BIW News October 2003 - Bath Iron Works

BIW NEWSOctober 2003CHAFEE (DDG 90) Sails—“It All Starts Way Backin the Process.”Before CHAFEE (DDG 90)departed on October 10 forcommissioning (October18) in Newport, RI, Hull ManagerDana McIntire (D10) reflected onwhat it takes to prepare a DDG toleave BIW. “It all starts way back inthe process” he said. Up-frontefforts set the stage for the periodof intense shipboard activity thatoccurs between “Charlie” TrialsINSIDEFrom the Helm - 2Safety Progress - 3Apprentices Graduate - 3Making Big Contributions - 4Environmental, Health & SafetyManagement SystemCertification - 4Classifieds - 5From the Fleet - 6SASC Staff Visit - 6Service Anniversaries - 7Recent Contract Awards - 7Fish Story - 8How Does Your Garden Grow? - 8and sailaway. Trades correct trial deficiencies,compartment ownership transitions tothe Navy, load-out and crew move aboardoccur, training is in full swing and newchallenges emerge each day. According toDana, “It’s a huge scheduling, integrationand coordination effort” as we balance shipyardneeds with those of the CommandingOfficer and crew.Our PRECOM Crew Training Team, ledby Paul Cullen (D38), a retired Navy ChiefWarrant Officer and 13-year employee,is right in the thick of this activity. Paulleads a nine-person team with 258 yearsof collective Navy operational and shipyardexperience. Cullen states, “our primaryfocus is to assist the crew in preparingfor Light Off Assessment (LOA) andensure they can safely operate the Hull,Mechanical and Electrical (HM&E)systems.” They do that under our DDGLead Yard Services and hull contracts byoffering 41 HM&E-related courses andservices that are tailored for each ship.Training starts 12 to 14 months beforedeparture and includes classroom andhands-on lab instruction that is reinforcedby significant on-board training, whichis tough to do on a ship in construction.“On-board training must occur on a not-Above left: Chuck Lawrence (D27) and DanaMcIntire (R) discuss last minute details prior toCHAFEE’s sailaway.Above: CHAFEE underway, and Bob Stevenson(D38) provides classroom instruction at thePCU Building.to-interfere basis with production.” A trainingplan exists but “we have to adjust to theactivities on the waterfront,” says Cullen.The drive for LOA begins immediately after“Charlie” trials—LOA is the acid test forCullen’s team, the ship and the crew. TheSquadron Commander and Afloat TrainingGroup must assess the ship and crew asbeing ready and safe for light off or sailawaywill be delayed. We haven’t missed one yetand our customer is happy. (See From theFleet – P. 6).Thanks to Dana’s and Paul’s leadership,the hard work of their respective crews andthe support of countless others, our customeronce again sailed down the Kennebecon schedule, safely and with pride!

From the HelmDugan Shipway, President, Bath Iron WorksWe, the men and women of BIW, are in the businessof building ships. Whether we sit at a CAD station,buy material, prepare financial reports or install pipein preoutfit, we all contribute to the total effort required to deliverour ships to the Navy. Read this month’s cover article that highlightsCHAFEE’s sailaway. Dana McIntire is right on the markwhen he says, “It all starts way back in the process.”Now, if we are to continue to succeed in this business, we mustkeep focused on our three basic goals—we have to achieve them.Every one of us must work to:■ Reduce the number of labor hoursto build DDGs to equal or beat anyshipyard in the country.■ Treat each other with dignity, actwith integrity, and use good old Mainecommon sense.■ Have a work place environment where everyworker goes home from BIW in the same conditionthey arrived at BIW.How well we accept and meet these three challenges is what willsecure our future as shipbuilders and provide opportunities forour sons and daughters. With our future in mind, I’d like to focuson the first of these goals—building DDGs for fewer hours—andspecifically on one thing every person at BIW can do right now tohelp us achieve it.To build our ships for fewer hours, all of us must ensure firsttimequality. When you’re on the job, think about whether you arecontributing to rework hours and ask yourself some simple questions:“Was my design or work paper done on time and withouterror? Was the material I was responsible for available and correctwhen it was needed? Was my craftsmanship of a quality I wouldwant in my home? Am I doing my job to the best of my ability?”If the answer to any of these types of questions is other than “yes”(even if only occasionally) then there is more you can contributeto reduce the number of labor hours it takes us to build ourDDGs. By achieving first-time quality in what we individually doon the job, each of us can be part of the solution that will take usto our goal. If we use the same kind of common sense, cooperationand good judgment here at BIW that we use when we’re athome, we’ll get there.We’re in the business of building ships and our business environmentis as complex as the ships themselves. Achieving firsttimequality and reducing our DDG labor hours will make thatenvironment a little less complex and help us to be successful atcompetitively winning new work in the future.I see the start of a new course for the BIW family but it willtake some time to navigate successfully. As we continue tofollow this course, we are charting our future. It will take allof us working together to provide a secure future for BIW—it’s up to us to do it.“TOGETHER WE CAN MAKE A DIFFERENCE”2 | October 2003 | BIW NEWS

Safety September 2003RECORDABLE INJURIES LOST-TIME INJURIES1,445 Injuries thru September324 Employees Lost-Timethru September2003 Reduction Target-1,0402003 ReductionTarget-233Holding SteadyApprentices GraduateHolding SteadyBIW NEWSBIW NEWS is published monthlyby the Strategic Planning andCommunications Department(D53) of Bath Iron Works andis produced internally in theBIW Print Shop.The primary objectives ofBIW NEWS are to recognizethe service, accomplishments,innovation, and contributionsof our employees and to provideinformation on matters that areof interest to our workforce.Comments and suggestionsare welcome and should beforwarded to Jim DeMartini atMail Stop 1210 or by e-mail atjim.demartini@biw.com.Since formal apprenticeship began atBIW in 1950, over 1000 students havegraduated and pursued various shipyardcareers in the manufacturing tradesand design disciplines. On October 8 atthe Taste of Maine in Woolwich, another19 names were added to the list whenBIW President Dugan Shipway presenteddiplomas, class rings and state certificatesto the Design Class of 2002 and the Designand Manufacturing Class of 2003.Congratulations to the graduates!Front Row (L to R): Rob Lailer, Lew Pratt, AimeeShurtleff (co-valedictorian), Eric Richard; MiddleRow (L to R): Maureen A. Kenney, Terry Drouin,Ryan Temple, Terry Melanson, Tim Moore, AndyVerge, Larry Shorette; Back Row (L to R): NormAlbert, Jeff Geiger, Marty Wheelan, CharlieKelley, Chad Fuller, Bob Newton, Russell Bernard(co-valedictorian), Scott Smith, Matt Jones, BillBell, Dugan ShipwayBIW NEWS | October 2003 | 3

Third Shift Team Making Big ContributionsRon Carr, Roger McNelley, BillRichardson and Al Soule (allD11) are third shift pipe andvent coverers in PO2. For about the last18 months they have been performing“pull ahead” work from the LLTF, whichis not only saving labor hours but alsohelping to prevent injuries to our fellowemployees.In the past, each of these individualshas done this kind of work on the LLTFor on ships in the water. They are veryfamiliar with the difficulties associatedwith installing pipe and vent covering inareas that a contortionist would find nextto impossible to get into. It is a toughtask and it’s easy to get hurt, which iswhy it makes great sense to move thework from the LLTF back into PO2where access is much easier and materialis readily at hand.Dan Nadeau,BIW’s Directorof Environmental, Healthand Safety, describes anEnvironmental, Health and SafetyManagement System (EHSMS) as“how we do our jobs every day toprotect the environment and stay safe.”In accordance with General Dynamics’policy, BIW is seeking accreditationfor our EHSMS. Since January 2003,representatives from Environmental,Health and Safety have been settingthe stage throughout the shipyard tohave our EHSMS certified under twointernational standards (ISO 14001for Environmental and OHSAS 18001for Safety & Health). American WasteManagement (AWM) will perform thecertification audit in February 2004.Vince Dickinson (D1310),projectleader for the certification effort andEnvironmental Operations manager,along with Laura Mathisen (D52),4 | October 2003 | BIW NEWSConstant communication is maintainedwith the crews on the LLTF and on thewater to identify the “killer” jobs that canbe shifted back to the pre-outfit building.This effort is progressing well and Hull477 (BAINBRIDGE) will be the first hullon which this team will have likely donesome “Pull Ahead” work on every unit—Blake Hendrickson(D1310), BobKnowles (D1310) andGreg Grondin(D1300) have beenworking with unionrepresentatives,mechanics, salariedpersonnel and managementto developthe foundation of theEHSMS. Accordingto Vince, “Every shipyardorganization isinvolved in the certification process. It’ssimilar to achieving ISO 9000 certificationfor our quality system and will be clearevidence of the program’s strength andour commitment toward environmental,health and safety.”Look for more information about ourroles in the certification process in upcomingeditions of BIW News.Third Shift PO2 Pipe &Vent Covering Team(L to R): Al Soule, BillRichardson, RogerMcNelley, Ron Carr.(NOTE: Al Soule is nowworking the USS MASON(DDG 87) PSA in Norfolk,VA and is expected toreturn in December.)and the search continues for additionalopportunities.Working smarter, saving labor hours,and reducing the risk of injury—big contributionsfrom a small team that quietly getstheir job done while the rest of us are probablysound asleep.Yard-Wide ISO/OHSAS Environmental, Health &Safety Management System Certification ComingEHSMS Certification Project Core Team(Clockwise from Lower Left): Vince Dickinson,Blake Hendrickson, Laura Mathisen, BobKnowles. (Not Shown: Greg Grondin)

BIW CLASSIFIEDS October 2003AppliancesCLARION STOVE / Enamel / No oil burners;recently burned wood. Good working condition.Buyer must move; Asking $100. 443-4640Autos/Trucks1990 PONTIAC FIREBIRD / 3.1 V-6 127K;T-Tops, AC, cruise, tilt, CD, runs excellent;Asking $2800. Call John - 495-2153 (evenings)1995 OLDSMOBILE / In Good Condition.Call after 4 PM; $2000. 725-76741998 CHEVY KIO / Low mileage, 4 X 2aluminum cap, 6 cyl.; $6500. 563-64822002 FORD FOCUS SE / 4 Dr Sedan, 5 spd/cruise/AC/CD/hwy miles; New sticker & newtires. Must sell; Pay-Off or Take Over Loan.754-1189Auto PartsSNOW TIRES / Four (4) / Goodyear w/studs;195-70-14 Mounted on rims for 96 DodgeStrattus; $100. 721-0201Boats1990 MAKO CENTER CONSOLE / 19' 6" /1991 200 HP Mariner, Ratheon radar, Bosestereo, GARMIN 45 GPS, Eclipse GX1250 SAtransceiver, Maintained by Bowden Marine,Bar Harbor; $18,000. 667-1147RALIEGH BICYCLES / Two; $300. 666-5775SNOWMOBILE / 1975 Harley Davidson / 440CCRuns great; have manuals & extra skis; $1,000OBO. 729-8187SNOWMOBILES / 1993 Yamaha Ventur 477;3000 Mi, Reverse, electric start asking $1300;1989 Yamaha Inviter 300; low miles, electricstart; $700. 353-4780Real Estate/RentalsGREENVILLE CABIN / 3 Miles from town,300 yds to lake, sleeps five; $400/Wk,$200/Weekend, $55 Wk Days. 353-4780Rides Wanted/NeededRIDE NEEDED / Ride needed from Bay BridgeEstates to / from BIW for day shift, 7:00–3:30 orride to James Building for 6:15 AM bus. Will pay;443-9926Wanted35 MM SLIDE EQUIPMENT /Kodak Carousel Slide Projector and Slide Traysand Portable Roll-Up Projection Screen for 35MM Slides; 586-5326Abbreviations:OBO / Or Best Offer; OBRO / Or Best Reasonable OfferClassified Ad FormSeptemberRetireesDept.Name09 David A. Wallace29 Years 7 MonthsOutside Machinist III15 John E. Wardwell23 Years 10 MonthsPipefitter III19 William W. Stewart14 Years 4 MonthsElectrician III26-01 Anthony S. Vecchione14 Years 10 MonthsCorporal40 Raymond A. Charest43 Years 1 MonthEngineer IIICANOE / Sawyer X-17; Kevlar/glass; $350.Please call 721-0201FurnitureBEDROOM SET / Light Pine king size waterbedw/6 drawer pedestal, 6 drawer bureau, full lengthupright mirror. Very good condition; $350OBRO. 721-0201MiscellaneousDRY SUIT / $400. 666-5775NAME DEPT. EXT.One form per ad; 25 words per ad; two ad maximum per issue. No faxed or phone-in ads. Includeitem description, price and home telephone.Circle category:Appliances Autos/Trucks Auto Parts Boats Computers Furniture Misc.Motorcycles Pets Rides Needed/Wanted Real Estate/Rentals Real Estate/Sales WantedFORCED HOT AIR FURNACE / Used to heathome last year; $150 OBO. Call Joe at 353-8948MUSIC EQUIPMENT / AMPEG BR2 BassAmp 350W - $450; SWR 4 X 10 Cabinet 400W -$350; SKB 6 Space Rack - $100; BehringerComp/Gate - $100; Furman Power Strip - $75 ;443-9567Mail to Sally Donahue, BIW Classifieds, MS 1210BIW NEWS | October 2003 | 5

From the FleetCDR John W. Ailes, USNCO, USS CHAFEE (DDG 90)“...it is clear to me that we havereceived a product of the highestquality and I am a very happy customer.The BIW/SOSB Team, led byDana McIntire, Mark Pitman, andDominic Vella, did a magnificent jobgetting CHAFEE ready for MoveAboard, LOA and now Sailaway...I would especially like to recognizeDana McIntire. His superior leadershipand the can-do attitude he fosteredin his team cannot be overstated...I could not be more pleased withthe entire PRECOM experiencehere at BIW.”E-Mail from CDR John W. Ailes, USN toCAPT John Ingram and Dugan Shipway“In the wake of what I believe was thefinest Light Off Assessment to date, I haveasked myself what were the keys to success.Clearly the answer is: it was a team effort.Moreover, your Fleet Services Crew TrainingTeam set a standard of excellence that Ihad heard of from previous CO’s, but onlynow fully understand. Your team: HarryCrutchfield, Clayton Yelverton, Al LeClair,Mike Blum, Dan Obie, Gary Morse, PaulRoy, Bob Stevenson and of course yourselfcan take a large measure of the credit forgetting us to this very happy day. In my perspective,no program gets more return oninvestment than your training program.Not only did the crew perform well duringthis assessment, but even more importantly,I can sail down the river with confidence inour ability to safely operate the plant...Well done to your team, which is part ofour team. I would sail with them anywhere.Their dedication—their Sailor’s heart andtheir knowledge are unsurpassed...”E-Mail from CDR John W. Ailes, USNto Paul Cullen, Section Manager, FleetServices Navy Training OperationsRick Knowlton, Jim Jordan and StewartHanna (all D86) were recently recognizedby CDR Matthew Loughlin, USN,Commanding Officer USS DE WERT(FFG 45), for their outstanding effortsduring performance of a 100% DamageControl ship check after the completionof a Drydocking Selected RestrictedAvailability (DRSA 03) in Mayport, FL.The CO presented each with ship’s coinsand ball caps.Senate Armed Services Committee Staff VisitOn Thursday, October 9th,Tom Mackenzie andCreighton Greene,ProfessionalStaff Members to the US SenateArmed Services Committee and SeapowerSubcommittee, visited us aspart of their official responsibilitiesto remain abreast of developmentswithin the Navy and in the US shipbuildingindustrial base. They weregiven an overall BIW update, programbriefings, and a shipyard tour thatincluded a visit to CHAFEE (DDG 90).A member of the Professional Staff ofthe House Armed Services Committeevisited BIW for similar briefings anddiscussion in early August.CDR Matthew Loughlin, USNCO, USS DEWERT (FFG 45)Senate Armed Services Committee Professional Staff Members Creighton Greene (L), ThomasMackenzie, and Navy Office of Legislative Affairs representative CDR Paul Siegrist, USN tourthe shipyard with Scott Kay (D 93—Foreground) and Gerry Lamb (Background), GD Director,Government Relations.6 | October 2003 | BIW NEWS

SeptemberService AnniversariesDept. Dept. Dept.35 Years10 Gagnon, Roger Joseph10 Hannan, Frederick Walter19 Morse, Richard Earl32 Doyle, Thomas Francis81 Glover, David Allen81 Mains, John Albert30 Years02 Proctor, Ellen Elizabeth09 Wallace, Daniel Louton10 Ponziani, Raymond Eugene15 Brown, Clifford Joseph20 Denis, Richard Albert20 Parent, Raymond Paul20 Wright, Albion James32 Caron, Roger Laurence43 Landry, Giles Francis43 Prindall, Lynn Richard50 MacGillivary, Daniel James50 Mitchell Jr, Sherman Hans81 Bancroft, Edward Jefferson84 Taylor, Anthony Berenhard86 Crocker, Scott Allen87 Mains, Charles Herbert25 Years09 Morin, Ronald Rosario10 Campbell Jr, Dennist Ray10 Doyle, Edward Dale10 Libby, Richard Scott10 Neagle, Timothy Dale10 Tynes, Oscar Edwin11 McNelly Jr, Roger Verl15 OLeary, Peter Kevin19 Beasley, Kenneth Raymond25 Buzzell, Edward Eugene27 Cloutier, Donald Gerard27 Jones, Dorothy Jean27 Lutz, John Alan27 Segars, Guy Aubrey43 Pepin, Carl Louis50 Desjardins, Jeffrey Joseph50 Dunn Jr, Marshall Aubrey50 Durgin, Gary William50 Harrington Jr, Douglas Harlan50 Plourde, Michael John66 Suitter, Paul David80 Young, Steven Emery81 Pono, Dominick Anthony86 Berube, Roger Wayne87 Lazure, Ivan Ludger91 Babine, Michael Robert91 Coonradt, Chester William91 Moody, Timothy Edward91 Racine Jr, Alfred Michael97 Sainio, Wayne Anthony20 Years20 Thomas, David Wayne50 Jewett, David Earl53 Nutter, Michael Carl84 Campbell, Nancy Ann91 White, Jack Henry15 Years07 Matthews, Charles Bartlett07 McKay Jr, John Jerry10 Bernier, Donald Victor10 Daigneault, James Albert10 Francisco, Daniel Lee10 Kaiser Jr, James Arthur10 Norzow Jr, Alex John10 Pellerin, Daniel Bernard10 Robishaw, Raymond Lawrence10 Shanholtz III, Wesley James11 Cornish, Steven Lane11 Harmon, David Wayne11 Lucente, Raymond Gerald11 McMillan, Angel Eleen11 Overlock, Maynard Warren11 Simmons, Connie Lee11 Tozier, Robert Arthur15 Bowden Jr, George Wesley15 Brewer, Richard Lawrence15 Carter, Randy Joe15 Kindlimann, Mark Anthony15 Lopez, Rene Peter15 McDonald, Blaine Russell15 McIntyre, Frederick William15 Page Jr, Stephen Emery15 Pinsonneault, Ronald Paul15 Smith, Gregory Stephen15 Tardif, Paul Julien15 Viles, Kenton Troy17 Bryant, Marshall Proctor17 Bureau, John James17 Collomy, David William17 Jones, Jeffrey Wayne17 Kirk, Kevin Lloyd17 Lecompte, Daniel Armand17 MacLean, Charles Allen17 Miller, Gary Edward17 Ostlund, Jeffrey Allen19 Berube, Dennis Charles19 Bodeen, Russell Ernest19 Burtt, Laurie Lee19 Doughty, Ronald David19 Ellingwood, David Frank19 Gregoire, Roger Paul19 Harmon, Richard Vance19 Hayes, Sandra Rita19 Heath, Joseph Russell19 Ludington, Ralph Neale19 Maddan, Eric Lee19 Morse, Barry Lee19 Saucier, Donald Edmund19 Tardif, Shawn Christophe19 Washburn, Jeremy John19 Yorke, Ronald Douglas20 Penney, Maurice Bertrand20 Vosmus, Kenneth Fowler24 Walfield, Bradford Robert25 Halsey, George Arthur25 Hilt, Glen Thomas25 Libby, James Alexander25 Miles, Steven Craig25 Roberts, Dean Matthew27 Blanchette, Guy Raymond27 Carpenter, John Henry27 Cary, Michael Manning27 Castonguay, Marc Roger27 Gray, John M27 Keenan, Brian Douglas27 Klimko, Shane Matthew27 Lavigne, Michael George27 Maier, David Joseph27 Naher, Gary Paul27 Page Sr, Joseph Pollard27 Pearl, Eugene Joseph27 Pushard, David Michael27 Veilleux, Mark Roger27 Williams, Joel McVey29 Brookes, Paul Archer29 Trufant, John Edward40 Breton, David James40 Clark III, William Alpheus40 Robertson, Jeffrey Tyrone43 Washburn, David Harvey45 Chatman, Patricia Ann45 Craige, Susan Jean45 Crocker, Elizabeth Lorraine45 Dodson, Karen Ann45 Galgovitch, Eva Marie50 Chouinard, Michael Marcel50 Dilley, Brian Gene50 Dulac, Wilbert Willie50 Krigbaum, Andrew William50 Payne, John David50 Westleigh, Eugene Elbert54 Floccher, Roberta Jenifer66 Chattley, Douglas Michael66 Deroche, Peter Joseph66 Gilley, Darry66 Letourneau Jr, Brian Paul66 Martel, Richard Alcide66 Webber, Merle Eugene78 Damato, Michael John78 Eddy, John Haven80 Vinal, David Wayne82 Jenkins, Gail82 McCole, Donna Gayle84 Dute, Frederick Harold86 Kerner, James Charles87 Blodgett, Dale Forrest87 Cloukey, Dennis Harold87 Morales, Gloria Jimenez87 Parr, Tony Rene87 Weakland, Glenn Alan87 White, William Leonard91 Dexter, Michael Wayne5 Years01 Joslin, Lynn Marie19 Frye, Gary Alan40 Buczkowski, Gregg Stanley50 Gilbert, James Alexander87 Fitzgerald, James LewisRecent ContractAwardsPLANNINGYARD SERVICESOn October 1, NAVSEAexercised its optionto continue DDG 51and FFG 7 PlanningYard Services for anadditional 12 monthsunder its current contractwith BIW. The contractis valued at $40 millionand includes engineering,design services, logisticsand materials support.FUEL CELL TECHNOLOGYThe Office of NavalResearch awarded a$2.6 million, 16 monthcontract for the MarineFuel Cell Verification—Trainer Project. Thisproject will investigateand test fuel cell powerplants for shipboard andland-based application bythe US Navy. BIW willlead a team that includesFuel Cell Energy, Inc. ofDanbury, Connecticut,the University of Maine,Maine Maritime Academyand Combined Energies,a division of Union WaterPower, of Augusta, Maine.BIW NEWS | October 2003 | 7

700 Washington StreetBath, ME 04530PRSRT STDU.S. POSTAGE PAIDBATH, MAINE04530PERMIT NO. 31Fish StoryIt was dark on theKennebec when MikeFrelk and HarlandStanley (both D26) ofWaterfront Security werepatrolling in our securityboat SEA ARK onSeptember 7. At about 8:00P.M. they suddenly heard aloud noise at the rear of theboat. Thinking they had struck somethingin the water, they shut down the enginesand went aft to inspect. To their surprisethey found a not-so-happy 5-foot, 65-pound, fully armored Atlantic SturgeonMike Frelk (L) and Harland Stanley with theirunexpected night visitor from the KennebecRiver.in the stern of the boat. Theprehistoric fish, obviouslyanxious to try its hand withthe waterfront securitydetail, had leaped out ofthe water and into the backof the boat. It quickly decidedthis duty wasn’t quitewhat it was all cracked upto be and was making quitea fuss (note the pieces of non-skid damagedby it’s armor). After quickly takinga picture, Mike and Harland somehowsafely returned their uninvited passengerback to the river.How Does Your Garden Grow?Bill Clark’s (D40SA) garden seemsto have done pretty well this year.He grew this 906.2 pound AtlanticGiant Pumpkin at his home in Bristol.His care and feeding produced the secondlargest pumpkin ever to be grown in Maineand earned him 18th place at the TopsfieldFair in Topsfield, MA, where he competedagainst growers from all over the Northeast.The largest pumpkin to come out of Mainethis year weighed in at 978 pounds—a newstate record.Bill Clark at his home in Bristol, ME with his900+ pound Atlantic Giant Pumpkin.