May - Bath Iron Works

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BIW-Trained Black BeltsBIW employees who recently completed onsite LSS Black Belt training include, l to r: Chris Barbor, Nannette Reed, Melissa Ouellette, Deb Augustine,Chris Ouellette, Mandy Heatley, Susan Sarber and Chris Teel. Tip Koehler was not available for the photo.BIW’s continuous improvementapproach requires that a numberof individuals within thecompany be trained and certified inLean Six Sigma (LSS) methodology.Those who have completed initialtraining are certified as Yellow or GreenBelts and BIW is fortunate to have alarge number of these people throughoutthe organization.However, an advanced level ofcertification is also available and theseindividuals—Black Belts—can bedeployed to lead large projects, towork with any area of the company todevelop lean initiatives, and to inspireand apply a lean approach to everyaspect of our business.Yellow and Green Belt training isheld at BIW, but until this year, BlackBelt training required BIW students totravel to either Norfolk to attend theNAVSEA Lean Six Sigma College orto Electric Boat in Groton to attendtheir program.To date, ten BIW people havereceived Black Belt certification by oneof these routes, including Paul Farrin(D10), Gerri Redmond (D0140) andScott Smith (D84) in 2006; BernieSibley (D10) and Luke Lyndaker (D40)in 2007; Bonnie Blanch (D87), MattBoyle (D10), Kim Goodspeed (D86)and Cary Hirnak (D40) in 2008; andCameron Shuck (D40) in 2010.In addition, Tom Bogucki and JerryGiordano (both D10) and Eric Kruger(D24) came to BIW with Lean BlackBelt certification. Jerry also wrote theAmerican Society of Quality (ASQ) certificationexam.With a number of interested and motivatedGreen Belts working towards thishigher level of certification, BIW needed todevelop a more cost-effective way to supporttheir efforts.In December 2010, BIW’s Trainingdepartment announced an onsite BlackBelt program. Gerri Redmond coordinatedthe effort which required modifying theNAVSEA lessons provided by SupShip,Bath; detailed reviews of homework andclassroom assignments; and creation of adatabase of questions to develop weeklyquizzes, review questions, and the finalexam. In addition to Gerri, instructorsincluded Matt Boyle, Bonnie Blanch, BobCameron (SupShip Bath), Paul Farrin,Jerry Giordano, Luke Lyndaker, CameronShuck and Scott Smith.The pilot program consisted of threeweeks of rigorous, full-time study as wellas homework and a comprehensive 4-hourexam. The first class of BIW-trainedstudents includes Deborah Augustine(D86), Chris Barbor (D28), Mandy Heatley(D10), Tip Koehler (D06), Chris Ouellette(D40), Melissa Ouellette (24), NannetteReed (D87), Susan Sarber (D08) and ChrisTeel (D24).However, the commitment and learningof these individuals does not end here.To receive Black Belt certification, withinone year each student must complete twoRapid Improvement Events (RIE) andone major project (DMAIC), all withexpectations for significant cost avoidance.Successful completion of the ASQ certificationexam is elective but strongly encouragedas it bestows international certification.On May 13, BIW’s first group of studentsto complete onsite Black Belt training metwith Jeff Geiger and his staff and receiveda certificate of completion.Gerri Redmond, program coordinator,said, “The Lean Six Sigma (LSS) programprovides a structured methodology andtool set to improve both production andbusiness processes. The primary role ofa Black Belt is that of a change agent tohelp process owners and subject matterexperts improve their processes by firstunderstanding their customer’s requirements.Black Belts provide and teachthe improvement methods while teammembers are responsible for sustainingthe process improvements.”Gerri continued, “The purpose of LSSis to identify and remove process waste toreduce cycle time and costs. While initialreductions tend to be cost avoidance, weknow that with diligence, cost avoidancewill become hard dollar savings.”She concluded, “The ability to provideBlack Belt training at BIW makes it easierfor our students to advance to this level ofLSS leadership and strongly supports thecompany’s efforts to build ships for fewerhours for the U.S. Navy.”10 | May 2011 | BIW NEWS
Dept. NameApril 2011Service Anniversaries40 Years26 Morin, Sharon Annette35 Years86 Amsden, Richard Paul86 Bishop, Dennis John86 Harvey, Stephen Carroll87 Hinds, David Frank84 Laroche, Paul Gerard30 Years45 Alexander, Carol Jeanne32 Bergeron, Paul Michael57 Bowie, Michael Robert19 Daggett, Steven Gary20 Doyon, Maurice Richard43 Enman, Daniel Joseph30 Gosselin, Alan Albert50 Grover, Patrick Gerald86 Higgins, Daniel Michael50 James, David Allen08 Johnson, Jean William26 Lavoie, William Joseph50 Leavitt, Kevin Lee19 Libby, Richard Scott15 Maschino, Stanley Walter17 Morin, James Charles86 Norris, Russell Heman5 Star ComplianceDept. Name50 Palmertree Jr, William Alvin50 Perreault Jr, Renald Rene50 Picard, Gerard Albert10 Schools, Mark Alan07 Scott, Ralph Andrew32 Seekins, Ralph Everett25 Years45 Andrew, Carol Tina87 Bailey, William Hugh20 Carter, Wayne Maurice97 Lasher, Mark Evans05 Sukeforth, Dale Rickmond10 Years43 Kilcrease, Dana Lynn43 Marquis, Timothy Scott43 Martin, Steven Daniel50 Mayo, Carl Leon10 McMahan, Charles Wayne50 Schools, Randy William43 Swift, Michael Edward27 Trebilcock, Sandra Joyce43 Tremblay, Robert Roger5 Years40 Albert, Lisa Rose87 Lamphere Jr, Bradley Russell26 Mora, Michael JosephThis year’s more rigorous approach to 5 StarCompliance has started to yield stars. However,Laura Mathisen (D52), Director of Environmental,Health and Safety, cautions, “The process of awardingstars will roll out fairly slowly as we continue to integrate5 Star inspections with wall-to-wall audits to ensure thatthe two are working in the same direction—towardscontinual improvement and sustainability.”Laura continues, “Involvement by management andunion alike is crucial to improving our safety position.A good example of this is the Area and Trade CRESTsubcommittees which are working together to reducefindings and using innovative ideas to reduce injuries.”Pat Thomas (continued from pg 4.)able level of outfitting, a testament to our strategies to supportManufacturing with the necessary material and a creditto the Engineering, Design and Materials Team.Q. What are your Materials concerns these days?A. I’m concerned about warehouse space. Just as DDG 1000units are noticeably larger and heavier, so is the material andequipment that we are buying. In addition to properly storingthe material until it is needed, warehousing involves kitting andother organizational steps to make sure that Manufacturingreceives kitted material for each specific job. All this requiresspace.Q. Your closing thoughts?A. Our mantra remains: Build ships for fewer hours. Send peoplehome in the same condition they came to work. Treat each otherwith dignity, act with integrity and use good old Maine commonsense. We must perform and the customer will come. I am reallyproud to be part of the BIW Team.MAY 5, 20115-SkidsAluminum ShopABC PlatBuildings 18, 19 and MERGAssembly BuildingPanel LineBoiler ShopTrade ShopsCarpenter ShopBlast IBlast IIBlast IIIHyde SouthHazardous Waste BuildingACE/CW/BissonsEBMFHardingsElectricalMachineGuardingFallProtectionFire, Health,SafetyHousekeepingFacilitiesMachine ShopMetals RecyclingDry DockH 601 (DDG 1000)H 505 (DDG 111)H 506 (DDG 112)MSC Warehouse/Service ShopLLTF Pump HouseLLTFAll OSTsP0II/Ultra HallSouth Central ReceivingCompliant Preparing for Assessment Lost StarBIW NEWS | May 2011 | 11
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Page 4 and 5: Pat Thomas on MaterialsPat Thomasis
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