Navy Manufacturing Technology Project S2437
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1 Navy Manufacturing Technology Project S2437 National Shipbuilding Research Program All Panel Meeting March 2015 John Mazurowski, Chief Technologist- Photonics Electro-Optics Manufacturing Technology Center DISTRIBUTION STATEMENT A: Approved for public release. Slide 1
2 Problem Technology Discussion High rework during installation of optical fiber in shipyard. Project Approach This project will decrease costs of fiber optic installation in ships at Ingalls Shipbuilding emphasizing defect reduction: PROCESS: Optimize cable routing, installation sequence, and test sequence. TECHNOLOGY: Assess latest available hardware and equipment. OPTIX Engineering LLC Slide 2
3 Project Team Program Office Representative Todd Hellman PMS 400D4 ONR Mantech Program Representative Richard Henson Penn State EOC Mantech Program Director David Ditto Huntington-Ingalls Shipbuilding ManTech Program Director Ambre Cauley Penn State EOC John Mazurowski, Lucas Cashdollar Ingalls Shipbuilding Jason Farmer, Ibrahim Sahawneh HII Shipbuilding Subcontractor: Optix Engineering Kim Jovanovich Slide 3
4 S2437 Technology Discussion PROJECT TASKS- 1) Optimal scheduling and sequencing; avoid conflicts with operations that cause conflicts such as contamination and cable crushing. 2) Manufacturing process improvements that come from recent products for installation and test. Testing technology improvements that come from newer components. 3) Installation methods for single mode fiber, cable, and termini, for future upgrades. 4) Experience with simple COTS based networks which use single mode fiber. 5) Evaluate new tools for connector / terminus assembly. TASK DESCRIPTION 1 Optimize routing, sequencing, and scheduling. 2 Engineering and system improvements. 3 Interconnection methods. 4 Single mode fiber. 5 Assembly tool evaluation. Slide 4
5 Project Metrics DESCRIPTION BASELINE THRESHOLD GOAL CURRENT Failure modes identified (100%) 5/10 (50%) Root cause analysis complete (100%) 5/5 (100%) Root cause known (100%) 6/5 (120%) Mitigation plan established (100%) 4/6 (100%)* Mitigation complete (100%) 3/6 (0%)** * One of the mitigation plans covers three of the root causes. ** Mitigation to be complete upon final implementation. Cost reduction goal per hull resulted from 10% reduction in defects. Analysis supports 78% from cable deployment improvements, and connector damage reduction 22%. Slide 5
6 Corrective Actions DEFECT Damage to un-deployed cable. Damage during cable pulling. Damage cable after deployment. Defects in cable termination. Defects in end face equality. Defects in end face geometry. MITIGATION Cable racks and awareness training. Tools to decrease friction and kinks. Color coded cable. Introduction of splice-on connectors. Introduction of splice-on connectors. Introduction of splice-on connectors. Slide 6
7 Cable Rack Slide 7
8 Cable Deployment Tools Examples of cable deployment tools: Courtesy ManTech S2472 and NSRP Cable Deployment projects. Slide 8
9 Splice-On Connectors (COTS) Mil-ST Connector Slide 9
10 Splice-On Connectors VIBRATION SHOCK Slide 10
11 Project Schedule Project re-plan / extension was used for Task 3.5 Preparation Tool Evaluation. Slide 11
12 Transition / Implementation TRANSITION STRATEGY: Documented in ManTech Technology Transition Plan (TTP), submitted August IMPLEMENTING ORGANIZATION: Ingalls Shipbuilding (Pascagoula). SUPPLY CHAIN: ManTech project S2472 has documented designs; stands will be fabricated by shipyard personnel; COTS connector supply chain. FUNDING SOURCES: Ingalls Shipbuilding is funding internal transition. DEMONSTRATION: Verification by Ingalls Shipbuilding Industrial Engineering. BENEFITING PLATFORMS: DDG51, LPD, LHA. PROJECT ACTIVITY IMPLEMENTATION ACTIVITY DATE Data Tracking Tracks effectiveness of improvements. FY14-16 Hardware Changes Requirements, design, implementation, certification. FY16 Process Changes Design, incorporation, training, approval. FY16 Slide 12
13 Next Steps Assist TWH and shipyard with implementation of splice-on connectors. Subsequent NSRP project Alternatives to Fiber Optic Connectors. Slide 13
14 Acknowledgements This material was supported by the Office of Naval Research under contract N D-0145 / Any opinions, findings, conclusions, or recommendations expressed in this presentation are those of the authors and do not necessarily reflect the views of the Office of Naval Research. Slide 14
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