APR - Bath Iron Works

BIW NEWSApril2004NITZE DDG-94ChristenedBIW Employees, honored guestsincluding The Honorable PaulH. Nitze, the ship’s namesake,and the crew of NITZE DDG-94watch as the ship’s sponsor,Nitze’s wife Elisabeth (Leezee)Scott Porter, christens NITZEDDG-94 on April 17, 2004.INSIDEFrom the Helm - 2Safety Progress - 3VLS Welders Set Records - 3EBMF ManufacturingExcellence Award - 4Classifieds - 5Retirees - 5LCS Proposal - 5From the Fleet - 6DDG Modernization - 6Service Anniversaries - 7BIW Marathoners - 8

From the HelmDugan Shipway, President, Bath Iron WorksAs you read this I will have just about completed my firstyear as President of Bath Iron Works. It’s really been ayear of learning for me, and I appreciate all the education,patience, and support you’ve each given me. Thank you for whatyou have done to help me this past year.In the January 2004 BIW News I looked back at 2003 and thismonth I’d like to look back at the first quarter of 2004.First, Safety: We started out in January with a great month.Many fewer recordable injuries than the first month of 2003and very few lost time injuries as well. As of the end of Marchrecordable injuries are on about the same pace as 2003 while weare continuing to keep the level of lost time injuries way down.As we move into the spring and summer months it’s importantfor each of us to stay focused on safety—our own safety andour fellow workers’ safety.Second, Schedule Performance: The result of ourfirst three months finds us about even on schedule. I learned thatMainers can build ships in zero degree weather in January. Youalso got the MOMSEN into the dock with a river full of ice flows.You sailed MOMSEN down the Kennebec into the Gulf of Mainein winter—some loved the seas—and you are now completing thefinal tasks that will enable us to deliver her to the Navy. The shipsfollowing MOMSEN continued to progress: NITZE has beenlaunched, BAINBRIDGE is holding schedule on the LLTF, and hullerection commenced for FARRAGUT and she has been transferredoutward. Finally we started fabrication of DDG 101 that in 27months will be our 27th DDG and the 6th to be launched fromour land level facility.Third, Hours to Build Ships: I have talked about thiswith both the union leadership and my management duringthe first quarter. Although some progress is being made (weare on the right track) much more is needed if we are going toachieve the basic goal of this company—“reduce the numberof labor hours to build DDGs to equal or beat any shipyard inthe country.”On April 17, 2004, we were honored to have an American Giantwith us for the christening of the ship named after him—TheHonorable Paul H. Nitze. I hope you were able to join us that dayto see this man about whom others have written:“As historians look back on the latter half of the 20th century,they will be hard pressed to find a single individual whoexerted more influence over every treaty related to armscontrol and the U.S. Strategic defense in the period betweenthe end of World War II and the end of the Cold war thandid Paul Nitze. ....It was his devotion to country—by constantlydoing what was in America’s best interests ratherthan solely adhering to political party lines—that resultedin Mr. Nitze being asked to serve both Democratic andRepublican administrations.”We can all learn from Paul’s example. He is a man who was neversatisfied with the status quo—a man who knew what was rightand who did what he had to do. We, too, must not be satisfiedwith the status quo. I see good things happening but we cannotkid ourselves—we have a long way to go to build these ships asefficiently as I know we are capable of doing. I know the folks inthe south are not satisfied with their performance and we cannotbe satisfied with ours either. Following Paul’s example each daywe come through the gates, we must continue to do what is rightfor ourselves, and our fellow shipbuilders if we are to achieve ourgoal. I know we can do it.So, as I prepare to start my second year as your President—let merepeat what I said a few weeks ago when I was in the company ofshipbuilding giants. The occasion—a luncheon to recognize eachof the 57 active BIW employees with 40 or more years of service.My message was simple—“I am proud to be your President”.“TOGETHER WE CAN MAKE A DIFFERENCE”2 | April 2004 | BIW NEWS

Safety March 2004RECORDABLE INJURIES LOST-TIME INJURIES2004 Cum. Rec.Injury Limit-1,2792004 Cum. LT Injury Limit-297March ’04 Cum. RI Actual=425March ’04 Cum. RI Limit=273March ’04 Cum. LT Actual=71March ’04 Cum. LT Limit=59BIW NEWSAbove CumulativeMarch ’04 LimitAchieving our goal to reduce thenumber of labor hours to buildDDGs to equal or beat any shipyardin the country will happen as a result ofmany individual successes throughout theshipyard. The VLS welding team on Hull477 is a good example of one of these successes.Recently, they set a shipyard recordfor welding the aft VLS launcher by completingtheir work in less time and laborhours than any other ship in the history ofthe DDG-51 Program at BIW. Teamworkwas clearly the key.Above CumulativeMarch ’04 LimitVLS Welding Team on Hull 477 SetsNew RecordA job kick-off meeting to review materialtype, pre-heat requirements, weld size,and sequence requirements was held priorto start-up that enabled everyone on theteam to perform most efficiently. DanaRichardson (D10) also noted that “theexcellent fit and prep by the Department50 installation crew made the welding goextremely well.”We’ll reach our goal by taking one step ata time. Together, our shipfitters and welderson Hull 477 have taken a big stride in theright direction.BIW 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.Record Setters (front row):Jeremy Redlon, LeeJohnson, BattisttaPassalaqua (back row):Cliff Littlefield andDana Richardson.The empty spools in thebackground representjust over 670 poundsof weld wire that wasneeded to completethe VLS sub bases.BIW NEWS | April 2004 | 3

EBMF Mechanicsand SupervisorsReceive BIW’sFirst GDManufacturingExcellence AwardAbout three years ago,our East BrunswickManufacturingFacility (EBMF) Teambegan to structureits ongoing processimprovement activitiesaround the applicationof LEANManufacturingprinciples. Sincethen, as a resultof solid leadership,teamwork, innovation, commitment,and plain old hard work, EBMF hasbeen showing some impressive results.The collective effort of both mechanicsand supervisors have substantiallyimproved cost performance and manufacturinglead times have improvedacross the board—both of whichdirectly contribute to our ability tobe competitive.Because of their demonstratedperformance, BIW’s first GeneralDynamics Manufacturing ExcellenceAward was presented to the employeesof EBMF on April 7, 2004 by ManufacturingCouncil Chairperson JosephT. Lombardo, Vice President and ChiefOperating Officer of Gulfstream Aerospace,at a Manufacturing Councilmeeting in York, PA. Plant ManagerRene Beliveau accepted the award onbehalf of everyone at EBMF. Eight otherGeneral Dynamics business unitsreceived similar awards.Winning this award is no easy matter.Written nominations are preparedManufacturingExcellence.The first and thirdshift teams (above)and the second shiftteam (right) acceptthe first GD ManufacturingExcellenceAward (left).from within each business unit and submittedto each company’s internal selectioncommittee for evaluation. The submissionsare reviewed against a set of rigorous criteriathat is based on the Shingo Prize (oftenreferred to as the “Nobel Prize of LeanManufacturing”) to select a winner. Byhighlighting the best manufacturing operationsof each subsidiary, the Council hopesto accelerate implementation ofmanufacturing lessons learned withinand between sister companies.On April 13, 2004, Jeff Geiger,VicePresident of Manufacturing, and DuganShipway, President of BIW, traveled toEBMF to congratulate the first, second andthird shift employees on achieving thishonor. Addressing those present as “trailblazersfor implementation of LEAN principlesat BIW” Geiger noted that the sheernumber of visitors coming to the facility tosee what is being done is clear evidence ofthe success of EBMF’s efforts.Harold Wills (Dept. 15) has beeninvolved with implementing LEAN principlesat EBMF from the very beginning. Heis a 40-year employee and he says he hasseen significant changes over the last threeyears. “The way work areas have been consolidatedis good,” he says, “now when youneed a brazer to complete a job, he comesright to your work area so you can leaveyour work right in your vice. It’s much betterthis way now that you don’t have to goand get things yourself—there’s a lot lessmoving around.”When a team pulls it together and getsthings moving in the right direction it feelsgood for everyone involved. It’s even betterwhen the team receives some recognitionfor their achievements. Being the very firstto receive an award makes it even morespecial—you set the standard for everyoneelse. It’s clear EBMF has set the bar at achallenging height. Congratulations toeveryone who is a part of the EBMF Team!Above: 40-year employee Harold Wills (Dept. 15).4 | April 2004 | BIW NEWS

BIW CLASSIFIEDSApril 2004Auto PartsTRUCK CAP - Gazelle, tan, for truck w/8' bed;$350. 633-2728Autos/Trucks1977 JEEP WRANGLER - w/extras, Blackw/Tan Soft Top, 4x4, 4 cyl, 87k mi; $6,900 OBO.353-60201996 DODGE DAKOTA - External Cab, 101Kmiles, good condition; $2,700. 882-9887Classified Ad FormMotorcycles2002 HONDA REBEL - 250cc, 2k miles,garaged. Call Tracy or Rich; $1,900. 443-1481.NAME DEPT. EXT.Real Estate/RentalsGREENVILLE CABIN - 300 yds to lake, sleeps5, all seasons; $400/wk, $200/weekend. 353-4780WantedPLAYERS WANTED - Interested in playingbasketball? Age 25+; 443-5563/725-6051Abbreviations:OBO / Or Best Offer; OBRO / Or Best Reasonable OfferOne 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 WantedMarch 2004RetireesDept.Name20-00 Wayne A. Anair16 Years 8 MonthsMaint. Pipefitter III27-00 John C. Christie29 Years 1 MonthPreservation Tech III43-00 Ronald A. Emmons31 Years 10 MonthsWelder III50-00 Norman F. Brown15 YearsShipfitter III50-00 Raymond E. Dube38 Years 7 MonthsShipfitter III50-00 Clifford M. Wells24 Years 4 MonthsShipfitter III78-00 Raymond P. Weber13 Years 1 MonthDirectorMail to Sally Donahue, BIW Classifieds, MS 1210LCS ProposalRevisionYouth Does Have Its Disadvantages.Kelly Bergkessel and Rob Remsen(both from EB) do the “heavy lifting”while seasoned veterans Mark Curry(D02) and John Colombraro (D38)(background) “supervise” loading theGD Littoral Combat Ship Team’s FinalProposal Revision for delivery to theNavy on April 9th. The Navy is expectedto announce its decision on LCSFlight 0 sometime in May.80-00 Robert Howes30 YearsCrane Operator III87-00 Andrew J. Molboski, Sr.29 Years 3 MonthsDesigner91-05 Robert F. Buccina30 Years 1 MonthPlanning TechnicianBIW NEWS | April 2004 | 5

From the FleetUSS HIGGINS (DDG-76),shown here leaving herhome port of San Diego,CA in November 2002, returnedhome on April 4, 2004, after an 18month deployment to the ArabianGulf in support of Operation IraqiFreedom.Employing a concept, known as SEASWAP, the Navy utilized crews fromdifferent ships to relieve the sailors onstation every 6 months. This allowedplanners to extend time on stationwithout putting the stress of such anextended deployment on any singlecrew. The entire ship’s company fromUSS BENFOLD (DDG-65) and laterUSS JOHN PAUL JONES (DDG-53),met Higgins for a brief crew swapperiod prior to being flown home.COMNAVSURFOR, Vice Admiral TimLafleur indicated the program added100 additional days of combat presenceover three traditional deployments,because about half of a standard six-monthdeployment was eaten up by the long transitacross the Pacific and Indian Oceans to theGulf. VADM Lafleur refers to those lost daysas “the tyranny of time”.Senior maintenance planners will takea detailed look at USS HIGGINS materialcondition to determine if there are any negativeimpacts arising from the ship beingdeployed for such a long period. The resultsmay provide valuable lessons BIW canincorporate into the design of follow-onDDGs and other new warship classes.DDG Modernization—Ensuring Maritime DominanceAs we deliver MOMSEN (DDG-92), the newest member of theUS Navy’s fleet, at the end ofApril USS ARLEIGH BURKE (DDG-51)will be just a few years away from hittingthe midpoint of her 35-year servicelife. To maximize its return on investmentin the class, the Navy has begun toplan for a “midlife upgrade” known as“DDG Modernization.” The large numberof ships in the DDG-51 class providesthe Navy a unique opportunity toengineer the latest technology into theremaining new construction hulls andincorporate those changes into theDDGs in the fleet. One area of focus isincreasing the level of onboard automationas a means of reducing crew size.To support this effort, a multi-disciplinedteam was assembled last year atContinued on page 7Planning for the Future. Larry Boyce conducts a peer technical review with other engineers on theDDG Modernization team. Pictured (left to right): Lu Lozano, Mark Haines, Dilip Chakravarty, LynnDavis, Larry Boyce, Lou Berthiaume, Shawn Weiblen, Reed Markley, and Mike Renaud (all D40)6 | April 2004 | BIW NEWS

MarchService AnniversariesDept. Dept. Dept. Dept.45 Years15 Carlton, Richard Howard35 Years10 Presby Jr, Alvin Lorenzo19 Cleaveland Jr, George Henry27 Gilliam, Richard Doughty27 Sanders, Frank Melvin27 Skelton, Leonard Oscar43 Varle, Michael James30 Years05 Gross, Stephen Edward06 St Hilaire, Ronald Lucien07 Watts, Robert Burton10 Fuller, Andrew Alan10 Hodgkins, James Albert10 Murphy Jr, Louis Michael10 Smith, Torrie Gene15 Martin, Richard Paul19 Beaudoin, Donat Patrick19 Fernald, Carroll Lee24 Lemont Jr, Paul McLellan25 Heath Jr, Lynde Allison27 Cray, Raymond Paul27 Jalbert, Normand Lionel27 Springer, Charles Leslie43 Lamarre, Maurice Norman46 Rau, Daniel Patrick69 Freeman, Richard George81 Cobb Jr, James Maurice81 Fairfield, Eugene David81 Lamontagne, Joseph Paul81 Pinkham, Gary Harlan82 Allen, Mark Andre82 Burr, Bruce William86 Peaslee, Kenneth Elwood87 Bean, Bruce David87 Dodge, Michael Howard87 Kennedy, Edward Ray87 Snell, Dean Earl87 Westleigh, Paul Roger91 Duquette, Michael Raymond91 MacDonald, Thomas Edward91 Poliquin, Richard Karl91 Simmons, Linden Calvin25 Years07 Fairhurst, Thomas Roy07 Marshall, Peter Bruce09 Laberge, Michael Lucien10 Darling, Danny John11 Delano, Jeffrey Dale17 Doak, Warren Frederick17 Raymond, Dean John19 Campbell, Michael Harry19 Caron, Ralph Joseph19 Coro, Darrell Richard19 Davis, Jeffery Allan19 Dickinson, Lee Roy19 Knight, James Bell19 Newbert, Cecil Dwight19 Wallace Jr, Roy David20 Banaitis, Richard Anthony20 Hall, Dana Roy20 Sirois, Richard Dennis25 Landry, Guy Raymond25 Vanwickler, William27 Black, Keith Allen27 Brannigan, Craig Thomas27 Watson, William Stuart40 Eaton, Glen Timothy52 Vaillancourt, Bert Michael68 Zubiate, Michael Joseph80 Otis, Randy Roy81 Boily, Rene Michel81 Coolong Jr, William George81 Gilmour, Kerry Eldon81 Leeman, Mark Wayne86 Crosby, Stephen John86 Gagne, Donald Roger87 Ottum, John Wiley87 Paradis, Ronald Roland91 Marco, Christopher Michael97 Stedman, Dixie Anne15 Years09 Demers, Ronald Joseph10 Buckowsky, Larry Dennis10 Garland, Joseph Allen10 Grant, Stephen Scott11 Stilphen, Todd Andrew15 Bujold, Donald Leo15 Cooper III, Fred George15 Crosman, Jeffrey Alan15 Darling, David Charles15 Hammer, Thomas Carlton15 Harvey Jr, Richard Charles15 Ingling, Roy Lee15 Malesiewski, Daniel Francis15 Mullen, Bruce Robert17 Martel, Jean Claude19 Belanger, Denis Roger19 Duquette, Paul Raymond19 Fritz, Daniel19 Giannotti, Richard John19 Hayes II, Nelson Edward19 Jordan, Mark Todd19 Rogers Jr, Robert Henry27 Demers, Marc Andrew27 Douin, Rodney Alan45 Crane, Sarah Bourget45 Vice, Dee Vance50 McNaughton, Lewis L50 Wilson, Donald Lee52 Nadeau, Kathleen Grace66 Patrie, Tamra Lee84 Bellas, Thomas Albert84 Kronstrand Sr, Kenneth David86 Ceklarz, Franck Bernard86 Davis, Scott William86 Moore, Ronald Forrest86 Tomer, Arthur William87 Anair, Richard Wayne87 Hawkes, Marjorie Christina87 Johnston, Sharon Elaine87 Maurer, Leo Richard93 Taylor, George Austin10 Years11 Merry, Jay Thomas17 Simmons Jr, Francis Loring27 Nichols, Douglas Allen30 Lackner Jr, Wendell Lorin43 Faucher, David Michael49 Kenney, Maureen Jeanette50 Johnson, William Russell50 McIntosh, Blinn Burton5 Years06 Libby, Wayne Preston10 Migliore, Joseph Philip10 Saxby, Chris David26 Panek, John Anthony26 Talbot, David Charles28 Shafer, David Adair40 Bradley, Deborah M40 Selian, Peter John49 Barron, Lee Ann S50 Ayub, Rashid Tiya78 Williams, Ronald WayneDDG ModernizationContinued from page 6the Surface Ship Support Center to initiateplanning and engineering tasks to definethe scope of the job. The team is being ledby Christopher Waaler (D90) and is comprisedmainly of 10 control and automationengineers from Department 40. However,the team draws significant support fromvirtually all engineering disciplines andour Fleet Service personnel conduct numerousinternal “subject matter expert”reviews. Additionally, the team is workingclosely with NAVSEA Philadelphia andLockheed Martin. According to Lu Lozano(D40), the DDG Modernization TechnicalManager, “This is a challenging task thatwill showcase our DDG program technicalknow-how and require new engineering,procurement, and back-fit supportstrategies.”The first significant milestone for theengineering development effort is theSystem Requirements Review scheduledfor later in the summer. This review willformalize the requirements for DDGModernization with the Navy and allowthe preliminary design to proceed. Theteam has already held several reviews withour primary customer, PMS 400D, andhas received high praise for the quality ofengineering products submitted thus far.Helping our Navy customer maximizeits return on the DDG class by completingthe design, testing, and installation of amodernized configuration for both forwardfit and backfit DDG hulls simultaneouslyis certainly a challenge. But it’s a challengefor which we are well suited and one thatwe are eager to tackle.BIW NEWS | April 2004 | 7

700 Washington StreetBath, ME 04530PRSRT STDU.S. POSTAGE PAIDBATH, MAINE04530PERMIT NO. 31BIW Marathoners Win in New OrleansBIW runners first began to competein marathons in 2001 when fiverunners participated in a MarathonRelay (four individuals each run 5 milesand one other runs a 10K anchor leg).On its first outing, the team placed secondin its Division. In February 2002, the teamtook on a bigger challenge and competedin the United States Corporate AthleticAssociation Marathon event. Here the gamewas different as this was not a marathonrelay and at least four runners each hadto finish the 26+-mile race in order toavoid team disqualification. The runnersplaced from 2nd to 39th out of over 1,300runners and blew the competition away,winning both Division I and Division IIand capturing the Corporate Cup.On February 29, 2004, a team comprisedof Lance Guliani (D84), Jeff Banger (D40),Robert Ashby (D43), and Guy Segars(D27) traveled to New Orleans, LA tocompete in the Nokia Sugarbowl MardiGras Marathon. The team turned in anoutstanding performance with Gulianiand Segars each placing second in theirrespective age groups, Ashby placing thirdin his age group and Banger, after injuringhimself at the thirteen mile point, stillfinishing the race to ensure the team wasnot disqualified. Their efforts earned themFirst Place in Division II competition and2nd overall beating teams from other largeBIW Marathoners (Left to Right) Lance Guliani, Jeff Banger, Robert Ashby, and Guy Segars displaytheir medals after finishing the 26+ mile marathon event at the Nokia Sugarbowl Corporate Cup MardiGras Marathon on February 29, 2004 in New Orleans.companies including AT&T (8 runners),Lockheed Martin (6 runners), and BoozeAllen Hamilton (11 runners). The GeneralElectric Team (30 runners from around theworld) won the marathon event.The Corporate Cup Relays, a nationalevent, will take place July 17–18, 2004 atFitzpatrick Stadium in Portland with teamsfrom all over the United States participat-ing. In 1994 BIW was the only Maine teamto medal in this competition, placing 3rdin their division. This year the team willparticipate in Division III.Congratulations to Lance, Jeff, Robert,and Guy on a fine performance and bestof luck in July.