implementation of navweld software to support electronic welding procedures

HUNTINGTON INGALLS INDUSTRIES PRIVATE/PROPRIETARY LEVEL I

Implementation of NAVWELD Software to Support Electronic

Welding Procedures

May 11, 2011

Paul HebertManager, Welding Engineering

AWS Shipbuilding Conference

2HUNTINGTON INGALLS INDUSTRIES PRIVATE/PROPRIETARY LEVEL I

Overview

Advantages

ChallengesSoftware Selection

Strategy/Implementation

Procedure of Tomorrow(POT)

Objectives


Objectives

#1 - Electronic Only

#2 - All Inclusive

#3 – User Friendly:- Finding Procedure- Navigating

- Comprehension


Software Selection

=> Commercial Standards (i.e. ASME)

=> MIL Standards (i.e. MIL-STD-248)

Develop MIL-STD Specific Software


Software Selection Development

2003 2004 2005 2006 2007 2008 2009

SBIRPhase I SBIR - Phase II

MANTECH

NAVSEANSWC - Carderock

NMCWeld QC

Team MembersNGSB-NNGDEB

NavWeldWeb-based software application & database that assists the user in developing

welding procedures according to NAVSEA requirements.


Software SelectionNavWeld 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)• Essential Elements• NDE Tests• Destructive Tests & Number of Samples• Qualified Ranges• Tracks Welder History


Software SelectionNavWeld – Processes and Documents

Process Qualification Documents

Fabrication Documents

Arc • TP248• ABS/NVR - 2007

• TP278• TP1688 • MIL-STD-1689A• ABS/NVR - 2007

Stud • TP248• ABS/NVR - 2007

• TP1688 • MIL-STD-1689A• ABS/NVR - 2007

Resistance • AWS D17.2 • AWS D17.2Brazing (Piping) • 0900-LP-001-7000 • 0900-LP-001-7000


Strategy / Implementation

Engineers

Revisions40+ YearsNAVSEAs

PQRs

SOSs

248sGrandfather

Fab Docs

Interpretations

Issue

s

All Inclusive Review = Specifications / PQR’s / History Document for Each WPS

Evolution of Legacy Procedures

Engineer

Historian

Fortune Teller

Clean Up for POT



Procedure = Handful of Pages = All Requirements = Certified = ApprovedHand to the welder to use

Welding Parameters

Base Metal

Preh

eat

Cleaning

Specification

Legacy Procedures – Information in Multiple Locations

Consolidate for POT



Generic Legacy Procedures – Given Material / Process

One filler = limited joint designs = minimal notes / exceptionsOne Technique in Legacy Procedure = 3 or 4 or 5 in POT (dbase – who cares?)

Multiple Filler Metals

Subtle Differences

Special Exceptions

Make POT More Specific

Multiple Joint Designs



User to ID Changes => 800+ Pg. Procedure

Revision Record - First Page of Each WTN = What + When + Why Changed

Legacy Procedure Revisions

POT Revisions – Clear and Visible


AdvantagesCreating PQR / WPS

Once PQR created - Print Qualified Range Report to ID procedure

ranges



Enables and Disables Fields Based on Inputs

***If you select ceramic backing you have to enter manufacturer and type***



Bounces input against the spec and flags incomplete info

***Missing Minimum Travel Speed***



Prompts user where to go in spec for rule


AdvantagesReal Time Revisions

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 – anytimeTaking something away – we need to take the action to let user know.

NAVWELD System: Make Change in Dbase + Validate electronically + Revised Procedure ready for use = Minutes

Old System: Make change in MS Word + send to QA + QA send to repro + QA make distribution + recipients make changes to paper copy = Weeks

Caution


Advantages Procedures Easy To Find


AdvantagesConsistent Format


AdvantagesProcedure Stand-Alone Printed Out


AdvantagesGreen

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


AdvantagesElectronic Data

Kiosk on shop floor / ship PDA – Foremen to carry procedure with them

Eng Data

Weld Procedure Data

Welder Qual data

User

Job Assignment


Challenges

ABCComputer Literacy – What about those who aren’t proficient with computers?

Reliability - What happens if the computer crashes?

Resistance to Change – Why can’t you leave the procedures the way they’ve always been?

- Ease of Use- Training

- Back-Up Paper Copy- Back-Up PDF Copy

- Involve users in the process- Stress the advantages- Listen - Tenacity

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