Implementation of NAVWELD
Software to Support Electronic
Welding Procedures
AWS Shipbuilding Conference
May 11, 2011
Paul Hebert
Manager, Welding Engineering
HUNTINGTON INGALLS INDUSTRIES PRIVATE/PROPRIETARY LEVEL I
Overview
Strategy/Implementation
Objectives
Advantages
Software Selection
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Procedure of Tomorrow
(POT)
HUNTINGTON INGALLS INDUSTRIES PRIVATE/PROPRIETARY LEVEL I
Challenges
Objectives
#1 - Electronic Only
#2 - All Inclusive
#3 – User Friendly:
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- Finding Procedure
- Navigating
- Comprehension
HUNTINGTON INGALLS INDUSTRIES PRIVATE/PROPRIETARY LEVEL I
Software Selection
=> Commercial Standards (i.e. ASME)
=> MIL Standards (i.e. MIL-STD-248)
Develop MIL-STD Specific Software
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HUNTINGTON INGALLS INDUSTRIES PRIVATE/PROPRIETARY LEVEL I
Software Selection Development
Team Members
NGSB-NN
GDEB
NAVSEA
NSWC - Carderock
2003
SBIR
Phase I
2004
2005
2006
2007
SBIR - Phase II
NMC
Weld QC
2008
2009
MANTECH
NavWeld
Web-based software application & database that assists the user in developing
welding procedures according to NAVSEA requirements.
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HUNTINGTON INGALLS INDUSTRIES PRIVATE/PROPRIETARY LEVEL I
Software Selection
NavWeld Modules
 Procedure Qualification Record (PQR)
•
•
•
•
Essential Elements
NDE Tests
Destructive Tests & Number of Samples
Qualified Ranges
• Fabrication Document Requirements
 Welding/Brazing Procedure Specification (WPS)
• Essential Elements
• Fabrication Document Requirements
 Welder/Brazer Performance Qualification (WPQR)
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•
•
•
•
•
Essential Elements
NDE Tests
Destructive Tests & Number of Samples
Qualified Ranges
Tracks Welder History
HUNTINGTON INGALLS INDUSTRIES PRIVATE/PROPRIETARY LEVEL I
Software Selection
NavWeld – Processes and Documents
Process
Qualification
Documents
Fabrication
Documents
• TP278
Arc
• TP248
• TP1688
• ABS/NVR - 2007
• MIL-STD-1689A
• ABS/NVR - 2007
Stud
Resistance
Brazing
(Piping)
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• TP1688
• TP248
• ABS/NVR - 2007
• MIL-STD-1689A
• ABS/NVR - 2007
• AWS D17.2
• AWS D17.2
• 0900-LP-001-7000
• 0900-LP-001-7000
HUNTINGTON INGALLS INDUSTRIES PRIVATE/PROPRIETARY LEVEL I
Strategy / Implementation
NAVSEAs
Engineer
Engineers
Historian
Evolution of Legacy Procedures
Fortune Teller
Clean Up for POT
All Inclusive Review = Specifications / PQR’s / History
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Document for Each WPS
HUNTINGTON INGALLS INDUSTRIES PRIVATE/PROPRIETARY LEVEL I
Preheat
Strategy / Implementation
Welding Parameters
Specification
Legacy Procedures – Information in Multiple Locations
Consolidate for POT
Procedure = Handful of Pages = All Requirements = Certified = Approved
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Hand to the welder to use
HUNTINGTON INGALLS INDUSTRIES PRIVATE/PROPRIETARY LEVEL I
Strategy / Implementation
Generic Legacy Procedures – Given Material / Process
Multiple
Filler Metals
Special
Exceptions
Subtle
Differences
Multiple
Joint Designs
Make POT More Specific
One filler = limited joint designs = minimal notes / exceptions
One Technique in Legacy Procedure = 3 or 4 or 5 in POT (dbase – who cares?)
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HUNTINGTON INGALLS INDUSTRIES PRIVATE/PROPRIETARY LEVEL I
Strategy / Implementation
Legacy Procedure Revisions
User to ID Changes => 800+ Pg.
Procedure
POT Revisions – Clear and Visible
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Revision Record - First Page of Each WTN = What + When + Why Changed
HUNTINGTON INGALLS INDUSTRIES PRIVATE/PROPRIETARY LEVEL I
Advantages
Creating PQR / WPS
Once PQR created - Print Qualified
Range Report to ID procedure ranges
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HUNTINGTON INGALLS INDUSTRIES PRIVATE/PROPRIETARY LEVEL I
Advantages
Creating PQR / WPS
Enables and Disables Fields Based on Inputs
***If you select
ceramic backing
you have to
enter
manufacturer
and type***
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HUNTINGTON INGALLS INDUSTRIES PRIVATE/PROPRIETARY LEVEL I
Advantages
Creating PQR / WPS
Bounces input against the spec and flags incomplete info
***Missing Minimum Travel Speed***
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HUNTINGTON INGALLS INDUSTRIES PRIVATE/PROPRIETARY LEVEL I
Advantages
Creating PQR / WPS
Prompts user where to go in spec for rule
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HUNTINGTON INGALLS INDUSTRIES PRIVATE/PROPRIETARY LEVEL I
Advantages
Real Time Revisions
Old System: Make change in MS Word + send to QA + QA send
to repro + QA make distribution + recipients make changes to
paper copy = Weeks
NAVWELD System: Make Change in Dbase + Validate
electronically + Revised Procedure ready for use = Minutes
Caution
Real Time Revision = Double Edged Sword
Person looks at procedure – we make
change afterwards – he is using an
outdated procedure.
Solution:
Adding something no big deal – anytime
Taking something away – we need to take the action to let user know.
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HUNTINGTON INGALLS INDUSTRIES PRIVATE/PROPRIETARY LEVEL I
Advantages
Procedures Easy To Find
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HUNTINGTON INGALLS INDUSTRIES PRIVATE/PROPRIETARY LEVEL I
Advantages
Consistent Format
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HUNTINGTON INGALLS INDUSTRIES PRIVATE/PROPRIETARY LEVEL I
Advantages
Procedure Stand-Alone Printed Out
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HUNTINGTON INGALLS INDUSTRIES PRIVATE/PROPRIETARY LEVEL I
Advantages
Green
SSPs = 16 Proc X 500 pgs each X 50 copies = 400,000 pages (not counting revisions)
SOPs = 91 Proc X 20 pgs each X 5 copies = 9100 pages (not counting revisions)
Not counting electricity to create and copy + fuel to distribute
Paper = .0038” thk. X 409,100 pgs. = 130 feet high stack
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HUNTINGTON INGALLS INDUSTRIES PRIVATE/PROPRIETARY LEVEL I
Advantages
Electronic Data
Kiosk on shop floor / ship
PDA – Foremen to carry procedure with them
Weld Procedure Data
Welder Qual data
Eng Data
User
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Job Assignment
HUNTINGTON INGALLS INDUSTRIES PRIVATE/PROPRIETARY LEVEL I
Challenges
ABC
Computer Literacy – What about those who aren’t
proficient with computers?
- Ease of Use
- Training
Reliability - What happens if the computer crashes?
- Back-Up Paper Copy
- Back-Up PDF Copy
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Resistance to Change – Why can’t you leave the
procedures the way they’ve always been?
- Involve users in the process
- Stress the advantages
- Listen
- Tenacity
HUNTINGTON INGALLS INDUSTRIES PRIVATE/PROPRIETARY LEVEL I
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