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
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Overview
Advantages
ChallengesSoftware Selection
Strategy/Implementation
Procedure of Tomorrow(POT)
Objectives
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Objectives
#1 - Electronic Only
#2 - All Inclusive
#3 – User Friendly:- Finding Procedure- Navigating
- Comprehension
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Software Selection
=> Commercial Standards (i.e. ASME)
=> MIL Standards (i.e. MIL-STD-248)
Develop MIL-STD Specific Software
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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.
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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
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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
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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
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Strategy / Implementation
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
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Strategy / Implementation
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
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Strategy / Implementation
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
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AdvantagesCreating PQR / WPS
Once PQR created - Print Qualified Range Report to ID procedure
ranges
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AdvantagesCreating PQR / WPS
Enables and Disables Fields Based on Inputs
***If you select ceramic backing you have to enter manufacturer and type***
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AdvantagesCreating PQR / WPS
Bounces input against the spec and flags incomplete info
***Missing Minimum Travel Speed***
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AdvantagesCreating PQR / WPS
Prompts user where to go in spec for rule
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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
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Advantages Procedures Easy To Find
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AdvantagesConsistent Format
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AdvantagesProcedure Stand-Alone Printed Out
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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
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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
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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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