JUL - Bath Iron Works

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PVLS Facility Now On Line in Building 18 Press Operator Todd Wright (D07) with the restored Clearing Press. Aric Gott is the 2nd shift operator. Building 18, located south of the Machine Shop, was almost left without a tenant as many production support services migrated to the south yard in support of Land Level Transfer Facility activities. Instead, it became the site of some of the company’s newest pieces of equipment and the proving ground for some innovative cost-cutting activities associated with DDG 1000 construction. Building 18 and the adjoining, former Main Engine Reduction Gear (MERG) building now house the DDG 1000 peripheral vertical launch system (PVLS) production process. DDG 1000’s PVLS replaces the traditional VLS configuration of centralized missile magazines and distributes the missile launchers along the ship’s hull. In planning for DDG 1000 construction, it was recognized that PVLS represents a complex manufacturing activity. To perform the work as efficiently as possible, the process required simplification and streamlining which in turn meant some new equipment, more space and a better physical layout. Facilities, working closely with production and planning, took the lead and conducted a series of benchmarking trips. The process dictated three major components—either purchased steel plates or the capability to mill on site, a press for straightening steel if onsite milling was to be used, and a welding machine. Only the latter already existed at BIW. In August 2007, it was decided to obtain a machine capable of milling PVLS plates and a vendor, Ingersoll of Rockford, Illinois, was selected. With a 16-month lead time, Facilities began planning for the facility to house this equipment. While Building 18 was available, it was not initially well suited to the task. Existing activity in the MERG building was moved out to make that floor space available. Then the roof of the East Bay of Building 18 was raised 22-feet to accept the welding machine which would be moved from the Aluminum Shop and to house a 1,500-ton press. A 3-foot deep fortified pit was created in the ground to support press installation. The process flow was laid out and building renovations included paint and lighting to bring it to what we identify in-house as “Ultra Hall” standards. Meanwhile, the search continued for a press capable of straightening the steel that is naturally curved by the milling process. Using the services of used machinery brokers, a number of candidates were viewed in various locations across the country. Don Bernier (D20) said, “We kept going back to a press in a Lansing, Michigan warehouse which was built in 1952 by a company named Clearing and still had a U.S. Navy asset tag on it—we don’t know why unless maybe it was at one time connected with the Great Lakes Naval Facility.” He continued, “What sold us in favor of this former Performance Incentive Three data points per hull are shown in the Performance Incentive chart: Cumulative Performance to Date (solid column); Future Performance Required to Achieve Level 1 Goal (blue bar); and Future Performance Required to Achieve Level 2 Goal (black bar). Performance Required values change month to month to reflect performance during the period. Performance incentives are paid to all eligible employees at sailaway. These planned dates are shown to the right. Payout amounts for all hulls can be found in BIW Bulletin 09-07A, available on the BIW Intranet. Contact your supervisor for more information. JULY 12, 2009 Cost Performance Index 150.0% 125.0% 100.0% 75.0% * * 50.0% Wayne E. Meyer Jason Dunham Spruance Michael Murphy Hull 503 Hull 504 Hull 505 Hull 506 SAILAWAY — Aug ’09 May ’10 Dec ’10 Feb ’11 Cumulative Performance — Lev 1 Future Perf Req’d— Lev 2 Future Perf Req’d Performance Required value exceeds the scale of the chart. * 6 | July 2009 | BIW NEWS
Navy asset was its simplicity, capacity and durability. It was not a particularly fast machine, but in this case, we didn’t need fast.” It did need a face-lift and was shipped off to Plant Engineering in Fort Wayne, Indiana for restoration. The press had one last, where’s Waldo-kind of road trip to Maine. In late 2008 it was loaded onto a 120-foot tractor trailer to distribute the weight and hauled east, traveling only in daylight under vehicle and sometimes police escorts. The combination of short days, two major storms in New England and holidays, plus one full week of downtime in New Hampshire finally resulted in delivery and installation on New Year’s Eve, 2008. From that point, building work led by Kevin Flanagan (D20), construction building manager, continued concurrently with interior installation. Heavy duty conveyors were built by Machinery Services Company of Wiscasset, Maine to support the press on two sides and also form a bridge to move steel between the mill and the press. The output of this area is the finished steel shapes which are created by the ESAB (brand name) welding machine which was moved from the Aluminum Shop to take its place in the floor plan. Rigorous planning preceded this last move and dictated a weekend move. The optimized PVLS fabrication process is now operational with additional projects being worked to further enhance capabilities. Many visitors have walked through this facility in recent weeks, including Dave Heebner, GD Marine President, in mid-July. He carefully studied what was explained and shown to him, and said, “Good job, all.” The Ingersoll milling machine is shown with George Feliciano (D20) and Mill Operator, Allan Winchenbach (D07). Other operators are Gary Blais (D07) and William Bean (D07). 5 Star Compliance The 5-Star Compliance Program includes compliance training, correction, and ongoing oversight designed to improve our regulatory compliance and ensure everyone’s safety on the job. The goal for each work area, noted on the left side of the chart, is to earn and maintain certification in all five categories shown at the top. Status is reported by colored symbols as explained in the legend. An area may be in compliance (green), involved in the assessment process (yellow), preparing for assessment (gray), or it may have failed to maintain its certification (red). JULY 27, 2009 LLTF/Hyde South ABC Plat H 503 (DDG 108) H 504 (DDG 109) Rigging/Carpenter/South Hyde Shops P0II/Ultra hall EBMF Hardings ACE/CW Bath Warehouses Blast I, II, III Aluminum Shop Assembly Building Panel Line 5-Skids Machine/Intake-Uptake/Strut shops Facilities Electrical Machine Guarding Fall Protection Fire, Health, Safety Housekeeping Compliant Engaged in Assessment Preparing for Assessment Lost Star BIW NEWS | July 2009 | 7
Page 1 and 2: BIW NEWS July 2009 Ultra 2000 Move
Page 3 and 4: Performance June 2009 RECORDABLE IN
Page 5: Wellness and Benefits Retirement Wh
Page 9 and 10: New EDP Class Announced In mid-July
Page 11 and 12: BIW Trekkers for Healthy Lungs The

JUL - Bath Iron Works

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