Overview
Project Number: S2975
Project Title: Improved Cable Installation and Testing
Period of Performance: JUN23 – MAR25
Objective
The objective of this Naval Shipbuilding and Advanced Manufacturing (NSAM) Center project is to improve performance of shipboard cable plant manufacturing and installation. This project will improve First Time Yield (FTY) of cable plant fabrication and focus on improvements to sensitive cable media, including coaxial and optical cable types. Improvements to the cable media, cableway design, planning, and installation and testing activities will be included.
The project began with a survey of current installation process and identification of failure modes. The initial phase of the project included specific focus on cableway design, planning activities, cable materials, installation, and testing processes. An evaluation of augmented reality technology and its application to shipyard cable installations will be performed. Proposed solutions will be developed and reviewed with shipyard management teams. Options will be down selected to address areas with the highest potential of impact within the project scope. The project team will work with Ingalls Shipbuilding teams on proposed options that address internal shipyard processes. The team will work with cable manufacturers on items that require material/product changes. New materials will be identified and evaluated for impact to installation performance. In phase two, a trial installation will be conducted on a ship or representative environment.
Benefits/Payoff
By enhancing the FTY of cable installations and reducing labor and material costs, the projected five-year cost savings are estimated at $7.6M across all Ingalls platforms and $3.0M for DDG 51 Class destroyer specifically. This corresponds to a return on investment of 5.3:1 and 1.5:1.
Implementation
Cable system options identified and evaluated through this project will be reviewed with the applicable Navy Technical Authorities for Navy acceptance and subsequently implemented at Ingalls on the DDG 51 Class destroyer, Amphibious Assault Ship (LHA), Amphibious Transport Dock (LPD) and/or Naval Safety Command (NSC) Platforms in the 4Q FY2026. Preliminary plans indicate full implementation of the equipment and methods will occur within 12 months of project completion.
*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
