Improved Pipe Processing Methods Expected to Save $590K per VCS Hull

Process Improvement:

The NMC-led project team investigated methods for improving the efficiency of specific areas of pipe preparation including fixturing, positioning, and fitting; automation of welding and drilling pipe bosses; pipe purging methods; and the use of internal pipe joint blending tools and applications to reduce pipe section cutting, rework, and pipe material scrap. The NMC project team developed several large diameter pipe process tool concepts, executed first-article prototype demonstrations, conducted feasibility studies based on projected man-hour and material cost savings, and performed demonstration testing and validation at both VCS shipyards.

Implementation and Technology Transfer:

Testing and validation of prototype process improvements were completed in the fall of 2011 at General Dynamics Electric Boat and Newport News Shipbuilding. The prototype tools were transitioned to the shipyards in April of 2012. Full implementation is expected in both VCS pipe shops for the SSN 788 hull in the fall of 2012.

Expected Benefits:

The current projected savings are 8,500 man-hours per hull in manual labor. The reduction in man-hours results in a projected $590K savings per hull and $5.9M savings over the next five years based on the VCS production build schedule of two hulls per year.