale.
Madere is responsible for assigning custodians to specific
closed areas on the LPD ships and for ensuring compliance
with rules concerning the safeguarding of locks, combinations
and security for these spaces on a round-the-clock basis.
“As a ship superintendent, Madere is very busy with a lot of
responsibilities,” Graham said, “and while this is a collateral
security duty, he obviously places security at the top of his
priority list.”
“Madere is very thorough and responsible,”Darrell Schreiber,
Avondale Industrial Security analyst, said. “His attention to detail,
excellent demeanor and positive attitude were just some of the
attributes that compelled me to nominate him for this award.”
Mike Madere, LPD ship superintendent, Test and Trials (second from
left), receives his Security All Star award certificate from Rick Graham,
director, Ingalls Security. Mark Washington, manager, Avondale Site
Security (left) and Avondale Site Director Lou Hose, also took part in the
presentation ceremony.
Mark Washington, manager, Avondale Site Security, noted
that during Madere’s time in this collateral security position, he
ensured that all documents and material were properly marked,
delivered and stored according to security requirements.
“Madere was also totally prepared for the recent Defense
Security Service inspection at Avondale, and his active
participation in this audit contributed tremendously to the
commendable rating attained by Avondale’s Industrial Security
team,” Washington said.
Avondale Site Director Lou Hose also attended the award
presentation and commended Madere for his contributions to
site and ship security at Avondale.
“Well done, Mike, and many thanks on behalf of all Avondale
shipbuilders,” said Hose.
3

Six Ingalls teams and two individual shipbuilders were honored for their com
As a result of Chris Helton’s efforts, Facilities
has implemented a Storeroom Management
System that has resulted in reduced material
and parts inventory and enabled the Facilities
Planning department to start ”kitting” all
accomplished repair work. He was a key
contributor in streamlining Facility and
Maintenance staff and saving in excess of
$12 million of departmental overhead. He also
played a key role in reducing the company’s
Capital Expenditure Plan by $19.8 million.
Individual award winner:
Chris Helton - Capital budget management
leadership
Doug Blethen used his extensive experience
and leadership skills to build a team that had
the technical skills, stamina and motivation
to make the critical delivery of LPD 22 happen
by the end of calendar year 2011, allowing the
company to meet its financial commitments in
the first year of its existence. Blethen’s team
overcame obstacles such as newly imposed
requirements and higher expectations from
the customer.
Individual award winner:
Doug Blethen - LPD 22 Delivery
Team winners : Foremen’s Notes – Newsletter
Foremen’s Notes is a monthly publication for
craft foremen that was developed to provide
direct and frequent communications to Ingalls’
deckplate leaders. It provides foremen with
specific and timely information on safety
and quality, updates of performance goals,
reminders about commitments and other
useful information. Foremen’s Notes helps
reinforce the relationship between foremen
and craft directors and shows foremen how
much they are valued as leaders.
Team winners : IT Outsourcing Initiative
(top row): Terri Broome, Dannon Butts and Arlene Grimme; (bottom
row): Angie Haynes, Matt Kieper, Ken Miller and Joaquin (Rosco)
Orozco
4
The IT Outsourcing team took on the task
of developing a proposal to replace the IT
infrastructure provided by Northrop Grumman.
They took on the additional task of revamping
the new infrastructure to align Ingalls IT with
industry standards for best practices and levels
of service. The team conducted extensive
research and participated in requirements
development, vendor evaluations, negotiations
and eventually in the selection of an outsourcing
provider.
(top row): Josh Barton, Frank Borden, Don Bourgeois and Greg
Cannella; (bottom row): Terry Creel, Jason Kilpatrick, David Rideout
and Glenn Vuyovich

mitment to excellence at the annual Ingalls President’s Award dinner in May.
While demonstrating the anchor windlass
during LPD 22 Acceptance Trials, the port
anchor chain was riding up and out of the port
wildcat. The day before DEBA trial, it became
apparent that the wildcat had to be replaced
or the ship would not be allowed to leave
port. With only a 21-hour window, this team
ensured a new wildcat was properly installed
and tested, leading to successful LPD 22
Acceptance Trials.
Team winners : Blast and Paint Operations
Optimization - Phase 1
Team winners : 21 Hour Windlass
Capstan Replacement on LPD 22
Team members (left to right): Brian Duhe, Kim Elliott Sr., David
Morano Sr. and David Thibodeaux. Not pictured: Charles Bond,
Donald Bourn and Dale Daunie
The Blast and Paint Optimization team
developed and implemented a new blast
and paint strategy that resulted in improved
environmentally compliant processes,
improved efficiency, lower costs and improved
ship schedules. Because of their efforts, unit
blast and paint processes were streamlined by
50 percent. By maximizing assembly sizes and
standardizing coating operations, this initiative
resulted in estimated ship program savings of
$400,000 for NSC, $500,000 for DDG 51’s and $3.3
million for LPD 17 class ships.
Team members (top row): Gilbert Arceneaux, Glenn Clement
and Alfred (Trip) Maumenee; (bottom row): Brian McVey, Ronald
Romero and Tim Warren
New Hire Assessment and Training
The New Hire Assessment and Training team
developed concrete methods of ascertaining the
skill level of job applicants to ensure the best
candidates were selected for assessment/hiring.
The team made sure skill level assessments
were accurate and that initial training was
conducted to familiarize newly hired personnel
with company policy and manufacturing
procedures, and to ensure that new hires were
capable of performing to expectations.
Rework Reduction Initiative on
LPD 23 & LPD 25
This team led a concerted effort between
Avondale shipbuilders, program management and
craft management that focused on a new rework
reduction initiative that resulted in a 23 percent
reduction in rework man-hours on LPD 23 and a 35
percent reduction in rework man-hours on LPD 25,
as compared to LPD 21. To date, this equates to a
reduction on each hull of 244,000 man-hours and
230,000 manhours, respectively.
Team members (top row): Laverne Burdine, Phil Marr and Tommy
Robison; (bottom row): Darren Haas, Lewis McLeod and Byron
Patton
Team members (top row): Joey Foret, Tommy Hebert and Terry
Knight; (bottom row): Mike Raney, PJ Sprunk and John Winn
5

On Target
Gulfport achieving goals on LPD 26 mast
By Ed Winter
The Gulfport Composite Center of
Excellence continues to make progress
in all of its projects, including the recent
delivery of the composite helicopter hangar
for Zumwalt (DDG 1000) and its ongoing
work on the composite deckhouse for the
first-of-class Navy ship.
But another project has also been
making steady gains at the facility -- the
construction of the two composite masts
for John P. Murtha (LPD 26), the tenth
amphibious transport dock ship Ingalls
Shipbuilding is building for the Navy.
“Our composite crafts people are doing
an outstanding job on the LPD 26 masts,”
said Donny Dorsey, director of Gulfport’s
Structural and Component Fabrication
Assembly Areas (SFA/CFA). “They are
producing a high-quality product while
meeting our cost and schedule targets.”
Dorsey added that one major reason for
the fine performance on this project is that
the mast team has significantly reduced
rework; particularly with the mast’s vertical
infusion process.
“Vertically shooting resin up into the
mast is a more challenging technique than
the flat-panel, horizontal resin infusion,”
Dorsey explained. “It’s a more complicated
procedure requiring a lot of skill. But
despite those challenges, our crafts are
accomplishing vertical infusion with zeropercent
rework.”
According to Dorsey, as a result of
lessons learned on LPD 25’s masts,
especially in the areas of cost and quality,
the overall LPD 26 mast project has
recorded less than one percent of rework.
“This is a significant improvement from
previous LPD masts built at Gulfport,”
Dorsey added.
A. R. Jones, Composite general foreman,
said the LPD 26 mast team takes a lot of
pride in its work and in the improvements
achieved. “The quality improvements
are not only a reflection of our desire to
get better, but also a result of our having
established an environment of teamwork,”
Jones said.
“We have been working on
improving engagement, ownership,
and communication, and that is paying
dividends and helping us get better at what
we do,” Jones continued. “We strongly
believe, as Ingalls President
Irwin F. Edenzon has stated before, that
‘Good Enough Never Is.’”
Gulfport’s composite craft workers
agreed that quality is a top priority.
6
Composite mechanic Tasha Reed works in Gulfport's Bay 3 prepping and cutting the peel-ply cloth
material that will be applied to the mast during the flat panel resin infusion process.
“We want to build the best and we pay
close attention to details and the quality
of our work,” said Tasha Reed Haskin,
Composite mechanic, who has been
working on LPD masts at Gulfport since
2001.
“Delivering on quality is very important
to me because I know when quality is built
into our ships the sailors will be safer and
better able to do their job of defending our
country,” Haskin said.
Samuel Evans, Composite apprentice,
noted that with composite work, especially
with the resin infusion processes, it is very
important to get it right the first time.
“Not only is it difficult to do it over
again,” Evans said, “but it also negatively
affects cost and schedule.”
Evans added that he and his fellow
workers also have a lot of pride in their
craft. “We don’t skip steps, and we do our
best to perform mistake-free work,” he
said. “Producing high quality builds trust
with your customers, and they know they
are getting the best and can depend on
you.”
Another Composite apprentice working
Photo by Steve Blount
on the LPD 26 masts, William Lange, said
quality is a direct product of someone who
cares about their work.
“A person who enjoys his job will try to
do it right the first time and deliver a higherquality
product than someone who just
shows up to collect a paycheck,” Lange
said.
Jasmine Adams, Composite foreman,
has also helped lead the LPD 26 mast
team’s improved performance.
“To me, quality is being accountable
for your work and taking pride in a job
well done,” Adams said. “It’s really what
enables me to sleep well at night, knowing
that I made the choice to do my job with
excellence in mind, because the effects of
poor quality can last long after my ship has
sailed.”
The 30-foot-diameter, 13-foot-tall lower
base unit of the forward mast for LPD 26
is being built in Bay 3. It will be joined to
five other composite mast components to
complete the ship’s forward mast that will
eventually measure over 36 feet tall and
weigh more than 26 tons.

Special
Olympics
Story and photos by Michael Duhe
More than 125 Ingalls shipbuilders and their
family members volunteered for the Mississippi
Special Olympics State Summer Games at Keesler
AFB on May 12.
“I can’t say enough about the volunteers….
they are awesome,” said Robin Poppenhouse,
who organized the Ingalls volunteer effort. “We
started out with a large tent a couple of chairs
and tables and we turned it into a carnival of fun.
Although it was a lot of work, it was gratifying.
It’s overwhelming to see our employees from all
different departments come together as one.”
In addition to providing volunteers for the day
of fun, Ingalls also donated $5,000 to Mississippi
Special Olympics.
“We were there for the athletes and did
whatever it took to ensure they had a good time,”
Poppenhouse said. “It was a very successful
event.”
Gavin Tanner, son of Lee Tanner, carpenter foreman, volunteered for the
water balloon toss booth.
Dave Morong, outside machinist, congratulates a Special
Olympic athlete in the Velcro ball toss booth.
Lillian Noble of Finance looks on as a Special
Olympian enjoys the baseball bean bag toss.
From left, Ingalls’ Kevin Amis, vice president of Operations, Robin
Poppenhouse, administration generalist and Dorothy Shaw, manager of
Community Relations present a check to Helen Parish, president and CEO
of Mississippi Special Olympics.
7

Home Port
San Diego enjoys a unique relationship with the Navy and Marine Corps. It is home to the Pacific
Fleet, the 1st Marine Expeditionary Force and the Amphibious Ready Groups lead by USS Essex
(LHD 2), USS Boxer (LHD 4) and USS Makin Island (LHD 8). USS San Diego (LPD 22) joined
that lineup May 19 when she was commissioned in her namesake city.
Story and photos by Lance Davis
San Diego is steeped in Navy tradition nation’s largest Navy base and largest
and history.
Marine Corps expeditionary training center
No matter where you go in “America’s became home to the fourth ship to bear the
Finest City,” there is a reminder that you are name San Diego.
in a military town.
When LPD 22 was commissioned at
The boardwalk along San Diego bay the Navy Pier in front of more than 6,000
comes to mind. There you will find the spectators, it became the first USS San
aircraft carrier-turned-museum USS Diego in Navy history to be stationed in its
Midway, the Bob Hope memorial, the namesake city.
Unconditional Surrender statue — a 25- “As such, I’m sure the city of San Diego,
foot tall recreation of the famous smooch as will every Ingalls shipbuilder, follow the
shared by a Sailor and a nurse in Times USS San Diego as she makes history in
Square at the end of World War II, the defending our nation and protecting our
Aircraft Carrier Memorial; a monument to national interests,” said Ingalls Shipbuilding
the Battle of Leyte Gulf and the USS San President Irwin F. Edenzon during the
Diego (CL 53) Memorial.
commissioning ceremony.
CL 53, a anti-aircraft light cruiser, served USS San Diego is the sixth LPD 17 class
in the Pacific Theater during WWII. She ship Ingalls has delivered to the Navy. Its
earned 18 battle stars during 13 major primary mission is to deploy combat and
engages, was the first ship to enter Tokyo support elements of Marine Expeditionary
Bay and never lost a single sailor to enemy Units and Brigades using air cushion or
fire.
conventional landing craft. The ship can
CL 53 was the second ship named for also support helicopters and the MV-22
San Diego. The third, AFS-6, was a Mars Osprey.
class combat stores ship that served with Now that she is a member of the
the Sixth Fleet from 1969 to 1993.
fleet, San Diego and her crew will ready
On May 19, the city that is home to the Photo by themselves Michael for Duhe the rigorous tasks the ship
8
was built for.
“Take a good look at this ship because
she will be very busy,” said Adm. Mark
Ferguson, vice chief of naval operations.
“Her time will be consumed fulfilling
the tenets of our Navy. She will focus on
warfighting, she will operate forward and
she will spend her time being ready.”
This is the mandate that every ship built
at Ingalls must assume. Knowing the ships
they build can be sent into harm’s way at
any moment motivates every shipbuilder
in Pascagoula, Gulfport and Avondale to do
the best job they can to produce a quality
ship for our nation.
When USS San Diego left Pascagoula
earlier this year, she was hailed as one of
the best ships in the LPD 17 class.
Doug Blethen, who served as the ship’s
construction manager, saw the signs early
in the ship’s life; and when the crew began
moving aboard, he knew this ship would be
in good hands.
“Every ship has a personality, and that
has a lot to do with the crew. You could tell
when they came aboard. They immediately
took ownership of San Diego. This ship and

Left: People began arriving at San Diego’s Navy
Pier early in the morning for USS San Diego’s
commissioning. More than 6,000 people came
to witness the ship officially begin its Navy
service.
Above: Kari Wilkinson, ship program manager
for LPD 22 and LPD 24, left, and Doug Blethen,
ship construction manager for LPD 22, present
the ship’s plaque on behalf of Ingalls Shipbuilding
to Cmdr. Kevin P. Meyers, acting captain of
USS San Diego (LPD 22).
Right: Meyers, right, salutes Adm. Mark E.
Ferguson, vice chief of naval operations, as he
assumes command of USS San Diego.
Below: Members of the ship’s crew man the
rails as the commissioning ceremony comes to
a close.
crew will do great things,” said Blethen,
who was awarded the Ingalls President's
Award for Excellence for playing a critical
role in ensuring the ship was delivered to
the Navy on time.
Blethen and Kari Wilkinson, ship
program manager for LPD 22 and
currently ship program manager for LPD
24, attended the commissioning in San
Diego on behalf of the thousands of men
and women who worked on USS San
Diego.
During the Chairman’s Reception the
night before, they presented Cmdr. Kevin
P. Meyers, acting captain of LPD 22, with a
the ship’s quarterdeck plaque from Ingalls.
“When I was growing up, I had no idea
I’d be a shipbuilder, or how important
it would become to me," Wilkinson
said during the presentation. "There
are better than 10,000 shipbuilders
back home on the Gulf Coast. It is on
behalf of all those shipbuilders who
put their hearts and souls into this ship
that we are here. Know that wherever
you go, the spirit and tenacity of those
shipbuilders goes with you.”
9

Peripheral vision: PVLS welding shines
By Shane Scara
Maximizing crew safety and ship
survivability is the ultimate mission of
Ingalls Shipbuilding and all producers of
U.S. Navy vessels.
One important measure engineers took
when designing the Zumwalt (DDG 1000)
class was to divide the missile launching
system around the ship’s outer hull.
Known as the peripheral vertical launch
system (PVLS), this first-of-its-kind
design makes launchers and missiles
resistant to battle damage while safely
isolating them from crew and equipment
spaces.
“If one of the missile chambers takes
a direct hit during a battle, the ship can
still deliver a strike with the remaining
launchers,” said John Broderick, Ingalls
Aft PVLS program manager. “More
importantly, the ship and crew will be
protected from harm.”
Broderick said the chambers housing
the missiles must be very strong, so the
job was placed in the skilled hands of
Ingalls Shipbuilding welders.
Ingalls delivered the final Aft PVLS units
for Zumwalt (DDG 1000) on Feb. 17 and is
scheduled to deliver two of the four units
for the Michael Monsoor (DDG 1001) this
summer. Contracts for future PVLS work
are also expected.
“These unique units are unlike anything
we’ve done in the past,” said Tommy
Brooks, director of Unit Construction and
Outfitting. “We’re dealing with very thick,
high-yield and high-strength-low-alloy
steel up to four inches thick, and the pulse
arc welding process required is very
challenging.”
To accomplish the mission,
Brooks asked Robbie Gardner, Hull
superintendent, and Neil Holden, Hull
general foreman, to find the best welders
who were capable of the difficult process.
They narrowed the field to a shock troop
of about 20 welders under welding
foremen Ernest Wilson and Reuben
McCon
Gardner says pulse arc is a low heat,
low penetration process necessary to
stop cracks from spreading and prevent
fissures in the weld. The welders must
constantly monitor their process and all
of their work is ultrasonically tested.
“The fitters and welders on this are
expert craftsmen well versed in the heat
requirements and very knowledgeable
of the specifications required for what
we do,” Gardner said. “They have some
outstanding excellent craftsmanship, and
our ultrasonic test findings rate was well
below our bid.”
Broderick added that the DDG
10
James Reed welds DDG 1000's Peripheral Vertical Launch System.
“These unique units are
unlike anything we’ve
done in the past.”
Tommy Brooks
1000-class inspections are the most
stringent of any U.S. Navy ship units.
“The 100 percent inspection of the
PVLS is four times greater than on the
DDG 51 class,” Broderick said.
“Compared to other ships, the low
rework rate is a tremendous testimony
to the quality performance by welders
and fitters. The Alignment and Non-
Destructive Test teams have also done an
outstanding job to ensure these units will
align well with the ship.”
Quality is on the minds of every PVLS
welder, like Antonio Mims, a 37-year
shipbuilder.
“To do a quality job, I have to prepare
my mind before I come to work,” Mims
said. “When I get on my job and discover
a problem, I correct it before I get
started.”
Stephen Lyon, a 14-year welder, says
it’s a matter of pride. “If you’re not going
to take pride in it, then you don’t need to
be on this job,” said Lyon. “If it’s not right,
it has to be cut out and you have to do it
over again.”
Holden says the quality demanded is
right on target, and the team continues
to improve cost
and schedule
performance.
“Lessons learned
have narrowed down
needed changes from
hull 1 to hull 2,” said
Holden. “We have
minimized overhead
welding and we’re
finding even greater
areas for improvement.”
Photo by Steve Blount
Lyon
The environment inside the units is
brutal. To prevent pores from forming
in the weld, air flow must be restricted.
During the summer months things get
hot.
“I fall back on my experience and what
I learn in Take Five safety briefs to stay
safe,” said 36-year welder James Reed.
“I stay well hydrated so the heat doesn’t
get to me. If it ain’t safe, it ain’t worth it.”

SPaM … it’s a good thing
By Leslie Mitchell-Gallop
Spam; it’s not just that mysterious lunch
meat anymore.
At AMSEC it’s a team of trained and
qualified shipbuilders delivering quality
customer support to the U.S. Navy Surface
Force Atlantic.
SPaM, or the Surface Proactive
Maintenance team, consists of Dennis
Plank, Tom Hubert and John Galle. Located
in Virginia Beach, Va., they are part of the
Naval Surface Force Support division
managed by Bob Perry.
The SPaM team uses proven
techniques – known as Reliability Centered
Maintenance (RCM) – and processes to
analyze and solve problems involving
electronic and Hull, Mechanical and
Electrical systems.
Originally developed as a maintenance
philosophy for the airline industry, it has
been applied to military and commercial
industrial arenas as well. The process is
designed to identify problems and root
causes that lead to functional failures,
re-engineer the maintenance strategy to
combat those problem areas and identify
and implement solutions.
The result is improved operational
availability at a lower cost.
The analysis is documented in a report
that chronicles the steps of the process, the
findings, solutions and implementation –
including measures of effectiveness and
return on investment.
The SPaM team also performs case
studies and root cause failure analyses
that identify causal factors of failures
for specific components in a system
or a specific failure mode. Each study
includes recommendations for improving
maintenance strategies, maintenance and
operating procedures, training, system
AMSEC “SPaMmers” are, from left, Tom Hubert, Dennis Plank and John Galle.
design and Integrated logistics support to
eliminate the causes of failure.
In one recent case, the SPaM team
provided recommendations to correct fire
pump failures on a ship class.
The SPaM team compared maintenance
data and other factors for the fire pumps
on several ship classes to see what the
maintenance and operating strategies
were and failure frequency for each of the
pump types, according to Galle. They also
found a NAVSEA study done in 1990s that
discussed the same problem.
Using their proven techniques, the
SPaM team recommended changes to
operating procedures, maintenance and
a possible alteration to monitor problem
pumps.
The Navy deemed the work of the SPaM
team “exceptional,” according to Galle.
The SPaM team has completed more
than 50 studies since 1996 for the Navy
and the Coast Guard on existing systems
and systems in design.
“I think the SPaM Team is successful
because we come across as an ‘honest
broker,’” Galle said. “We do not have an
inside agenda, nor do we misinterpret data
to fit agendas. Instead, we let the RCM
process and impartial data analysis drive
the identification of failures and solutions.
We want the right answer.”
New group exercise classes at FitCenter turn up the fun
By Michael Duhe
New group exercise classes now available at the FitCenter offer a
wide variety of fitness and fun.
The classes and times are:
Boot Camp – Anything goes during this hour of high-intensity
cardio, strength training and fun; 3:45 p.m. on Tuesdays and
Thursdays.
Fab Abs – Kick your core into gear with this all out 15-minute abs
blast; noon on Tuesdays and Thursdays.
KickFit – This high-energy mix of kicks and punches combines
martial arts, boxing and cardiovascular exercises; 3:45 p.m. on
Mondays and Wednesdays.
PiYo – <strong>Focus</strong>es on total-body conditioning and flexibility with a
mix of Pilates exercises and Yoga poses, with the primary focus on
the core muscles group; 4:30 p.m. on Tuesdays and Thursdays.
Zumba – Combines high-energy, captivating music with Latin
inspired moves that will leave you asking for more; 4:30 p.m. on
Mondays and Wednesdays.
“Our focus is to have a group exercise program that implements
the various components of fitness,” explained Joni Goodman,
HealthWaves program manager. “Zumba is a great cardiovascular
workout; Boot Camp and KickFit offers both cardiovascular
and strength conditioning; and PiYo addresses the flexibility
component of fitness in addition to excellent core training.”
An Open House at the Fit Center will be held in late June, with
the exact date to be published in Centerline, according to Melissa
Schnoor, HealthWaves senior wellness coordinator.
“Not only will guests be able to experience the various group
exercise classes, racquetball courts, cardiovascular/strength
equipment and friendly, experienced staff that the FitCenter offers,
but we will be introducing the new programs available here,”
Schnoor said. “Our goal is to have Ingalls employees see that the
benefit of the FitCenter is well worth the drive over the causeway.
There will be games, prizes and refreshments and, as always, a fun
time.”
To join the FitCenter, call (228) 935-3486.
11

Anchor(age) Away
LPD 23, the second amphibious ship named after the Alaskan city,
successfully sails through builders trials and moves toward acceptance
Editors Note: Shane Scara, Ingalls
Shipbuilding communications
representative, traveled aboard Anchorage
(LPD 23) during builder’s sea trials. The
former U.S. Marine has seen shipboard
duty before, but this is his first builder’s
trials for Ingalls Shipbuilding.
Anchorage (LPD 23) and her crew of
Avondale shipbuilders had a lot to live
up to as they piloted the seventh Ingallsbuilt
landing platform dock ship through
builder’s trials in May.
USS New York (LPD 21) set the standard
for how the ships perform on trials, and
USS San Diego (LPD 22) raised that
expectation with the Navy.
“There was a lot riding on this,
and Anchorage excelled,” said Doug
Lounsberry, vice president and LPD 17
program manager. “Operationally, LPD
23 is a much better ship than LPD 22; and
22 was a huge success. From a trial card
perspective, we had 14,000 to 15,000 trial
cards on LPD 22, which is about the norm.
On Anchorage, we had 8,000 – virtually half
– and they were fit-and-finish type things.
There were no showstoppers.”
The ship began its four-day voyage on
May 14 as it navigated the Mississippi River
past New Orleans and into the Gulf, where
trials began.
“Once we clear the sea buoy, we are
chock-a-block full of tests,” said John
Lindgren, director of Test Engineering.
“There may be as many as a dozen tests
going on at one time. So it’s non-stop 24/7,
and everybody’s scrambling.”
Lindgren pointed out that the keys
to success are five major tests, ballast/
deballast, anchor handling, detect to
engage weapons, full power propulsion
and steering.
According to Robert Hayes, LPD 23 ship
construction manager, builder’s trials gives
Ingalls a chance to shake down the ship’s
systems before undergoing the final test on
U.S. Navy acceptance trials.
“Shipbuilders at Avondale and across the
company built LPD 23 with a lot of pride,”
said Hayes. “This is one of the least costly
and most complete LPD ships to date. Now
it’s time for Anchorage to prove she can do
what she’s built for.”
One of the first tests was the aqueous
film forming foam (AFFF) system. The
Damage Control Team (DCT), a select
group of shipbuilders from different crafts
who are trained to protect the ship and her
crew from fires and floods, conducted the
test.
“In port the company has a fire
department at all three yards,” said
Russ Loyd, test engineer and DCT lead.
“When we come out here, we are the fire
department.”
A thick, white foam covered the entire
flight deck as if a snowstorm had hit the
ship. Loyd said AFFF robs fuel based fires
of oxygen and fuel vapors. The system is
conveniently located everywhere a fuel fire
might occur, including the flight deck, the
vehicle stowage and engine rooms.
The function of the AFFF, plumbing
systems, and fuel and oil systems rely on
the skilled craftsmen and women from the
Pipe Department. Riding aboard LPD 23
on the trial were 16 pipe personnel ready
Anchorage (LPD 23) sails past downtown New Orleans as
she heads down the Mississippi River to the Gulf of Mexico
to begin builders trials.
Photo by Steve Blount
12

to fix any leaks at the direction of their Pipe
general superintendent O.L. Wally and Pipe
general foreman Roy Stewart Jr.
“We’ve seen very few issues on this
trial,” said Stewart. “Our team comes to
work every day focused on quality and it
shows.”
Next came anchor handling. With a
deft swing of a sledge, rigger Oliver Gill
released the pelican clamp from the chain,
allowing one of the seven ton anchors and
the huge chain to slide forward. Sparks
literally flew from the chain as it gathered
speed until a quick turn of the brake wheel
stopped it with a loud clang that echoed
across the deck of the ship. Around 10:30
p.m. shipbuilders gathered to witness what
makes LPDs capable of sending Marines
ashore – ballasting, deballasting and the
flooding of the well-deck.
The next morning, shipbuilders prepared
for the full propulsion run.
“Big Randy” Edwards visited main
machinery room 1 where test operators
and craftsmen were checking the oil and
grooming the engines for the test. Edwards
oversaw the construction of these spaces.
“It means a lot from a construction
perspective to take your guys from the
deckplate to hearing the roar of the engines
at full speed ahead,” said Edwards. “It’s
a thrill for the electricians, machinists,
pipefitters and painters to know they
worked on something that is now sailing
across the Gulf of Mexico.”
The engines surged with the power
of more than 40,000 horses as LPD 23
steamed forward at full speed. Instantly the
ship stopped and reversed as the pitch of
the propeller blades rapidly changed with
the pull of a throttle.
Avondale shipbuilders lined the levee and
cheered as LPD 23 returned dockside. The
proud shipbuilders must now prepare her
for U.S. Navy acceptance trials.
“It took the dedication of hundreds
of shipbuilders to get to this point, and
they went above and beyond to ensure
Anchorage met systems capabilities
and functionality,” said Bruce Knowles,
LPD 23 program manger, “Rework
reduction efforts at every level kept
costs low, and the quality shows in her
performance at sea.”
A slideshow of Anchorage builder’s
trials can be found at:
ingalls.huntingtoningalls.com/events.
Above: Damange Control
Team members Nicholas
McAlpin, Chris Babineaux
and Larry Alexander test a
fire main on LPD 23’s flight
deck. Top right: Crane Rigger
Ray Derouen stirs a kettle
of rice in the ship’s galley.
Craft workers are regularly
tapped to serve as stewards
aboard ships during builder’s
and acceptance trials.
Right: Avondale electrician
Demarcus Wells, a member
of the Damage Control Team,
carries supplies from a
helicopter landing on the LPD
23 flight deck.
13

New eyewear keeps focus on safety
By Michael Duhe
Ingalls has seen a drastic drop in eye injuries thanks to a
unique type of safety eyewear.
From Jan. 1 to April 22, 2010, Ingalls recorded 222 on-thejob
eye injuries. The Safety Department focused on reducing
this number. Tim Hammerstone, who was then Gulf Coast
safety and health manager, encouraged his department
to look for other types of eye protection, according to
Joaquin “Rosco” Orozco, safety engineer. Orozco contacted
Honeywell, the maker of the Uvex Seismic model, and
purchased a shipment of the eyewear later that year.
“We knew that the Electrical Department was having the
most eye injuries, so we provided more than 100 pairs to
them,” Orozco said. “They were our pilot
group. We realized a significant reduction
in eye injuries in that department once the
electricians began wearing them, especially
with certain tasks, such as overhead work.”
“We saw some improvement in the
numbers, then we started issuing them to
workers who had experienced eye injuries,”
14
McCray
said Cecil McCray, manufactory analyst
3, Electrical Department. “All total, we’ve
issued about 125 pairs.”
In late 2010, the Safety Department began providing the
Uvex Seismic eyewear to other departments, such as Hull.
“We began using the Uvex glasses because of the number
of eye injuries that we were having in all of our departments,”
explained Phil Marr, administration manager 3 (shipfitting
general superintendent) for the Hull Department. “We started
with the grinders, who were having the most eye injuries
within the department.
The Safety Department also issued the glasses to
shipbuilders in other crafts who had experienced an eye injury.
The overall statistics have been eye opening. From Jan. 1-April
22, 2012, the number of recorded eye injuries dropped to 66,
a decrease of approximately 70 percent in nearly three years,
Orozco said. Recordable eye injuries have been reduced as well.
The design of the Uvex glasses has received rave reviews
By Michael Duhe
With the coming of the summer months,
shipbuilders are faced with the challenge
of heat-related injuries and incidents in the
shipyard.
Each year, Ingalls launches a Heat Stress
Awareness campaign to keep that threat
of heat injuries at the forefront. This year,
the campaign began May 7, as Safety
Department and Operations personnel
handed out Heat Stress pamphlets
at various gates in the shipyard. The
pamphlet offers information on heat stress
prevention, warning signs and treatment.
“It’s also crucial that we look out for one
another in this high-threat environment,”
said David Glynn, director of Environmental
Health & Safety. “Shipbuilders should be
aware not only their surroundings, but their
fellow shipbuilders. If you suspect a coworker
is showing signs of heat stress, take
immediate action.”
Glynn said he encourages shipbuilders
to educate themselves on the symptoms of
heat stress so that you can recognize it, and
know what to do about it. The pamphlet is a
good source of information.
Although safety is our top priority in the
shipyard, by no means does it stop at the
gate, Glynn added. The risk of injury during
summer is also high at home or while
enjoying summer activities, from grilling on
weekends, to water sports, to cleaning out
the rain gutters on the house. “Always wear
proper safety gear when accomplishing
tasks at home, such as safety glasses when
using a weed trimmer,” Glynn advised.
“Stay hydrated at work or play, especially
if you’re out in the sun for long periods of
time. If your vacation plans involve a long
Kenneth Knowles, electrical combination,
wears Uvex safety glasses while installing
wireways and routes cable in the LHA 6
radar room.
Photo by Michael Duhe
at Pascagoula.
“The glasses have great coverage,” Orozco said. “They
keep inadvertent particles out of your eyes and they generally
don’t fog up, either. The straps are good for overhead work,
too, because it keeps the glasses in place.”
“It’s a good product,” McCray commented. “We have
demonstrated that it works.”
“I think they are a great improvement over our regular
safety glasses because of the foam around the inside of the
glasses,” Marr said. “This closes the area between your
skin below the rim of the glasses to prevent particles from
entering the eye.
“I believe that new products like these glasses and the
research that the Safety Department is performing will help
with reducing the injury rates for all departments in the
shipyard over the next few years,” Marr added.
Stay cool: Heat Stress Awareness campaign kicks off
road trip, avoid departing at the end of
a work day. Wear your seatbelt and take
frequent breaks to stretch your legs and
avoid getting sleepy behind the wheel.”
Ingalls’ overall safety numbers are
showing a positive trend, according to
Glynn. “Compared to this time last year,
we’ve reduced our Lost Time Case Rate
by 31 percent; reduced the Total Case Rate
by 6.4 percent; and reduced the number
of days lost due to an industrial injury by
32.5 percent,” he said. “Also, the number of
employees with two injuries has dropped
by 67 percent, while the number of
employees with three or more injuries has
been reduced by 57 percent.
“These numbers show that we’re making
solid progress, but we must remain vigilant
and committed to our top priority, safety,”
he added.

Long Service
June
MASTER SHIPBUILDERS
Mallory Clark
40 years
Edward Clements
40 years
Albert Cole, Jr.
40 years
Richard Olsen
40 years
William Parker
40 years
George Ray
40 years
Heber Robertson, Jr.
40 years
Eric Weeks
40 years
40 years
Mallory Clark
Edward Clements
Albert Cole, Jr.
William Fairley
Gwendowlyn Fairman
Wyman Harrell
Thomas Hudson
Richard Olsen
William Parker
George Ray
Heber Robertson, Jr.
Eric Weeks
Alton Williams
35 years
Judy Applegate
Dembray Archie
Paul Becton
Gerald Bosarge
Louis Buras III
Carl Comer
Jack Daniels, Jr.
Bobby Dudeck
Allen Fairley
Curtis Hill
Eric Holmquist
Thomas Page
Gary Randall
Terry Robbins
Troy Smith
Brenda Straight
David Utz
Thomas Woods
30 years
Richard Barlow
Tracy Box
Terry Buckley
Kevin Eck, AMSEC
Jack Harrell III
Joseph James, Jr.
Steven Pierce
Gerard Plahn,
AMSEC
25 years
Robert Ardoin
Justin Lovorn, Jr.
Vien Luong
Darryl Pennex
Leslie Saxon
Randy Walker
20 years
Roger Adams, AMSEC
Michael Chandler, AMSEC
Robert Grout
Larry Hunley, CMSD
David Kopelman, Jr.
Michael Mitchell III
Andrew Nguyen
Roberto Pavia
Phillip Woods
15 years
Arluster Burks
Hilary Campbell
Sampson Creer
Broderick Dedeaux
Ruth Eurystthee
Edgardo Favela, CMSD
Devallan Hawkins
Stephanie Hebert
Jeremy Huntley
Ida Joseph
Anthony Kneale
Lionel Knox
Janice Louis
Thomas Lundy
Reuben McCon
Herman Mitchell, Jr
Darrell Necaise
Brian Roberts
Clifton Rogers
Jennifer Ross
Gary Spring
Kristopher Stewart
Matthew Tayloe
Milton Travis
Robert Tyson, Jr.
Sharon Walker
Pamela Webre
John White
Bobby Williams
Casey York
10 years
Jonathan Aguilar
Victor Alao
Joshua Alford
Patricia Cameron
Leap Chea
David Criddle
Kim Elliott, Jr.
Samuel Fitts
Roscoe Fletcher
Alan Gay
Joshua Hammond
Leon Harry
Brandon Hattox
Thanh Huynh
Karl Jahn Jr., AMSEC
Catherine Key
Jesse Leboeuf
Bryan Manson
Edward Marsh
April McGinley, CMSD
Dejuan Miller
Carlos Moya
Leon Nelson
Prentiss Nelson, Jr.
Marino Niccolai
Kenneth Parker
David Pierovich, CMSD
John Preisel
Walter Ross III
Shunn Sanders
Ronald Skelton
Timothy Stover, AMSEC
Charles Stringfellow
Jessie Thigpen
Penny Thompson, AMSEC
Matthew Thornton
Spencer Tillman
Minh Tran
Jose Zepeda, CMSD
WHERE ARE THEY NOW?
An MH-60S Sea Hawk helicopter delivers cargo to the Ingalls-built amphibious assault ship USS Makin Island (LHD 8) during
a replenishment at sea with the Military Sealift Command fleet replenishment oiler USNS Patuxent (T-AO 201), which was
built at Avondale. (U.S. Navy photo by Mass Communication Specialist 2nd Class Dominique Pineiro)
15

1000 Jerry St Pé Hwy
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Vol. 2, Number 5 • June 2012
INGALLS SHIPBUILDING