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detailed mock-ups. Future potential useincludes precomm crew training, shorebasedbridge trainer design decisions andfinal verification of the crew design.One other HSI mock-up, the HeloControl Station (HCS) was also movedfrom Dahlgren to Hardings and is collocatedwith the bridge. The HCS has beenextensively used by Navy Aviation certificationand HCS hardware vendors to assessand refine the design. OPTEVFOR representativescommented that use by AviationCertification representatives so early in theprocess was very productive.T.J. Champion (D40), who led thedesign and construction of this module,reported that “Usability testing of the HCSrevealed things that both should be fixedand could be fixed due to the stage ofdesign. For instance, the operator’s view ofthe flight deck was not as good as it couldbe. By rethinking the layout of a few keycomponents, we were able to optimize theoperator’s ability to perform his job.”L to r: T.J. Champion, Cameron Shuck and Vince Quintana in the Bridge Mock-up facility at Hardings.Vince Quintana (D40), HSI DesignVerification Lead, said, “Through usabilitytesting using these full scale models, wehave proven that the planned manning iscorrect in many spaces. However, testinghas also shown that manning had to beincreased in certain spaces while manningcould be reduced in others. The result ofthis work is increased confidence in theship’s design.”A Better ApproachIn the past, welders on the Panel Line have faced a difficulttask when welding plates together. Where the metal isthick, it has to be gouged out on the back side whichrequires a mechanic to lay on his or her side to perform thetask, repositioning every 6- to 12-inches along a seam thatcan be 50-feet long. It’s a time consuming, dirty job for themechanic and imperfections from the hand gouging processincrease the likelihood of weld defects.Brian Fraser (D43) observed the advancements availablewith automated welding technology and on his own, beganto research the availability of an automated gouging tool.He presented his findings to Mike LeMay and Justin Clark(both D10) who liked what they saw and in turn, broughtin Ryan McNulty (D10), a manufacturing engineer, toinvestigate further.Further research resulted in a vendor equipment test inthe welding lab, which Brian witnessed. The test indicatedgood results and a much reduced process time.Justin Clark said, “The old method was difficult from anergonomic point of view. The automated equipment doesaway with the mechanic having to maneuver that long,slow slide across the floor and it also eliminates a lot of thevibration from the hand grinding and the need to be soclose to the process. This is much better and it came aboutthrough Brian’s initiative.”Dean Brown fromthe welding lab andBrian Fraser duringtraining exercises inthe Aluminum Shop.BIW NEWS | January 2010 | 7Ultra 3000 leaving the building.