| 10 - Industrial Processes (Welding, Metal Working, Repair) |
Air Hammer
Use of an air hammer (similar to the Chicago Pneumatic Hammer) in conjunction with a wide chisel to remove synthetic foam from void spaces inside Trident submarines. Process is currently done manually with a hand held hammer and a chisel and is exceptionally slow and physically difficult. Following use of the pneumatic hammer chiseling there could be high-pressure water slicing. End results would be savings in man hours and carpal tunnel syndrome injuries.
Best Management Practices
Machinery Shop uses oil based solutions as coolant. Industry trends are moving towards synthetic coolants which require more labor in solution management and are prone to fouling by bacteria. Shop already has a recycling program in place and does not generate a large waste stream. FASTT recommends not changing over to synthetics.
The SIMA R-2 Machinery Division used to operate a small electroplating facility (these operations are often used when there are not suitable alternative repair methods). A DOD push has eliminated many electroplating operations. While there are suitable technologies to replace electroplating in many operations, this facility needs a silver seal ring plating capability. Without its own electroplating facility the work is being farmed out. This causes delays and leaves quality control out of the SIMAs hands. FASTT recommends re-establishing a small capability electroplating operation at the SIMA.
Equipment Repair or Modification/BMP
Repairs on two forklifts (5 Ton and 7.5 Ton) performed by contractors who do not keep any spare parts on hand. Equipment downtime is estimated to be at least 500 hours per year. FASTT Team recommends procurement of high failure items to prevent any further idle weeks waiting for parts.
Power Plant performs maintenance on P-3 engine propellers. A hydraulic service unit (HSU) is used to add oil to the pitch control system. The HSU is inadequate because it does not have a flow meter and only pumps 4-6 ounces per stroke of the hand pump. The time required to dispense a large quantity is excessive. New HSUs have flow meters but the same manual pump. Workcenter does an average of 10 propellers per month, two people spend five hours each month just pumping the HSU. FASTT team will address this issue and take action to improve the pumping system.
Oxygen shop repairs on-board oxygen generator systems (OBOG). Equipment contains electro-chemical oxygen sensors which they periodically replace. Approximately 10-12 replacements are made each year at a cost of $750 each. They are non-repairable. Recent months have seen a sensor failure rate of 50% on operational tests after installation. The NAVAIR FASTT team rep will coordinate with NAVAIR Aircrew Systems Division in researching this problem.
Shop disassembles, repairs and assembles miniature electronics. Noxious fumes are emitted when technicians are soldering or performing other hot work. A vent booth or hood should be installed to vent fumes away from technicians. FASTT is researching booths and hoods, and will submit information to AIMD OIC and CINCPACFLT environmental.
An old cutting machine is used to cut hoses and requires an excessive amount of time to operate due to faulty equipment. It is recommended that the electric motor be overhauled so that the machine will run in a more efficient manner. This will reduce labor, blade wear, and turn around time.
Hermetic Sealing Unit
Shop 31C is responsible for large amounts of injector work for diesel engines on ships and for the Supply system. The shop is concerned that they are doing a large amount of rework of "off the shelf" injectors due to the amount of time that they sit idle. It is estimated that 50% of the injectors from the shelf must be reworked before they are used on ship's engines. If the injectors went back to the shelf, they would expect to see 50% of them back for rework. Elimination of this rework would reduce labor costs as well as reduces the amount of waste (oily rags, spent cleaning solutions) generated. The shop and FASTT team agrees that most of the injection failures are due to poor packaging after refurbishment. If all injectors were sealed properly they would not be subject to failure and less injectors would be needed for spares. Use of a small Hermetic sealing unit would ensure that no contaminants are introduced to the injectors during storage. Implementation of this unit would eliminate rework, and result in $26,161 of labor savings annually.
Metal Chips & Coolant/BMP
Metal chips with coolant residue are placed in 30 gallon garbage cans with holes drained in the bottom. This is elevated over another container fashioned to collect the drainage. Shop personnel find it difficult to pick up and drain the spill container. FASTT recommends procuring a container with a conical bottom (plastic is available), and a screen to separate it from the spill container. A drain valve is located at the bottom fitting of the tank for easy coolant draining. Action would save on man-hours.
Coolant contaminated metal chips are placed in an outside dumpster in an open area. Rainwater and other contaminants mix with the coolant and increase the amount of waste stream. FASTT Team recommends covering the collection area to prevent the intrusion of rainwater.
Note
Welding Qualification area of the SIMA has developed a "Boiler Mock Up" used to mimic conditions found in the field. FASTT Team believes it is the best training aid they have ever seen and that it should be manufactured and shared with other Naval commands that do this sort of support work.
Process Change/BMP
Pipe shop personnel experience excessive down time waiting for NDT personnel to respond to work requests for PT tests on welded components. Pipe shop personnel are qualified to perform these tests. Allowing pipe shop personnel to conduct PT tests would increase shop productivity by reducing turn-around time.
Foundry has problems during the pouring of molten metal from the furnace. Spilled metal flows under the furnace and contacts a flex hose on the hydraulic line. The line ruptures from the heat and the hydraulic fluid ignites. Personnel use sand to extinguish fires. Sand is disposed of as hazardous waste. The flex hose should be replaced with hard piping to prevent fires and eliminate need for sand/sand waste disposal. SIMA foundry has a lead furnace with a water-drain nearby. Lead splatter can migrate to the storm water drain. Floor sweepings (approximately 400lbs per month) must be disposed of as hazardous waste. FASTT team recommends this lead work be moved to NAS North Island, thus eliminating waste-stream and potential spill into water drain.
Spray Mist Cutting Fluid Dispenser
Machine shop changes cutting fluid based on calendar date cycles rather than equipment use. Since equipment use fluctuates, there are times when good oil is discarded. Use of a cutting fluid dispensing system, known as "Spray Mist", would eliminate this problem because it dispenses environmentally-friendly cutting fluid only in the amount necessary and is changed out only when necessary. The system is portable and can be placed where needed.
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