Overview
Project Number: S2874
Project Title: Digital Common Layout and Inspection Process
Period of Performance: MAY20 -SEP23
Objective
Many of the components and assemblies that are manufactured at Huntington Ingalls Industries – Newport News Shipbuilding (NNS) have historically been inspected using manual methods. In this manufacturing state, efforts are often duplicated as multiple stakeholders perform independent inspections and variations in inspection methods present false-positive or -negative findings, which create production delays. These variations are due to the time-intensive process to ensure the part is level, which becomes increasingly difficult when inspecting large parts. Even though common datums and inspection standards exist, slightly different interpretations of the standards and complex geometries often create different results and add non-value-added rework to the process.
The objective of this Naval Shipbuilding and Advanced Manufacturing (NSAM) Center project was to develop common reference datum targets on components based on the analysis of survey data of key features. The monument systems allow technicians to tie an instrument back into the digital datum coordinate system by resurveying these monuments – with a laser tracker, laser scanning, and probing metrology tools – and performing a transformation analysis. This capability means that any technician can obtain a monument, tie into the component, and perform dimensional surveys or layoffs. This capability persists through a build schedule and can be independent of component relocation.
Benefits/Payoff
By reducing the labor hours associated with rework and providing timely and efficient dimensional process control data, the project team anticipates a reduction in non-value-added work. Increased efficiencies and quality improvements enabled by the technology are anticipated to result in five-year savings of $5.0M and a five-year return on investment (ROI) of 1.99:1.
Implementation
Based on the results of testing, NNS generated the data needed for internal process verification and validation, finalized the business case analysis, and created shipyard implementation plans. The transition event for this project was the successful execution of NNS’ performance demonstration activities, verifying the improved process met the expectations of the project team and stakeholders. Initial implementation efforts have initiated and are to complete in 4Q FY2025.
Implementation will utilize a phased approach, where the most beneficial opportunities will be assigned a higher priority and implemented first. The results of this ManTech project may be implemented in the production of CVN 78 Class Aircraft Carrier, VIRGINIA Class submarine (VCS) and COLUMBIA Class submarine (CLB).
*Prepared under ONR Contract N00014-24-D-7001 as part of the Navy ManTech Program.
*DISTRIBUTION STATEMENT A. Approved for public release: distribution unlimited. DCN# 2024-10-17-189; Approval Date: 10/24/2024
