Naval Sea Systems Command
Total Ownership Cost
Initiatives
Joint Industry-Navy Improvements Initiative
(JINII) Brief
24 April 2001
CAPT William D. Needham
Assistant for Maintenance
Process Improvement, SEA 05N
202-781-3575
-NeedhamWD@navsea.navy.mil-
Agenda
Areas of Discussion
• Introduction
• Cumbersome Work Practices
• Engineering for Reduced Maintenance
• Top Management Attention/Top
Management Issues
• Capital Investment For Labor
2
Introduction
Naval Sea Systems Command Strategic Plan
• Strategic Goal
– Reduce total ownership cost of our products.
• Strategy
– Improve maintenance and lower costs by
eliminating our cumbersome work practices,
implementing condition-based maintenance, and
engineering for reduced maintenance.
– Improve fleet readiness with reduced maintenance
dollars
3
Cumbersome Work Practices
CWP - Fleet/NAVSEA System to identify high cost and
sailor workload processes for modification or deletion.
Results
• Received 283 items for review
• Dispositioned 150 CWP items
• Generated 250 document changes including
– 86 NSTM changes
– 86 PMS documents
– 27 GSO ACN/changes
– 16 DDGOS ACN/changes
• Currently reviewing 133 CWP items impacting 178 documents
for possible change and additional effort reductions
• Sailor workload reduction: 233 myr/yr
4
Cumbersome Work Practices
JINII Initiatives Selected for Briefing
• AWS Weld Procedure
• Shock Qualification Database
• Dry Dock Certification
• Hull Paint
5
Cumbersome Work Practices
AWS Weld Procedure
CWP-151
Source: JINII
• DISCUSSION :
– Current guidance requires that each activity (contractor) qualify
procedures to be used when performing welding
– Steps involve generation and demonstration by the shipyard and
submittal of procedure and results to SOS/NAVSEA for approval prior
to use in production
– American Welding Society (AWS) currently has tested weld
procedures for different applications and distribution as required
• ACTIONS:
– NAVSEAINST 9074.xx has been drafted that provides guidance for
reviewing AWS procedures
– $8K needed to review 9 submitted AWS procedures for Navy
application
6
Cumbersome Work Practices
Shock Qualification Database
CWP-123
Source: JINII
• DISCUSSION :
– Shock tests are required for shipboard machinery, equipment, and
systems
– Shock test requirements met by either testing or previous approval
– Shipbuilders often develop a new database for each program
– NSWC maintains Shock Qualification Database (SQD)
• ACTIONS:
– MOA established to allow use of SQD between SUPSHIP and
associated shipbuilder
– New construction ship shock data incorporated as completed
7
Cumbersome Work Practices
Docking Certification
CWP-129
Source: JINII
• DISCUSSION:
– Safety Certification Program for Dry-docking Facilities and
Shipbuilding Ways for US Navy Ships require audits every 2 years
or recertification every 5 years
– Navy Dry-dock Certification Program expensive
– Research indicates that no commercial equivalent is available
– Navy MIL-STD used by Fleet for certifying floating dry docks
• ACTIONS:
– Changed audits from 2 to 3 years
– Evaluating results of 3 year audits for further audit extensions
8
Cumbersome Work Practices
Hull Paint
CWP-139
Source: JINII
• DISCUSSION:
– Naval ships stay in dry-dock 2 to 3 times longer than commercial ships
– Primary reason is requirement for near-white blasting of entire hull vice
allowance for spot blasting
– Projected schedule improvement up to 5 days with spot blasting
– Project $40K cost reduction per DDG-51 hull if only 15,000 square feet spot
blasted vice entire hull (40,000 square feet)
• ACTIONS:
– Completed Standard Work Templates (SWT) for
• 631-97 - 100% preservation of underwater hull
• 631-98 - Underwater hull inspection/assessment only
• 631-99 - Preservation of underwater hull: options for top coat with anticorrosion and/or anti-fouling paint
– NAVSEA drawing 53711-803-7379820 to be issued to release SWT
9
Cumbersome Work Practices
Other JINII Issues
CWP
112
Issue
Welded CRES Pipe
115
Closure Couplings
152
Contractor Weld Procedure
213
Calibration Lab
226
Hand Rail Piping
228
Mechanical Valve Operators
10
Cumbersome Work Practices
Other CWP Examples
• Hydrostatic Testing
• Lube Oil Flush
• Tank Issues
• Controllable Pitch Propellers
11
Cumbersome Work Practices
Hydrostatic Testing
CWP-7, 59, 60
• Discussion:
Source: NNSY
– Testing to 135% of system pressure required periodically and for all pressure
components repaired or replaced
• Actions:
– Issued ACN 1/A and ACN 2/A to NSTM 505 approving the use of elevated NDT
(welding) and tightness check at NOP vice post repair hydrostatic testing following
weld or braze repairs
– Issued Standard Item 009-71 of FY99 that allows the contractor to select NOP vice
hydrostatic test pressure following weld repair, braze repair, and MAF installation
– Issued DDGOS ACN M09-97 to allow NSTM 505 requirements for brazed systems
– Currently reviewing request to reduce hydrostatic testing applied pressure duration
from 30 minutes (NSTM 505) to 10 minutes to coincide with commercial
specifications (ASME B31.1) and deleting additional weld NDT requirements
– Resolving comments on ACN 8/A to NSTM 505 specifying hydrostatic testing
requirements of fittings and components
12
Cumbersome Work Practices
Lube Oil Flush
CWP-75
Source: PNSY
• Discussion:
– Lube oil flushes are performed to remove corrosion and contaminants after work
is performed in the system
• Actions:
– Changed GSO for flush only when cleanliness is lost (ACP 514)
– Issued NSTM 262R4
• Flushing only required when cleanliness lost
• Reduced number of flushes (2 vice 3)
• Circulate oil for 2 sump volumes or 12 hours vice minimum of 12
hours
• Cleanliness criteria of NAS 1638
• Final flush temperature at NOT 125º F vice 165º F
13
Cumbersome Work Practices
Tank Issues
CWP-62, 182, 190, 223
Source: CNSL
• Discussion:
– NAVSEA documents provide various tank maintenance routines
• Actions:
– Issued ACN 1/A to NSTM 631 to inspect potable water tanks every 72
months (vice automatically paint tanks every 72 months)
– Issued MRCs changing JP-5 tank clean and inspect periodicity
• From 18 to 36 months for Service Tanks
• From 36 to 60 months for Storage Tanks
– Issued ICMP for surface ships changing fuel oil tank clean and inspect
periodicity
• From 60 to 120 months for Service tanks
• From 84 to 120 months for Storage Tanks (Compensated and
Uncompensated)
– Changing fuel oil tank clean and inspect MRCs to unscheduled
14
Cumbersome Work Practices
Controllable Pitch Propellers
CWP-237
Source: SEA 05
• Discussion:
– CPP ships currently require a DSRA every 5 years and an ROH every 10 years
– Desired to extend the docking interval for CPP ships to DSRA every 7 years
and ROH to every 14 years
– Controlling components are seals in the propeller blade mounting plate area
(Failure allows sea water to enter system)
• Actions:
– Developing AER to machine an O-ring groove in the propeller blade mounting
plate providing a backup dynamic O-ring seal which will allow DSRA
extension to 7 years
– Reviewing implementation of other system upgrades
• Improved blade mounting bolts
• Improved blade seal material
• Improved valve guide rod/spider assembly
15
Engineering for Reduced Maintenance
ERM – Fleet/NAVSEA process to reduce
maintenance and repair costs by implementing
advanced technologies.
• Fleet initiated program in 1996 to address Navy-wide
maintenance cost drivers
• New items added at Fleet request
Results
• Maintenance cost reduction of $100 M/yr to date
• 162 ship installations
• 23 new processes introduced into Fleet
• 36 new products introduced into Fleet
16
Engineering for Reduced Maintenance
Areas
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Tanks and Voids
Piping
Fasteners
Bilge Preservation
Tank Level Indication
Hull Systems
Composites
Ventilation Systems
Hydroblast Technology
17
Well Deck Systems
Sea Water System Fouling
Topside Systems
Combat Systems
Deck Coverings
Electrical Systems
Non-Paint Coatings
Closures
Engineering for Reduced Maintenance
Initiatives Selected for Briefing
• Tanks and Voids - Preservation
• Fasteners - Multijack Bolt Tensioners
• Sea Water System Fouling - Chemical Cleaning
• Combat Systems - Gel-in-Middle Connector Protectors
18
Engineering for Reduced Maintenance
Tanks and Voids
USS OGDEN (LPD-5) (PAC)
Preservation
• Problem:
– Current solvent-based coatings fail within 5 years.
– About 15,760 tanks (116 M sq-ft) targeted
– Tank preservation costs are $230 M/yr.
• Solution:
– Establish high build, solvent free epoxy protocols
to extend
• Sea water tanks from 5 years to 20 years
• CHT tanks from 2 years to 8 years
• Fuel/comp fuel tanks from 5 years to 20 years
• Potable water tanks from 5 years to 20 years
– About 10% of the ballast tanks (4.5 M sq-ft) are
coated with advanced coatings to date
– Projected cost avoidance is approximately $2 B
Current Tank Coatings after 36 months
Improved Tank Coatings after 36 months
19
Engineering for Reduced Maintenance
Fasteners
Multijack Bolt Tensioner
• Problem:
– Large bolts are used in high torque applications
– Often galling occurs when bolt and nut materials
are different and the component is exposed to heat
– Interference removal may also be required to
perform tightening
• Solution:
– Implement alternate bolting methodology to delete
galling and reduce area needed for conducting
tightening
– Technology installed on carrier reboilers, buttress
plate fasteners, and main steam guarding valve
cover plates; DDG main reduction gear snubber
sets and VLS foundation bolting; LHA main
propulsion boiler water drum access covers; and
submarine 3” launchers
– Projected cost avoidance of about $20.4 M
(reboilers on carriers)
20
Regular Nut
Multijack Bolt Tensioner
Engineering for Reduced Maintenance
Sea Water System Fouling
Chemical Cleaning
• Problem:
– Biological fouling in piping/heat exchangers leads
to poor operation
– Condenser head removal for water lancing and
mechanical cleaning costly and time consuming
Before
Cleaning
• Solution:
– Issued authorization and procedures for “I level”
organizations to conduct chemical cleaning of heat
exchangers shipboard
– PSNSY reported reduction of 1500 MH per
condenser using the approved in-place chemical
cleaning method as compared to the conventional
water lancing and mechanical cleaning method
– SIMA Norfolk, SIMA San Diego, and SIMA
Mayport completed qualification process
– Portable chlorinator installed on USS Carr (FFG52) (LANT)
21
After
Cleaning
Engineering for Reduced Maintenance
Combat Systems/Connectors
Gel-In-Middle (GIMCP) Connector
Protectors
• Problem:
– Preventive maintenance performed on over 32,000
topside connectors per year
– Current connector preservation is labor intensive
– Current materials are hazardous
– Service life varies widely
• Solution:
– GIMCP connector protectors are easily installed
and removed and are reusable
– No hazardous materials
– Service life increases and is consistent
– Projected Sailor workload reduction is 2K myr/yr
– Projected cost avoidance is $2M/yr
– 3000 GIMCPs currently installed (59 ships)
22
Top Management Attention/Top Management Issues
Vision
• Primary means for the Fleet, OPNAV, and
SYSCOMs to
– Identify surface ship and aircraft carrier
top maintenance problems
– Develop and execute solutions that
achieve targeted levels of performance
– Track results
23
Top Management Attention/Top Management Issues
Highlights
120
Open
Systems
100
Track
Closed
49
50
80
2
60
1
40
42
9
0
20
9
9
11
10
20
11
14
48
15
20
5
47
52
51
48
45
98-2
99-1
99-2
00-1
37
30
54
0
96-2
97-1
97-2
98-1
00-2
Cycle
*Overall decrease in systems due to merge of LANT and PAC databases in baselining of TMA/TMI
process; four new systems added.
24
Top Management Attention/Top Management Issues
Program Review
MK75 GUN MOUNTS
CI WS BLK 0
CI WS BLK 1
MK92 MOD 2 FCS
MK92 MOD 6 FCS
MK13 MOD 4 GMLS
AN/ SPS- 49 RADAR
OIL WATER SEP AR ATORS
BOAT DAVITS
AN/ WSN- 1,2,3,5 INS
RD- 379/ 390 RECORDER/ REPRO
AN/ USQ- 153 LAN
MK45 GUN MOD 1 GUN MOUNT
MK45 GUN MOD 2 GUN MOUNT
HF TRANS MITTER GROUP
CV INCINERATORS
CV SHIP SERVICE TURBINE GEN
CV BILGE AND DIRTY DRAIN SYS
MK 41, MOD 0 VLS
MK57 NSS Ms MODs 2/ 3
MK86 GFCS
SHIP SERVICE DIESEL GEN
AN/ SPS- 48E RADAR
LM 2500 GAS TURB PROP
AN/ SPN- 46( V)
HIGH PRESS AIR COMP
AN/ SP Y- 1B/ D RADAR
AN/ URT- 23C( V)1 HF XMTR
AN/ SQS- 53B SONAR
AN/ URT- 23D HF XMTR
AS- 4037/ 4037 A ANTENNA
DISTILLATION UNIT
AN/ SQQ- 32 SONAR
AN/ SLQ- 48 MINE NEUTRAL SYS
WATERTIGHT DO ORS
LCAC PROPULSION GAS TURB ENG
MECHANICAL SE ALS
GALLEY/ SCULLERY EQP T
DDG- 51 501K34 GAS TURB GEN
AUTO BUS XFER (ABT) S WITCHES VCHT SYSTEM AND INCINERATOR
RAPID SECURING DEVICE (RSD)
LSD 41/ 49 STERN TUBE SEAL
AN/ USQ- 119 GCCS
LCAC LIFT FAN
CONSOLE CONTROL PROP
DD- 963 CL DISTILLLING PLANT
LSD- 41 CL SSDG
RETRACTABLE KINGP OSTS
R- 12/ R- 114 A/ C PLANTS
LHA/ LHD BALLAST COMP
LSD- 41 CL PROPULSION DIESEL
CV 400HZ GENERATOR
CV FIRE PUMPS
CVN- 68 GENERATOR
CV MOTOR OPERATED VALVES
CV AIRCRAFT ELEVATOR
MK 41, MOD 1 VLS
CV ELEVATOR DECK EDGE DOOR
501 K17 GAS TURBINE GENERATOR AN/ SPN- 43C RADAR
AN/ SQR- 19 TOWED ARRAY
FO PURIFIERS
25
Capital Investment for Labor
CI Labor – ASN (RD&A) directed program to reduce
Sailor workload.
• All areas endorsed by Fleet
• Cost Reduction and Effectiveness Improvement
(CREI) Council oversight
Results
• Sailor Workload Reduction of 400 myr/yr
• Savings of $9M annually
• 273 ship installations
• 27 new products introduced into Fleet
• 31 new processes introduced into the Fleet
26
Capital Investment for Labor
Program Initiatives
• Machinery Space
Ventilation
• Mechanical Seals
• Nonskid Preservation
• Preservation Teams
• Sanitary Spaces
• Sealed Bearings
• Tank Level Indicators
• Tank Monitoring
• Ventilation
• Water Tight Doors
• Well Deck Overheads
•
•
•
•
•
•
•
•
•
Anti-Stain Paints
Automated Oil Analysis
Bilge Preservation
Calibration Reduction
Composites
Freeboard Paints
Fuel System Training
Hand Tools
High Durability Coatings
and Coverings
• Hydroblasting
• Improved Fuel Fill Control
System
27
Capital Investment for Labor
Initiatives Selected for Briefing
• Preservation Teams
• High Durability Coatings and Coverings
• Stainless Sanitary Space System
• Water Tight Doors
28
Capital Investment for Labor
Preservation Teams
• Problem
– Sailors devote more than 16 man-years per
year per ship to organizational level
preservation
– Sailors lack the training to utilize
advanced coatings
– Ships lack the resources to conduct
warfare training and execute preservation
Sailor Needle Gunning
• Solution
– Provide contractor, corrosion control
specialists to complete organizational level
preservation
– Utilize advanced coatings to drive down
life-cycle maintenance costs
29
Contractor Needle Gunning
Capital Investment for Labor
Preservation Teams
• Benefits:
USS Fitzgerald DDG 62
Fantail Whip Antenna
Motor
– Trained corrosion control specialists will conduct
preservation tasks normally performed by ship’s
force.
– Sailors will be better able to focus their attention on
training and increased opportunities for enhanced
leave & liberty while in homeport.
– Contractor personnel properly preparing and
preserving surfaces aboard ship removes the
preservation burden from ship’s force and provides
long-lasting solutions to troublesome shipboard
corrosion.
As Found
• Status:
– 15 Preservation Teams have been stood up
– Preservation Teams have performed work on 104
ships to date
– To date over 200,000 Sq Ft of surface area has been
preserved by Preservation Teams
After
30
Capital Investment for Labor
Preservation Teams
Accomplishments
USS Stump (DD-978)
• #2 GTG Intake (Dirty Side)
•
•
•
13 Month Evaluation
Material condition: Excellent
Normally recoated every 18 months
• #4 GTG Intake (Dirty Side)
•
•
•
13 Month Evaluation
Material condition: Excellent
Normally recoated every 18 months
31
Capital Investment for Labor
Preservation Teams
Accomplishments
USS Los Angeles (SSN 688) Valve Station - Port Side
As found
After
32
Capital Investment for Labor
Preservation Teams
Metrics to Date
Surface Area
Preserved
Sailor Workload
Reduction
(Sq Ft)
(man-years/year)
Number of Ship’s
Completing an
Availability
CARRIERS
15,881
4
6
CRUDES
90,227
43
43
AMPHIBS
91,696
45
19
SUBMARINES
40,689
26
36
Total
238,494
101
104
33
Capital Investment for Labor
High Durability Coatings & Coverings
• Problem:
– Current coatings and coverings require sailors to
spend 3,200 man-years per year fleet wide preserving
and 18,000 man-years per year maintaining deck
coatings and coverings
• Solution:
– Install NAVSEA approved, Fleet tested high
durability/wear resistant coatings and Durable Easy
Care (DEC) tile coverings in high traffic areas
– Projected sailor workload reduction
Conventional Deck
• For paint and DEC vs. vinyl tile: 12,750 myr/yr
• For paint and DEC vs. PRC: 864 myr/yr
– Projected cost avoidance
• For paint and DEC vs. vinyl tile: $18.15 M
• For paint and DEC vs. PRC: $29.69 M
– Currently installed on 57 ships
34
Low Maintenance Deck
Capital Investment for Labor
Stainless Sanitary Space Systems (S4)
• Problem:
– Current head design demands up to 4 manhours per day per head to maintain functional
performance and cleanliness.
• Solution:
– Implement Stainless Sanitary Space System
concept including
•
•
•
•
•
Multi-layered decking
High grade stainless steel components
High solids coatings
Reduced edge profile design
Overhead and bulkhead mounted fixtures
Current Conventional Head
– Projected sailor workload reduction is 2250
myr/yr
– Projected cost avoidance is $375M over 10
years
– Currently 19 spaces installed on 6 ships
35
Stainless Sanitary Space System
Capital Investment for Labor
Water Tight Doors
• Problem:
– Watertight doors require frequent maintenance.
– Fleet-wide, sailors spend over 590 manyears/year maintaining watertight doors.
• Solution:
– Redesign door hinge pins, bushings, and hinge
yokes to eliminate premature hinge failures
Hinge Pins and Bushings Currently in Use
– Redesign door dogs to incorporate more resistant
materials to extend life of dog bushings.
– Projected sailor workload reduction is 350
myr/yr
– Projected cost avoidance is $100 M
– Improved hinge installed on 3012 doors on 96
ships
– Improved dog sleeve installed on 1018 doors on
33 ships
36
Redesigned Hinge Pins and Bushings
Communications
Web Site
• Address
http://maintenance.navsea.navy.mil
• Contains basic information
– CWP
– ERM
– CI Labor
– TMA/TMI
37
Closing Comments
• TOC reduction requires partnership
between industry and government
• Cumbersome technical requirements
are sometimes needed due to unique
Navy requirements (e.g. Hand Rail
Piping)
38