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Norfolk Naval Shipyard
Any Ship, Any Time, Any WhereAny Ship, Any Time, Any Where
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Norfolk Naval Shipyard
Any Ship, Any Time, Any WhereAny Ship, Any Time, Any Where
AGENDA TOPICS
INTRODUCTIONINTRODUCTION
FLEET READINESS CONSTRUCTFLEET READINESS CONSTRUCT
USS GEORGE WASHINGTON USS GEORGE WASHINGTON LEAN APPROACHLEAN APPROACH
CAPSTONE SHIPALTCAPSTONE SHIPALT
WRAP-UPWRAP-UP
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Norfolk Naval Shipyard
Any Ship, Any Time, Any WhereAny Ship, Any Time, Any Where
NAVY ENTERPRISE CONSTRUCT
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Norfolk Naval Shipyard
Any Ship, Any Time, Any WhereAny Ship, Any Time, Any Where
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Norfolk Naval Shipyard
Any Ship, Any Time, Any WhereAny Ship, Any Time, Any Where
January 22nd, 2007, visit to NNSY to see LEAN in action.
Takeaways from visit:• Process improvement needs to be senior manager driven• Requires employee engagement & enthusiasm• PI focus on bottom line – ROI• Aggressive pursuit of process consistency and knowledge sharing
CFFC “BOOTS ON THE GROUND”CFFC “BOOTS ON THE GROUND”
CFFC, NAVSEA, SUBFOR, AIRLANT, SURFLANT, CFFC N43, SEA04, & MARMC attended. 5
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Norfolk Naval Shipyard
Any Ship, Any Time, Any WhereAny Ship, Any Time, Any Where
eee aaa nnnLLL eee aaa nnnLLL
SortSituateShine
StandardizeSustain
* Safety (NNSY)
Value Stream Champion Execute
Projects(notional 3-6
months)
Projects(notional 3-6
months)
Rapid Improvement Event (RIE)(7 week cycle)
Rapid Improvement Event (RIE)(7 week cycle)
Just Do ItsJust Do Its
5S Standard Work Flow Pull
Team Leader (Line)Team Members (Line)GreenBelt (GB) Facilitate
Rapid Improvement Event (RIE)(7 week cycle)
BB
Value Stream Analysis (VSA)Value Stream
Analysis (VSA)Rapid Improvement
Plan (RIP)
Value Stream Analysis (VSA)Value Stream
Analysis (VSA)
BB/Value Stream Champion, Execute RIP
Value Stream Analysis (VSA)
BB/Sensei, 2-3 days, Develop RIP
Executive Planning Session (EPS)
BlackBelt (BB)/Sensei, 2 days, 6-7 Value streams
Projects(notional 3-6
months)
Team Leader (Line)Cross-Functional TeamBlackBeltGB (assist as needed)
Just Do ItsProjects(notional 3-6
months)
Projects(notional 3-6
months)
Rapid Improvement Event (RIE)(7 week cycle)
Rapid Improvement Event (RIE)(7 week cycle)
Just Do ItsJust Do Its
5S Standard Work Flow Pull
Team Leader (Line)Team Members (Line)GreenBelt (GB) Facilitate
Rapid Improvement Event (RIE)(7 week cycle)
BB
Value Stream Analysis (VSA)Value Stream
Analysis (VSA)Rapid Improvement
Plan (RIP)
Value Stream Analysis (VSA)Value Stream
Analysis (VSA)
BB/Value Stream Champion, Execute RIP
Value Stream Analysis (VSA)
BB/Sensei, 2-3 days, Develop RIP
Executive Planning Session (EPS)
BlackBelt (BB)/Sensei, 2 days, 6-7 Value streams
Projects(notional 3-6
months)
Team Leader (Line)Cross-Functional TeamBlackBeltGB (assist as needed)
Just Do Its(Single Action/Short Turnaround Time)
Value Stream Champion Execute
Projects(notional 3-6
months)
Projects(notional 3-6
months)
Rapid Improvement Event (RIE)(7 week cycle)
Rapid Improvement Event (RIE)(7 week cycle)
Just Do ItsJust Do Its
5S Standard Work Flow Pull
Team Leader (Line)Team Members (Line)GreenBelt (GB) Facilitate
Rapid Improvement Event (RIE)(7 week cycle)
BB
Value Stream Analysis (VSA)Value Stream
Analysis (VSA)Rapid Improvement
Plan (RIP)
Value Stream Analysis (VSA)Value Stream
Analysis (VSA)
BB/Value Stream Champion, Execute RIP
Value Stream Analysis (VSA)
BB/Sensei, 2-3 days, Develop RIP
Executive Planning Session (EPS)
BlackBelt (BB)/Sensei, 2 days, 6-7 Value streams
Projects(notional 3-6
months)
Team Leader (Line)Cross-Functional TeamBlackBeltGB (assist as needed)
Just Do ItsProjects(notional 3-6
months)
Projects(notional 3-6
months)
Rapid Improvement Event (RIE)(7 week cycle)
Rapid Improvement Event (RIE)(7 week cycle)
Just Do ItsJust Do Its
5S Standard Work Flow Pull
Team Leader (Line)Team Members (Line)GreenBelt (GB) Facilitate
Rapid Improvement Event (RIE)(7 week cycle)
BB
Value Stream Analysis (VSA)Value Stream
Analysis (VSA)Rapid Improvement
Plan (RIP)
Value Stream Analysis (VSA)Value Stream
Analysis (VSA)
BB/Value Stream Champion, Execute RIP
Value Stream Analysis (VSA)
BB/Sensei, 2-3 days, Develop RIP
Executive Planning Session (EPS)
BlackBelt (BB)/Sensei, 2 days, 6-7 Value streams
Projects(notional 3-6
months)
Team Leader (Line)Cross-Functional TeamBlackBeltGB (assist as needed)
Just Do Its(Single Action/Short Turnaround Time)
Lean Release 1.0: (SEA04X 25 Jan 06)Initiatives:
WIPCON: Work In Process Controls at the Supervisor Level
WATERFRONT Improve ContinuousANDON Flow of WaterfrontSERVICES: Production Work
BUNDLED Install Temporary SERVICES: Services to Efficiently
Support the Mechanic
Lean Release 2.0: (SEA04X 11 Sep 06)Initiatives:
PROJECT Suite of 6 initiativesMANAGEMENT:
REMOVE DT-276 Cut Cables to ReduceHYDROPHONES: removal time
PLURAL PAINT Reduce Travel Time for PUMP HOUSE: Preservation Workers
DEPOT LEVEL Material Turn In ProcessREPAIRABLES(DLRs):
MATERIAL: Co-locate material toENVELOPE project team
Lean Release 3.0: (Draft Package Developed)
Expected Results:- Standardization- Improved CostPerformance
Lean Release 1.0: (SEA04X 25 Jan 06)Initiatives:
WIPCON: Work In Process Controls at the Supervisor Level
WATERFRONT Improve ContinuousANDON Flow of WaterfrontSERVICES: Production Work
BUNDLED Install Temporary SERVICES: Services to Efficiently
Support the Mechanic
Lean Release 2.0: (SEA04X 11 Sep 06)
Initiatives:PROJECT Suite of 6 initiativesMANAGEMENT:
REMOVE DT-276 Cut Cables to ReduceHYDROPHONES: removal time
PLURAL PAINT Reduce Travel Time for PUMP HOUSE: Preservation Workers
DEPOT LEVEL Material Turn In ProcessREPAIRABLES(DLRs):
MATERIAL: Co-locate material toENVELOPE project team
Lean Release 3.0: (Draft Package Developed)
Expected Results:- Standardization- Improved CostPerformance
CONTINUOUS PROCESS
IMPROVEMENT
Pennsylvania
Indiana
California
Virginia
Maryland
Florida
Maine
33
L e a n
Hawaii
Mississippi
WashingtonPUGET SOUND NSY & IMF
NUWC KEYPORT
PEARL HARBOR NSY & IMF
SUPSHIP Bath (detachment)NSWC CORONANSWC PORT HUENEME
South West Regional Repair
NSWC CRANE
SUPSHIP GULF COAST
NSWC Coastal Systems Station (Panama City)
NSWC Ship Systems EngineeringStation
NAVAL Foundry & Propeller Center
NAVSHIPYD NORFOLKNSWC DAHLGRENSurface Combat Systems
Center (Dam Neck)Mid Atlantic Regional Repair
NAVSEA HQ PEOsNSWC HQ
Washington DC
NSWC CARDEROCKNSWC INDIAN HEAD
SUPSHIP GROTON
NUWC HQNUWC NEWPORT
Connecticut
NAVSHIPYD PORTSMOUTHSUPSHIP BATHSUBMEPP Rhode Island
Pennsylvania
Indiana
California
Virginia
Maryland
Florida
Maine
333333
L e a nL e a n
Hawaii
Mississippi
WashingtonPUGET SOUND NSY & IMF
NUWC KEYPORT
PEARL HARBOR NSY & IMF
SUPSHIP Bath (detachment)NSWC CORONANSWC PORT HUENEME
South West Regional Repair
NSWC CRANE
SUPSHIP GULF COAST
NSWC Coastal Systems Station (Panama City)
NSWC Ship Systems EngineeringStation
NAVAL Foundry & Propeller Center
NAVSHIPYD NORFOLKNSWC DAHLGRENSurface Combat Systems
Center (Dam Neck)Mid Atlantic Regional Repair
NAVSEA HQ PEOsNSWC HQ
Washington DC
NSWC CARDEROCKNSWC INDIAN HEAD
SUPSHIP GROTON
NUWC HQNUWC NEWPORT
Connecticut
NAVSHIPYD PORTSMOUTHSUPSHIP BATHSUBMEPP Rhode Island
NAVSEANAVSEACorporateCorporateTraining:Training:
Courses –
• NAVSEA HQ/PEOs
• Naval Warfare Centers
• Naval Shipyards
• SUPSHIP
• NAVSEA HQ/PEOs
• Naval Warfare Centers
• Naval Shipyards
• SUPSHIP
Black Belt Green Belts ChampionsMARMC 17 49 86SERMC 3 37 1
FFC 0 2 3
(MARMC provides a full-time BB instructor to support colleges efforts)
Regional Training for Green Belts &
Champions
Regional Training for Green Belts &
Champions
West Coast L6SC Site –NSWC Port Hueneme
East Coast L6SC Site –
Norfolk Naval Shipyard
# of Classes
Average Class Size
Total Trained
Black Belt -Five weeks of instruction over six months 22 22 379
Green Belt -Five days of instruction over one week 89 22 1828
Champion - Three days of instruction 47 22 1003
19 22 499
177 3709
Course Title
TOTALLean Repair Exercise
OUTPUT
4 NSYs +
2 Private
Project ManagementProject ManagementNVSNVS – NSSG Lead– NSSG Lead
Platform NVS (Tier-One)Platform NVS (Tier-One)
Lifting & Handling NVSLifting & Handling NVS– NNSY Lead– NNSY Lead
Industrial ProcessIndustrial ProcessNVSNVS – PSNSY Lead– PSNSY Lead
Pro
ce
ss
/Fu
nc
tio
na
l NV
S (
Tie
r-T
wo
)P
roc
es
s/F
un
cti
on
al N
VS
(T
ier-
Tw
o)
Standardizing Across PlatformsStandardizing Across Platforms
Sta
nd
ard
izin
g A
cro
ss
Sta
nd
ard
izin
g A
cro
ss
NS
Ys
NS
Ys
Material NVSMaterial NVS ––
SEA04L LeadSEA04L Lead
Training NVSTraining NVS ––
NNSY LeadNNSY Lead
Resource ManagementResource Management
NVSNVS – SEA04X Lead– SEA04X Lead
CarrierCarrierNVSNVS
NAVSEA 04XNAVSEA 04X
Submarine NVS
SSN 688SSN 688 SSBN/SSGNSSBN/SSGN
NAVSEA 04XNAVSEA 04X
1 2
3 3 3
1 211 1
2 333
1 2
444 555
OUTPUT
4 NSYs +
2 Private
4 NSYs +
2 Private
Project ManagementProject ManagementNVSNVS – NSSG Lead– NSSG Lead
Platform NVS (Tier-One)Platform NVS (Tier-One)
Lifting & Handling NVSLifting & Handling NVS– NNSY Lead– NNSY Lead
Industrial ProcessIndustrial ProcessNVSNVS – PSNSY Lead– PSNSY Lead
Pro
ce
ss
/Fu
nc
tio
na
l NV
S (
Tie
r-T
wo
)P
roc
es
s/F
un
cti
on
al N
VS
(T
ier-
Tw
o)
Standardizing Across PlatformsStandardizing Across Platforms
Sta
nd
ard
izin
g A
cro
ss
Sta
nd
ard
izin
g A
cro
ss
NS
Ys
NS
Ys
Material NVSMaterial NVS ––
SEA04L LeadSEA04L Lead
Training NVSTraining NVS ––
NNSY LeadNNSY Lead
Resource ManagementResource Management
NVSNVS – SEA04X Lead– SEA04X Lead
CarrierCarrierNVSNVS
NAVSEA 04XNAVSEA 04X
Submarine NVS
SSN 688SSN 688 SSBN/SSGNSSBN/SSGN
NAVSEA 04XNAVSEA 04X
1 2
3 3 3
1 211 1
2 333
1 2
444 555
Lean Release 1.0Lean Release 2.0
SEA 04 Target Pace for FY07One LR/Quarter
Lean Release 1.0USS THEODORE ROOSEVELT CVN 71 PIA NNSYUSS ALASKA SSBN 732 ERO NNSYUSS GEORGE WASHINGTON CVN 73 PIA NNSYUSS TUCSON SSN 770 DMP NNSYUSS OLYMPIA SSN 717 ERO PHNSY & IMFUSS COLUMBIA SSN 771 DMP PHNSY & IMFUSS GREENEVILLE SSN 772 DMP PHNSY & IMFUSS HARTFORD SSN 768 DMP PNSYUSS SANTA FE SSN 763 DMP PNSYUSS PHILADELPHIA SSN 690 PIRA PNSYUSS LOUISVILLE SSN 724 EOH PNSYUSS MEMPHIS SSN 691 PIRA PNSYUSS ALABAMA SSBN 731 ERO PSNS & IMFUSS ABRAHAM LINCOLN CVN 72 PIA PSNS & IMFUSS NEBRASKA SSBN 739 ERP PSNS & IMFUSS SAN FRANCISCO SSN 711 EDSRA PSNS & IMFUSS RONALD REAGAN CVN 76 PIA PSNS & IMFUSS JOHN C STENNIS CVN 74 PIA PSNS & IMF
Lean Release 2.0USS DWIGHT D.EISENHOWER CVN 69 PIA NNSYUSS THEODORE ROOSEVELT CVN 71 PIA NNSYUSS HARRY S TRUMAN CVN 75 PIA NNSYUSS AUGUSTA SSN 710 IA NNSYUSS TUCSON SSN 770 DMP NNSYUSS MINNEAPOLIS-ST PAUL SSN 708 IA PHNSY & IMFUSS COLUMBIA SSN 771 DMP PHNSY & IMFUSS CHEYENNE SSN 773 DMP PHNSY & IMFUSS MEMPHIS SSN 691 PIRA PNSYUSS HYMAN G. RICKOVER SSN 709 IA PNSYUSS OKLAHOMA CITY SSN 723 EOH PNSYUSS LOUISVILLE SSN 724 EOH PNSYUSS GREENEVILLE SSN 772 DMP PNSYUSS NIMITZ CVN 68 PIA PSNS & IMFUSS JOHN C STENNIS CVN 74 PIA PSNS & IMFUSS RONALD REAGAN CVN 76 PIA PSNS & IMFUSS NEVADA SSBN 733 ERO PSNS & IMFUSS SAN FRANCISCO SSN 711 EDSRA PSNS & IMF
NAVSEA LEAN APPROACHNAVSEA LEAN APPROACH
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Norfolk Naval Shipyard
Any Ship, Any Time, Any WhereAny Ship, Any Time, Any Where
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Norfolk Naval Shipyard
Any Ship, Any Time, Any WhereAny Ship, Any Time, Any Where
CAPSTONE - OVERVIEWCAPSTONE - OVERVIEW
CAPSTONE - Group of 13 Ship Alts that include:CAPSTONE - Group of 13 Ship Alts that include:• Main mast replacement (Mast Correction SHIPALT)Main mast replacement (Mast Correction SHIPALT)• Installation of new weapon, radar, & CInstallation of new weapon, radar, & C22 systems systems
– Improvement of CVN self-defense capabilitiesImprovement of CVN self-defense capabilities
Core Capstone Self-Defense System comprises:Core Capstone Self-Defense System comprises:
• Ship Self Defense System (SSDS Mk2 Mod 1)Ship Self Defense System (SSDS Mk2 Mod 1)
• Cooperative Engagement Capability (CEC)Cooperative Engagement Capability (CEC)
• AN/SPQ-9B, AN/SPS-49A, & AN/SPS-48E radars AN/SPQ-9B, AN/SPS-49A, & AN/SPS-48E radars
• Rolling Airframe Missile (RAM)Rolling Airframe Missile (RAM)
• NATO Sea Sparrow Missile System re-architectureNATO Sea Sparrow Missile System re-architecture
• Enhanced Sea Sparrow Missile (ESSM) Enhanced Sea Sparrow Missile (ESSM)
5th CAPSTONE Install – 3rd In-Service9
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Norfolk Naval Shipyard
Any Ship, Any Time, Any WhereAny Ship, Any Time, Any Where
MAIN MAST REPLACEMENTMAIN MAST REPLACEMENT
Requirements for CAPSTONE Alteration:Requirements for CAPSTONE Alteration:• Larger stronger mastLarger stronger mast
– CAPSTONE mast 112K lbs, old mast 89K lbsCAPSTONE mast 112K lbs, old mast 89K lbs
• Allows for running cabling inside mast Allows for running cabling inside mast
• Remove / Reinstall Legacy Antennas & EquipmentRemove / Reinstall Legacy Antennas & Equipment
• New mast installed in two sections (Base and New mast installed in two sections (Base and entire Mast)entire Mast)
New mast supports future upgrades and has reduced maintenance requirements.
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Norfolk Naval Shipyard
Any Ship, Any Time, Any WhereAny Ship, Any Time, Any Where
CAPSTONE MAIN MASTCAPSTONE MAIN MAST
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Norfolk Naval Shipyard
Any Ship, Any Time, Any WhereAny Ship, Any Time, Any Where
SCOPE OF AIT WORKSCOPE OF AIT WORK
• 12 Alteration Installation Teams (AIT)12 Alteration Installation Teams (AIT) • Upgrade and or installation of 12 Combat Upgrade and or installation of 12 Combat
SystemsSystems
• 63 affected spaces63 affected spaces
• Extensive work in CDC, IFF Equipment Room, Extensive work in CDC, IFF Equipment Room, BFTT Equipment Room, NSSMS Launcher BFTT Equipment Room, NSSMS Launcher RoomsRooms
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Norfolk Naval Shipyard
Any Ship, Any Time, Any WhereAny Ship, Any Time, Any Where
CVN 73 CAPSTONE APPROACHCVN 73 CAPSTONE APPROACH
Problem:Problem:• NNSY to accomplish CAPSTONE install during an NNSY to accomplish CAPSTONE install during an
11 month availability 11 month availability – Benchmark was 13 months by PSNS on CVN-74Benchmark was 13 months by PSNS on CVN-74
Solution (two parts):Solution (two parts):• Main MastMain Mast
– Implement LEAN processes for the planning, Implement LEAN processes for the planning, fabrication, and replacement of the mastfabrication, and replacement of the mast
• AIT work (Island and below) AIT work (Island and below) – Incorporate and utilize lessons learned from NGNN and Incorporate and utilize lessons learned from NGNN and
PSNS into production and testing implementationPSNS into production and testing implementation
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Norfolk Naval Shipyard
Any Ship, Any Time, Any WhereAny Ship, Any Time, Any Where
MAST REPLACEMENT LEAN MAST REPLACEMENT LEAN IMPLEMENTATIONIMPLEMENTATION
• Joint pre-fab effort between PSNS and NNSY– Mast assembled at PSNS and shipped to NNSYMast assembled at PSNS and shipped to NNSY
– Designed & established inside shop fab cell for yardarms & platforms
– Established Dock-side assembly area
• Old Mast removed in one piece Old Mast removed in one piece – CVN-74 mast removed in 10 pieces
• New mast installed in one pieceNew mast installed in one piece– CVN-74 mast installed in 3 piecesCVN-74 mast installed in 3 pieces
• Equipment and Cable installation Equipment and Cable installation – Detailed integrated schedule for work sequence and cable installationDetailed integrated schedule for work sequence and cable installation
Substantial savings:schedule (35 days) & cost (2.5K MDs or 13%)
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Norfolk Naval Shipyard
Any Ship, Any Time, Any WhereAny Ship, Any Time, Any Where
AIT INSTALL LESSONS LEARNEDAIT INSTALL LESSONS LEARNED
• NNSY involved early in co-yard Capstone lessons learned
• NSWC-PHD implementation of lessons learned:– Formulated Installation Coordination Team (ICT)– Integrated production schedule & testing schedule of CAPSTONE alts – Port Hueneme POC actively involved in AIT activities– Dedicated personnel: Main Mast APS, AIT Coordinator, and two CCTCs– Weekly teleconferences & space deconfliction meetings– Walkthroughs at 25%, 50%, 75% point for each alt
• Combat Systems Trials Rehearsal (CSTR)– Live aircraft test runs performed pierside, vice at-sea
» Reduces sea trials by 3 days
Production efficiencies coupled with program level oversight Production efficiencies coupled with program level oversight enabled 28 day reduction in Combat Systems Testing!enabled 28 day reduction in Combat Systems Testing!
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Norfolk Naval Shipyard
Any Ship, Any Time, Any WhereAny Ship, Any Time, Any Where
WRAP-UP WRAP-UP
• Still marching to the same drumbeat
• Enterprise/LEAN approach
– Standardized, disciplined, and holistic
– CVN-73 CAPSTONE is an example
• Build the fleet of the future
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Norfolk Naval Shipyard
Any Ship, Any Time, Any WhereAny Ship, Any Time, Any Where
Questions?
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