News for the employees and friends of Northrop Grumman Marine Systems 2012 Volume 1

contents

Cutting Manufacturing Costs with High Speed Milling

Navy Honors WWII Vet ........................ 2

FBM Service Awards ............................ 3

Health & Safety Team.......................... 4

HealthWaves ............................................. 5

ECHO Corner ............................................. 6

SCS Community Services ................ 6

greeNG............................................................7

New Hires .................................................... 8

Training Calendar ................................... 8

Today’s competitive business environment requires each of us to reduce costs. The Operations

Department is improving affordability and exploring new technology and tech-niques to build production hardware. We are using the Manufacturing Technology Activity (MTA) process to get these results. MTA projects help us meet production milestones and deliver quality Virginia-class hardware, as well as provide innovative and affordable ORP designs. The team evaluated high-speed milling, or HSM as a potential cost saver. HSM is machining at a surface speed that is high enough to form a chip before the heat of deformation can enter the work piece itself. Keeping most of the heat in the chip, and out of the part surface and cutting tool, improves surface finish and cutting tool life compared to conventional machin-ing methods. Because HSM develops the required metal-removal horsepower at higher speed and lower torque, the force on the work piece is reduced and vibration-induced chatter can be more easily managed. The carbide cutting tools used for HSM can tol-erate surface speeds an order of magnitude greater than conventional high speed steel. The far greater toughness and the availabil-

l-r: Judy Benner, Daljit Singh, Larry Pfafflin, Stan Fornal, and Leticia Carreon.

ity of special coatings for carbide cutting tools make it possible to maintain their edge sharpness and profile accuracy for much longer than high-speed steel tools. The team evaluated HSM as a replacement process for broaching in generating suitable turbine blade grooves in rotors. We milled a scrap Virginia-class MPU rotor section with the Deckel Maho (DMG) machine in L1 using three tooling vendors (Seco, Niagra and Alden) to cut three groove types (curved, angled and straight). We demonstrated immediate benefits in this manufacturing process while main-taining quality. Average processing time using HSM was one-sixth of the conventional process, yet it still yielded superior surface finish and highly repeatable cutting.

(continued on page 3)

by Leticia Carreon and Judith Benner

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Congratulations to the New ERG Chairs for 2012Adelante – Jose Luis NarajanoAPPN – Janet ZhenConnect1NG – Bruno Gordonne

MsW – Greta PooserNGWE – Julia Chan PRIDA – Sarah Doan, Aram Yoo

SPROUT – Abbigail CeceVERITAS – Dave BostonVOICE – Valerie Marchand

Almost 67 years after the Battle of Okinawa, the US Navy finally recognized a South Bay resident for his heroics, and Marine Systems employees were there to witness it.

On the night of May 3, 1945, after Japanese kamikaze pilots attacked his ship, the USS Aaron Ward, Steward First Class Carl E. Clark, was the only one of his eight-man damage control team to survive. Despite a broken collarbone, Clark worked all night to put out the fires, including those near the ammunition locker, prevent-ing a fatal explosion that would have split the ship in half. After putting out the fires, Clark saved the lives of his ship-mates by single-handedly carrying fellow wounded sailors to the Aid Station for medical treatment. His heroic actions on the night of May 3 are the reason why so many sailors survived the attack and why the ship did not capsize. Clark received the Purple Heart and the Presidential Unit Citation after the incident, but it was the work of a history profes-sor at a local community college that uncovered the Menlo Park resident’s actions and, with the help of Congresswoman Anna Eshoo (D-CA), ensured that he received the Navy and Marine Corps Commendation Medal with the Combat “V.” Secretary of the Navy, Ray Mabus, presented Clark the medal in a ceremony held at Moffett Field on January 17. The Congresswoman’s office invited Glenn Perkins to attend the event, and he was joined by Jim Diani, PPG Capture Manager, and Andy Garlikov, Marketing Project Manager. While at the event, Perkins chatted with Congresswoman Eshoo and invited her to visit the plant. Her last visit in 2006 was to take part in the 100-year celebration held that year. Perkins also met Secretary Mabus, invited him to visit our plant, and discussed our work on the Virginia-class submarine. Perkins made certain that he knew some of the most critical work on both Virginia and Ohio Replacement was taking place just a few miles from Moffett Field, and that our employees would love to welcome him to the plant the next time he visited. s

Editorial BoardCamille Barnes-Mosley Ommer Bruce Steve Delmar Kris Falconer

Alisa GeeDerek GonzalezKimberly GrayLinda Harmon

Steve Harper Julie Morley Carol Pace Janet Tsai

Layout & DesignGail McClainMark Perry

Editor-in-ChiefAndy Garlikov

Assistant EditorKatie Liedtke

PhotographerJeremy Pommier

Navy Honors WWII Vet for Heroism in Battle of Okinawa by Andy Garlikov

Secretary of the Navy (SECNAV) the honorable Ray Mabus presents retired Chief Petty Officer Carl E. Clark with the Navy and Marine Corps Commendation medal with Combat “V” Device. Mabus presented the medal to the 95-year-old Clark for his actions during World War II. (U.S. Navy photo by Chief Mass Communication Specialist Sam Shavers/Released)

Glenn Perkins shares a light moment with the honorable Ray Mabus, Secretary of the Navy, at the commendation ceremony for retired Chief Petty Officer, Carl E. Clark.

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With these words, SP22 Launcher Branch Head CDR Dan Rochford, opened the annual FBM Service Awards at the December 12 Visibility Meeting, the final meeting of the year. Marine Systems has been a partner in the FBM Program since its in-ception in 1956. The award honors service in the FBM Program in increments of ten years. This year’s FBM Service Award recipients are: 10 Years: Matthew Cangianelli Bruce Fredrickson Bill Huffman Lisa Powell Russ Yamaichi

30 Years: Alan Ana Sandy Jennings Jack Martin Jim Wright Kris Falconer Congratulations to all recipients! s

Cutting Manufacturing Costs (continued from page 1)

2011 FBM Service Awards Presented to Ten Employees

“The people receiving these awards today represent nearly 200 years of service to the Fleet Ballistic Missile Program … that is a tremendous amount of talent and a remarkable achievement”

FBM Service Award recipients for 2011 from left to right: Alan Ana, Jack Martin, Russ Yamaichi, Bruce Fredrickson, Kris Falconer, Jim Wright, CDR Dan Rochford (SP22), Bill Huffman, Sandy Jennings, Matthew Cangianelli, Lisa Powell

This project shows that HSM can replace broaching. We found that process parameters, costs, and capabilities are superior even to the original assumptions used to justify this investigation.

by Kris Falconer

Process Speed

25

143

Hours

Tool Costs

1,746

$$$BroachingHSM

Surface Finish: Consistently better than required with no hand re-work

Root Profile Accuracy: All coupons cut during testing were within the toler-ance band.

Process Versatility: Straight, curved, and angled slots were produced within minutes of each other through simple programming changes.

Process Support: It was demonstrat-ed that this process could be supported by existing programming, tooling, machining, and engineering personnel without special training or equipment. Thank you to the design and test crew who worked hard to make the test possible: Judith Benner, Craig Brunson, Leticia Carreon, Stan Fornal, Andre Gaoiran, Nandor Horvath, Ming Ng, Dang Nguyen, and Larry Pfafflin. Special thanks to: Bruce Badger, Dante Balesteri, Merle Barron, John Chiprich, Roland Dumlao, Jose Lagos, Phu Phan, Daljit Singh, Michael Schneider, Mark Stallings. s

18,000

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by Marilu Perfetto and Alisa Gee

l-r: Marilu Perfetto, Richard Rosdail, Alisa Gee, Elizabeth Carbajal, Joanne Hickey, Dan DePalmo

Up Close and Personal with the Health and Safety Team

The Health and Safety Team brings a wealth of talent and experience to support our facility’s challenges and needs.

Alisa Gee, Health and Safety Manager, joined the company in 2010. She brings 21 years of EHS experience to Marine Systems. She has worked in other manufacturing and electronics assembly facilities, and is well-versed in the issues that plants like ours encounter. Alisa has regulatory experience from her work as a Hazardous Materials Specialist with Solano County Environmental Health. She is also a Registered Environmental Assessor with the State Department of Toxic Substances Control. Elizabeth Carbajal, who joined Northrop Grumman in 2007, is a Medical Assistant. She has eight years of experience and is a certified National Institute for Occupational Safety and Health-approved spirometry and occupational hearing tester. Dan DePalmo, Health and Safety Analyst, joined Northrop Grumman in 2003. He started his career as an industrial engineer and has 21 years of industrial hygienist/safety specialist experience. Dan believes that world-class injury anticipation and prevention is the key to ensuring the personal and professional future of every employee. Joanne Hickey just joined the company as the Health and Safety Administrator. She brings 25 years of administrative experience, 17 of which were spent with the Health and Safety department at United Defense. Joanne is a licensed Notary Public. Marilu Perfetto, Health and Safety Analyst, joined the company in 2003. She has 31 years of Occupational Health and Safety experience, including nineteen years with FMC/United Defense and four with SanDisk. Marilu administers Medical Services, Workers’ Compensation, and the Ergonomics program at Sunnyvale. “I believe we must embrace safety for our own good and the

quality of our lives,” says Marilu. “It’s not just about compliance. Safety is good business sense!” Richard Rosdail, Health and Safety Analyst, joined Northrop Grumman in 2002. Richard was an air crewman on the Grumman S2F (an anti-submarine warfare aircraft) while serving in the US Navy. Fol-lowing his Navy career, he worked for Pacific Airmotive Corporation, United Airlines, and Siemens Cor-

poration (where he was responsible for environmental health and safety for 16 years) before joining Northrop.

The following services are provided on-site to all employees:• Ergonomic Evaluations • First Aid • Vaccinations • Vision Testing and Certification • Audiogram • Spirometry • Blood Pressure and Weight Measurement • Mother’s Room for Nursing • Worker Compensation Evaluation and Management • Referral to Medical Provider Network (MPN) Physician • Near Miss and Incident Investigation • Coordination of Physical Examinations/ New Hires Physicals • Coordination of Substance Abuse Screening • Early Return-to-work Program • Parking Issues • Health and Safety Manufacturing Process Reviews/Evaluation

For more information about the Health and Safety team and how we help keep Marine Systems employees healthy and safe, please visit: http://marinenet.ca.essd.northgrum.com/hs/ or contact us at x5244. s

“I believe we must

embrace safety

for our own good

and quality of our

lives. It’s not just

about compliance.

Safety is good

business sense!”

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Be Smart About Your Heart!HealthWaves Presents

HEARTCHECK WEEK

Did you know that heart disease is the number one killer in the United States today? This February, HealthWaves is kicking off its HeartCheck screening campaign. HealthWaves encourages you to know your numbers by attending the heart health events offered onsite during HeartCheck week starting February 13th. Here’s the list of events taking place here in Sunnyvale:

MONDAY, FEBRUARY 13Take 5! Cholesterol and Blood Pressure ChecksBldg 41/44 Shop Area, 11:30 am-12 pm

WellCheck HealthWaves Screening Room (downstairs Bldg 82) 2 pm-4 pm ZumbaCafeteria, 4:30 pm-5:30 pm

TUESDAY, FEBRUARY 14WellCheck CR82-4, 6 am-12 pm

WEDNESDAY, FEBRUARY 15Healthy Heart SnackHealthWaves Office, 2:30 pm-3:30 pm THURSDAY, FEBRUARY 16Take 5! Cholesterol and Blood Pressure ChecksBldg 61 CR, 11:30 am-12 pm

Healthy Heart WalkMeet in front of HealthWaves Office2:30pm-2:45pm

ZumbaCafeteria, 4:45 pm-5:45 pm

E-mail kimberly.gray@ngc.com or call x3328 for additional information. s

Each year Healthwaves offers signature campaigns (i.e. Pressure Points, Biggest Loser, Cholesterol Countdown) corporate-wide. The 2012 signature campaign will be the Live Well Challenge, designed to address the most pressing concerns identified through the completion of the Live Well Profile: weight management, blood pressure, and stress management. This three-month challenge will focus on physical movement, nutri-tion and stress management/relax-ation. HealthWaves will provide par-ticipants with information about small steps they can take to improve in the specified focus area each month, ad-dressing each of the top three health concerns of our workforce. Participants will receive activity sheets, e-mailed weekly. By completing the weekly activities, they automatically enter monthly raffles. These activities will not only make the participants eligible for prizes, but will improve their energy level and reduce stress by incorporat-ing positive changes into their wellness routines. Monthly raffle prizes include an iPod, fruit baskets, and a SpaFinder gift-card. Also, all participants who submit an “I did it!” statement at the end of each month will receive a small additional prize. The challenge will kick off in early February. E-mail kimberly.gray@ngc.com or call Kimberly at x3328 for addi-tional information, or if you wish to register for the Live Well Challenge. s

Get ready to

think outside the gym. The Virgin Health-Miles program makes getting active not just

another to-do, but a fun and integral part of

your world. And did we mention rewards?! Northrop Grumman employees can earn up to $150 a year for getting active and participating in other healthy activities. Every non-represented Northrop Grumman employee who belongs to a company-sponsored health plan is eligible to receive a free GoZone activity tracker. The GoZone, a device that connects to the internet (via a personalized LifeZone web site) allows employees to track their activ-ity and exercise every day. It counts the steps you take and the minutes you engage in vigorous activity, to earn points toward “HealthCash” gift cards. Through the LifeZone web site, em-ployees can see their progress over time, connect with fellow employees to motivate each other and participate in challenges that earn additional points toward Health-Cash rewards. Some of the Sunnyvale employees who have signed up for the program and started using it are already seeing results. According to Abbigail Cece, HR general-ist, “Tracking is simple and easy, and best of all, earns you rewards! I’ve earned 2,000 points in 10 days just by keeping track of what I’ve always done! That means I’m one-third of the way to earning my first $25 reward card!” When you receive your GoZone and log in for the first time, search for the group “Northrop Grumman Marine Systems” or “Zumba Fitness Sunnyvale” to find colleagues. To learn more, call Abbigail Cece at x2487. Or visit www.virginhealthmiles.com/ngc to find out how to earn up to $150 – or to sign up today! s

Virgin HealthMiles: The World is Your Workout™

by Kimberly Gray

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The Employees Charity Organization of Northrop Grumman (ECHO) allows our employees to contribute to charitable and non-profit organi-zations through workplace giving. Through ECHO, employees can give to schools, religious organizations, art and cultural organizations, services for the elderly, youth groups and disabled, animal welfare, environmental groups, and health-related organizations. Each issue, we will profile an organization our Marine Systems colleagues support. ECHO is accessible from the Marine Systems Home Page. If you are not registered yet, click on ECHO and follow the registration instructions.

At Marine Systems, when we think of Sunnyvale Community Services (SCS), we picture the regular volunteers who package food bags with canned goods, cereals and other essentials. SCS distributes these bags to low-income families in Sunnyvale who live in poverty. Poverty in Sunnyvale? People don’t usually associate Sunnyvale with poverty or people in need, but sadly, they should. United Way Silicon Valley identified Sunnyvale as one of the two fastest growing poverty areas in the county. 27% of the city’s 140,000 residents fall into extremely low-income categories based on national standards. But Sunnyvale Community Services is a lot more than bagged foods. Founded in 1970, Sunnyvale Community Services is an independent, non-profit emergency assistance agency. It’s mission is to prevent homelessness and hunger for low-income families and seniors facing temporary crises. They provide financial aid, food, and other support that prevents larger problems with more expensive solutions. These services include:

• Financialhelptopreventevictionsandutilitydisconnectionsand to pay medical and other critical bills

• Financialaidtohelpworkinghomelessfamiliesregainpermanenthousing• Monthlyfoodprogramsforfamiliesandseniors• AKids’SummerFoodprogram,providingmorefoodtolow-incomefamilieswhose

children rely on free school breakfasts and lunches during the school year • Emergencyfoodbags• CommunityChristmasCenteraffordinglow-incomefamiliesthedignityofselecting

a two-week supply of food, toys and gifts for children of all ages• ClothesCloset• Informationandreferralservices

With your support, Sunnyvale Community Services can continue to help reduce the barriers for individuals and families here in Sunnyvale facing hunger, homelessness, and other challenges, by helping them become productive and healthy members of the com-munity. Your donations through ECHO help make this possible. s

Thank You!

Second Harvest Annual Food Drive

Sunnyvale Community Services

Marine Systems Employees Volunteer at SCS On Friday, December 12th, 33 Marine Systems employees volunteered to assist SCS in their Community Christmas Center. During the morning shift, our employees restocked, repacked, sorted, and organized the food and toys on all the shelves. By 1 p.m. the “store” was ready for the SCS clients to do their Christmas shopping. Our employees assisted SCS clients with shopping and loading their cars with a two-week supply of food and gifts, and continued to re-stock the shelves. It was an amazing day and everyone came away humbled by the experience and proud to have helped.

A special thanks to our employees: Camille Barnes-Mosley Lynn Bui Nelda Carveiro Abbigail Cece Ellen Chan Brandon DeGuia Sarah Doan Ellexis Frantz Bruno Gordonne Ricardo Grillo Linda Harmon Steven Harper Jaime Hinojosa Craig Hultgren Pam Kalkat Dennis Kuruma Cally Lam

Katie Liedtke Tommy Lo Valerie Marchand Bob Miller Lisa Moore Madeline Nguyen Carol Pace Rose Padilla Jed Parker Arlene Pedroia Gil Rios Valerie Salcido Chris Shelner Lee Smith Gigi Spencer Cheryl Yee Ying Zhang

for your generous donation of 1,492 lbs of food

Triple the amount from 2010!

Corner

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Water Conservation The water conservation initiative focuses on buildings larger than 100,000 square feet at each campus. At Sunnyvale, there are five buildings subject to the water conservation best management practices (BMPs): 11, 21, 31, 41, and 61. We assessed each building against 22 BMPs, which determined compliance to the 2011 Sector goal of 55%. BMPs assess water usage in restrooms, cafete-rias, labs, cleaning facilities, irrigation and landscaping, and manufacturing processes. After implementating the 2011 BMPs in each building, we finished off the year with all five buildings surpassing the goal.

The greeNinG of Marine Systems Continues…by Julie Morley

NG Corporate finalized the details of the greeNG Initiative last year. The major components include carbon footprint (greenhouse gas emissions) reduction, water conservation, solid waste management/reduction, and employee engagement.

2012 TECH CHALLENGE Advisors Needed!

Everyone is invited to join the advisor team for the 25th Annual Tech Challenge.

No technical background is required,

but enthusiasm to inspire innovation is desired.

Please e-mail Camille Barnes-Mosley if you are interested.

Greenhouse Gas Reduction Once again we surpassed our green-house gas goal in 2011 by more than three times! We made these reductions through a combination of Facilities and Engineering, Manufacturing, and Logistics (EM&L) projects. EM&L projects resulted in a 73.82 metric ton greenhouse gas (GhG) reduction. We did this by removing or no longer using non-essential equipment, installing energy-efficient motors in manufacturing equipment, and welding pre-heat process changes. The energy savings equated to 3,667 kWh electricity, 13,164 therms natural gas, and 347 gallons propane.

Solid Waste Management The solid waste management program is similar to the water conser-vation policy in that it applies to buildings greater than 100,000 square feet. Solid Waste BMPs address waste streams gen-erated by facilities and food service operations, handling of electronic equipment and batteries. We surpassed the Sector’s goal of 66% for each building. Our plant has excelled in its recycling program. We’ve gone from a 40% recy-cling rate in 2007 to 73% in 2011, and from recycling less than 400 tons of solid waste in 2007, to more than 1,000 tons last year. You probably could guess that most of it – 60%, or 608 tons – was scrap metal. But, did you know that we also recycled more than 34 tons of paper and almost ten tons of batteries? Or that our efforts kept about 3,000 pounds each of lamps and janitorial supplies out of landfills? And even though we started late in the year, our newest recycling effort yielded almost three tons of cardboard! Everyone at Marine Systems con-tributed to the success of our recycling programs. Recycling saves the company money and reduces our impact on local landfills. Keep up the good work! s

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Welcome New Hires

Jarrod CarterPamela Burrows Ryan Harper Aaron Chiu Jesse Cox

Wilfrido Zambrano Kevin Louie Joann Hickey Hassan Naqvi David Underwood

Marine Systems Training Calendar Training information is now available via the Marinenet home page. On it, you can find out about available Sunnyvale training that:

• IspartofyourJSSIcurriculum • Willimproveyourskills • Isbeneficialforyourcareerdevelopment

By clicking on the link under “Local Info” indicated below, you can view the scheduled and planned trainings on-site.

For more information, the site lists the Point of Contact for each training. For further questions, please contact Learning and Development Generalist, Connie Saito, at x2482. s

Marine Systems Training Calendar