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Standardization of Periscope and Imaging Systems Repairs and Waterfront support

Standardization of Periscope and Imaging Systems Repairs and Waterfront support. 15 December 2008.

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Standardization of Periscope and Imaging Systems Repairs and Waterfront support

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  1. Standardization of Periscope and Imaging Systems Repairs and Waterfront support 15 December 2008 Distribution Statement D: Distribution authorized to the Department of Defense and U.S. DoD contractors only; Critical Technology; December 2008. Other requests for this document shall be referred to the Naval Undersea Warfare Center Division, Newport.

  2. Agenda • Goal and Purpose • Catalyst • USEBoD Actions • Existing Repair Structure • Plan Forward • Benefits • Changes • Schedule • Feedback

  3. Goal and Purpose • Goal • Be known as the World Leaders in periscope maintenance by providing reliable, high-quality periscopes to the Fleet at the time of need, at a reasonable cost • Standardize Periscope Repairs in order to create a more controlled environment to: • Improve maintenance documentation • Develop and provide training and certification • Establish requirements • Establish compliance process • Serve as a basis within which to improve, share ideas, benchmark • Obtain an accurate understanding of capability and capacity • Prioritize effort, investment and improvement • Set expectations and measure performance • Complete USEBoD actions • Purpose of Visit • Share background for this effort • Discuss Plan Forward • Discuss Changes to facility • Review Proposed Schedule • Solicit Feedback Before Moving forward

  4. Catalyst • BACKGROUND • Oct 2007, COMSUBFOR VADM Donnelly requested RDML Brady establish a group to look into the causes of periscope system failures and address system reliability • Report back during USEBoD meetings • FINDINGS • Increase in deployed Unit Type 18 failures/Tech Assists in FY07 • Overall Type 18 Periscope reliability approximately the same over past 6 years • Majority of failures occur within the three units: • Eyepiece Box (EPB) • Electrical & Electronic (E&E) Adapter • Barrel • Intermediate level maintenance of Type 18 Periscopes accomplished at three main centers, Newport, RI, TRF Bangor, WA, and Pearl Harbor Naval Shipyard, HI • Maintenance also performed by periscope on site reps at the various submarine home ports as well as by ship’s force • The vast majority of maintenance accomplished in accordance with the Interactive Electronic Technical Manual (IETM) which is maintained by the ISEA and distributed to all sites and all on site reps. However local variances and procedures exist.

  5. Catalyst(Cont) • FINDINGS (cont) • Rules governing the presence of the on site rep for various Type 18 maintenance activities vary among home ports • In some cases maintenance evolutions occur without the presence or oversight of the on site rep • The formality of training and training materials varies among the maintenance activities and on site reps • Certification of facilities, procedures and training across all sites was discontinued in 2005 • Formal requirements for such certifications do not exist • Although much data is tracked on Type18 reliability, metrics must be refined and maintained to more rapidly identify root causes of failures

  6. USEBoD Action Items

  7. Existing Repair Structure Northeast Periscope Regional Repair Center (NEPRRC) National Maintenance Manager Naval Intermediate Maintenance Facility, Pacific Northwest Bangor, WA USS EMORY S LAND Undergoing MSC conversion Naval Submarine Support Facility (NSSF), NAVSUBASE, Groton, CT (2 OSRs) Yokosuka, Japan U.S Naval Base, Norfolk, VA (2 OSRs) U.S. Naval Base, San Diego, CA (1 OSR) U.S. Naval Base, Pearl Harbor, HI LaMaddelena, Italy NUWC DET KPT (2 OSRs) TRF Kings Bay, GA GUAM USS FRANK CABLE (1 OSR) Tasking: _________________ Guidance: FLEET

  8. Plan Forward • Establish Facility Requirements and Certification • Requirements • Management • Metrics • Expectations, Performance measures • Processes • Training • Improvement / Pursuit of Perfection • Facilities • Clean Room • Rails, Towers, Environment • RFI Inventory • Certification • Mandated by COMSUBFOR, NAVSEA PMS435, NAVSEA 04 via MOA and NAVSEA 04 letter (in development) • Performed by ISEA as part of FMMA Audits • Team to consist of members from repair facilities, ISEA and external • First years will establish baseline and goals • Periodic follow on audits. Not as a witch hunt but a means for identifying needs and opportunities for improvement.

  9. Plan Forward (Cont) • Training and Certification of Periscope On Site Reps and Craftsman • Developed by ISEA (in process) • Implemented by Repair Activities • Certified by Repair Activities • Oversight and guidance by National Maintenance Manager • Surveillances • Performed by ISEA

  10. Plan Forward (Cont)Future Structure National Imaging System Maintenance Organization COMSUBFOR / COMSUBPAC N4 CDR Prescott / CDR Reische NAVSEA PMS 435 Fleet Maintenance Activities Code 3492 NUWCDIVNPT Frank Bolano National Maintenance In-Service Engineering Agent William Petruff National Maintenance Manager John Ingalls On-Site Representatives (LANT & PAC) Northeast Regional Periscope Repair Center Trident Refit Facility Optical Repair Shop (Kings Bay) Northwest National Optical Regional Repair Center PHNS IMF Optical Shop Limited Repair Facilities (Tenders, Yokosuka) Funding Tasking Authority Technical Authority Regional Repair Center RRC

  11. Benefits of Facility Certification • Establishes consistent level of quality and performance across all periscope repair facilities • Increased Imaging System Reliability and Predictability • Perform repairs/maintenance at improved quality, in reduced time, and at reduced cost • Reduction of variation • Failure prevention (mandatory replacement ) • Establish common expectations and measure for performance • Continual improvement

  12. Benefits of Facility Certification Initial steps taken at NUWC have produced the following: • Ceiling replacement • Floor replacement • Daily cleaning contract • Air lock doors • Planning Positive Air Pressure System/Air filtration/ temperature-humidity controls • 5S • Entryways • Traffic Reduction • Material Characterization • Sustainment • Other

  13. Benefits of Facility Certification Clean Area Audit Form

  14. Benefits of Facility Certification Clean Area Audit Form (cont)

  15. Benefits of Facility Certification SOP for Building Cleanliness Control

  16. Periscope Repair Process Steps

  17. Benefits of Facility Certification Before After A picture is worth a thousand words

  18. Expected Changes to your Facility • Near Term • NAVSEA 04 Letter will establish the facility certification process IAW NUWCDIVNPT ISEA requirements: • Process development • Training and Certification for Craftsman (No personnel changes are required) • Lean and 5S conduct • Data collection in support of Metrics • RFI requirements • Facility improvements • Continual improvement • Use of “best practices” • Option • Explore benefits of transitioning work

  19. Schedule • Issue MOA (Dec 08) • Pre-brief PHNSY, NUWCDIVNPT, TRF Bangor, TRF Kings Bay (1st and 2nd QTR FY09) • Issue letter establishing Periscope and Imaging Systems Facility Certification requirements (2nd QTR FY09) • Publish Facility requirement (2nd QTR FY09) • Perform Self Assessments Site Visits ( Start 2nd /3rd QTR FY09) • Audit/Surveillances (recurring) • Option • Explore benefits of transitioning work from PHNSY (2nd QTR FY 09)

  20. Feedback

  21. BACKUP

  22. TYPE 18 PERISCOPE RELIABILITY FOR USEBOD Captain David Duryea PMS 435 30 NOVEMBER 2007

  23. Background and Findings • BACKGROUND: • COMSUBFOR VADM Donnelly requested RDML Brady establish a group to look into the causes of periscope system failures, address system reliability and report findings NLT 1 December, 2007 • FINDINGS: • Although overall Type 18 reliability has remained approximately constant over the past 6 years, there was an increase in failures of Type 18’s on deployed submarines in FY07 • Majority of failures occur within the three units: • Eyepiece Box (EPB) • Electrical & Electronic (E&E) Adapter • Barrel • Maintenance is accomplished in accordance with the Interactive Electronic Technical Manual (IETM) which is maintained by the ISEA (SUBIS is a PDF addendum to the IETM). However, local variances and procedures exist due to discovery of vagaries in the IETM and to accommodate local differences in site layouts and equipment

  24. Background and Findings(Continued) • FINDINGS: • Rules governing the required presence of Periscope On-Site Representatives (POSR) for Type 18 maintenance vary among submarine home ports • The various maintenance activities do not use the same training and qualification programs for maintenance technicians • Not all maintenance activities have a surveillance program • Although much data is tracked concerning Type18 reliability, metrics must be refined to allow more rapid identification of root cause failure analysis

  25. Type 18 Periscope Responsibilities

  26. Deployed CASREPs Periscope Units

  27. All Hardware CASREPs Component Replacement (by Unit) Per Fiscal Year

  28. FY07 Type 18 Technical Assists FY 07 Specifics (15) Type 18 Material Issues (Details below) and (10) Non-Material Issues • Flex Shaft Design (maintained by OSR*) • Key West d. Boise • Oklahoma City e. San Juan • Scranton f. Alexandria • Eyebox Optics (maintained by OSR*) • Dallas – Doubler Assembly - Motor failed • Albany – Doubler Assembly - Dashpot failed • Ashville – Day Photo Mirror – Carbon build up on motor • Night Prism (maintained by OSR*) • Newport News – Day/Night cube assembly – loose in mount • SUBIS (maintained by OSR*) • Houston – Loss of Magnification display on flat panel • Mast Optics (maintained by Regional Repair Activities) • Newport News – Head Skeleton – 1.5X motor high resistance (Barrel repaired in 2002 at NPT motor did not require maintenance) • Philadelphia – Head Skeleton – Displacement error due to Dashpot assembly (Barrel repaired in 2004 at NPT) • Yoke Bolts and periscope alignments (maintained by OSR and Sail reps*) • Los Angeles • Albany * In PAC this maintenance function is sometimes performed by the Regional Repair Activity

  29. Type 18 Failure Analysis • 6 of 15 deployed failures due to flex shaft • 2006 Annual FRACAS analysis identified design flaw in flex shaft • Failures occur in the range 2000-3000 cycles • BLOCK 1 Upgrade Program developed by PMS435/NUWC to address flex shaft and other high failure rate EPB items • 6 of 15 deployed failures due to wear and tear • EPB Optics (3), Night Prism (1), Mast Optics (2) • Current maintenance strategy repairs/replaces components upon failure • 2 of 15 deployed failures due to Yoke Bolts • Previous Critique action plan being executed • 1 of 15 deployed failures due to software anomaly • Selected magnification field blank on flat panel display but available on training handle

  30. Recommended Plan Forward • Material Near Term • Replace flex shaft on all deploying submarines during POM period until Eyepiece Box Block I upgrades are in place • ISEA forward validated procedure to SUBMEPP and POSR (Action: NUWC 3492 Due Date: 14 Dec 07) • SUBMEPP incorporate as a maintenance standard in Force Revisions (Action: SUBMEPP Due Date: Updated monthly. Working with SUBMEPP for a February update) • TYCOM Schedule Flex Shaft replacement during POM period for all deploying submarines (Action: SUBFOR N4 Due Date: 14 Dec 07) • Identify high failure rate items to be replaced in Electrical and Electronic Adaptor prior to deployment • ISEA identify high failure items (Action: NUWC Code 3492 Due Date: 28 Feb 08) • On site reps replace high failure items if required (Action: On site reps Due Date: During POM period) Follow On • Eyepiece Box Block I Upgrade includes redesigned flex shaft, modified Left Training Handle (LTH) and Right Training Handle (RTH), Image Intensifier Tube (IIT) upgrade, Eyepiece Box (EPB) computer upgrade and replacement of waveguides • ISEA Complete Design of upgrade (Action: NUWC Code 3492 Due Date: 28 Feb 08) • Installations at 5 per year scheduled to begin Oct 08. PMS 435 Investigating acceleration of start date and rate of installations (Action: PMS 435 Due Date: 31 Mar 08)

  31. Recommended Plan Forward (Continued) • Material Follow On (continued) • Electrical and Electronic Adapter Block II Upgrade will address high failure items • ISEA Design of upgrade (Action: NUWC Code 3492 Due Date: 30 Sept 09) • PMS435 investigate acceleration of design (Action: PMS 435 Due Date: 31 Jan 08) • Barrel: Conduct Business Case Analysis to evaluate revising maintenance strategy to incorporate scheduled replacement of high failure components (Action: PMS 435/NUWC 34 Due Date: 30 June 08)

  32. Recommended Plan Forward (Continued) • Material Follow On (continued) • Complete Yoke Bolt Critique follow up Action (Action: TWH – Dr. Frank Chan Due Date: 31Mar 08) • Revisit Business Case Analysis for Digital Periscope (Action: PMS 435 Due Date: 30 Sept 08)

  33. Recommended Plan Forward (Continued) • Procedural Near Term • Evaluate and baseline current test and repair procedures used by Periscope On-Site Reps and Repair Activities • Action: TWH physically verify that POSRs and repair activities are in compliance with annual ISEA letter of instruction which mandates use of (list) of current test and repair procedures (Action: TWH-Dr. Chan Due Date: 21 Dec 07) • Standardize POSR policies across all sites • ISEA develop proposed list of waterfront evolutions requiring oversight by POSR (Action: NUWC 3492 Due Date: 14 Dec 07) • PMS 435 and COMSUBFOR N4 approve and promulgate list (Action: PMS 435/COMSUBFOR N4 Due Date: 31 Dec 07) Follow On • Establish common training program for POSRs and IMA personnel • ISEA to develop plan (Action: NUWC Code 3492 Due date: 30 Jan 08) • PMS 435 and COMSUBFOR N4 approve plan and establish program (Action: PMS 435/COMSUBFOR N4 Due Date: 30 Sept 08)

  34. Recommended Plan Forward (Continued) • Procedural Follow On • Establish certification program for IMA sites to ensure that IMA sites are in compliance with standard processes and procedures, have certified personnel, and have required test and support equipment/facilities • ISEA develop plan and compliance standards (Action: NUWC Code 3492 Due: 31 July 08) • PMS435/COMSUBFOR approve plan and standards and establish certification process (Action: PMS435/COMSUBFOR N4 Due date: 30 Sept 08) • Establish standard repair log-in process across all IMA sites and on-site reps (Action: NUWC Code 3492 Due: 31 Mar 08) • Establish surveillance program for IMA Sites and POSR • ISEA/COMSUBFOR establish surveillance team and schedule (Action: NUWC 3492/COMSUBFOR N4 Due date: 30 April 08 for on site rep surveillances) (Action: NUWC 3492/COMSUBFOR N4 Due date: 30 Sep 08 for facility surveillances)

  35. Recommended Plan Forward (Continued) • Procedural Follow On • Metrics:In coordination with FRACAS process, develop and maintain metrics to: • Provide timely data on In-Service failures • Current FRACAS report is annual • Enhance FRACAS root cause failure analysis • Quantify system usage • Track progress of Reliability Improvement Plan Actions: • ISEA provide recommendation to PMS435 to identify metrics, periodicity, process, and cost (Action: NUWC Code 3492 Due date: 31 Jan 08) • PMS435 approve plan (Action: PMS 435 Due date: 28 Feb 08)

  36. Next Steps • Execute Action Plan • Follow On Information Brief to USEBoD • Stop Light Chart on Actions • Stop Light Chart on Latest Reliability Metrics • PMS 435 and COMSUBFOR N4 to Conduct National Periscope Maintenance Joint Quarterly Program Reviews with ISEA

  37. Questions?

  38. DEPARTMENT HEAD CODE 34 Dr. Gerard M. Exley x25588 DEPUTY DEPARTMENT HEAD CODE 34A Craig E. McMillian x25587 TECHNICAL WARRANT HOLDERS TECHNICAL PROJECT MANAGERS ADVANCED TECHNOLOGY CODE 3491 William P. Craig x25470 Dr. Tariq Manzur (D) (A) x26887 TECHNICAL DIRECTION AGENTS PERISCOPE SYSTEMS CODE 3492 COMMUNICATIONSANTENNAS SYSTEMS CODE 3493 SUBMARINE COMMUNICATIONS TECHNICAL WARRANT Franklin W. Bolano x25594 Joseph E. Clement (D) x23919 Stanley C. Stefanowicz x25461 Donald C. Portofee (D) x25486 CHIEF ENGINEER CODE 3401 Paul S. Sheldick x25586 PLANS & OPERATIONS CODE 3402 Kathleen A. Buda x25409 Dr. Gerard M. Exley x25588 IMAGING & ELECTRONIC WARFARE TECHNICAL WARRANT SUBMARINE EXTERIOR COMMUNICATIONS CODE 3494 Dr. Francis Chan x25519 Darlene A. Sullivan x25463 James P. Boylan (D) x25437 COMMUNICATIONS SYSTEMS DIVISION CODE 341 IMAGING & ELECTRONIC WARFARE SYSTEMS DIVISION CODE 342 ENGINEERING DIVISION CODE 343 ELECTRONIC WARFARE SYSTEMS CODE 3495 Ralph C. Olesen x25453 Steven A. Devin x21411 Angela G. Ramsarup x25456 Dr. Francis Chan x25519 James E. Goodger x25499 John S. Wilson x21155 Thomas R. Floyd x25574 David J. Swanick x25508 John F. Koshar (D) x25504 SATCOM SYSTEMS CODE 3496 Vacant Thomas D. Downie (D) x25443 Undersea Warfare Electromagnetic Systems Department COMMUNICATIONS SYSTEMS TDA CODE 34T1 Mary Ann Brereton x25629 Vacant (D) ANTENNAS SYSTEMS TDA CODE 34T2 Vacant Vacant (D) IMAGING SYSTEMS TDA CODE 34T3 Carl E. Lindstrom x25531 Monica T. Hallisey (D) x28536 EW SYSTEMS TDA CODE 34T4 Robert J. Mayo x23985 Raffi Khokasian (D) x25503 ADVANCED CONCEPTS CODE 3403 C. Philip Amidon x25402 Dr. Stuart C. Dickinson x21729 CHIEF SCIENTIST CODE 3404 Dr. Donald H. Steinbrecher x25656 PLATFORM SYSTEMS ENGINEERING BRANCH CODE 3411 Michael P. Gozzo X21277 RADIO FREQUENCY SYSTEMS BRANCH CODE 3412 Kenneth F. White x25511 ANTENNA AND ELECTROMAGNETIC SENSOR BRANCH CODE 3413 Grant M. Miller X25699 NETWORKING & INFORMATION SYSTEMS BRANCH CODE 3414 Charles M. Sykesx26064 ELECTRONIC WARFARE SYSTEMS BRANCH CODE 3421 Stanley I. Shermanx23852 ELECTRO-OPTIC SYSTEMS BRANCH CODE 3422 Michael J. Umeharax25790 ISR SYSTEM & PLATFORM ENGINEERING BRANCH CODE 3423 Christopher Shaw x23063 ELECTROMAGNETIC ENVIRONMENTAL EFFECTS BRANCH CODE 3431 Craig F. Derewianyx25542 IN-SERVICE ENGINEERING BRANCH CODE 3432 George A. Nichols IIIx25429 MECHANICAL SYSTEMS ENGINEERING BRANCH CODE 3433 Wendell C. Maciejewskix25791 Naval Undersea Warfare Center Division, Newport 1176 Howell St Bldg 1319, Newport, RI 02841-1708 Rev. 26 Nov 07 (A) = Acting (D) = Deputy

  39. Type 18 Periscope OPTICAL, COMMUNICATION & ESM CAPABILITIES • OPTICAL • Magnification Control 1.5x to 24x • Field of View -10to + 60 • Color & Hi Res Monochrome Visible Imaging • Ka Band Radar for Ranging, Situational Awareness and Collision Avoidance • PATRIOT w/Iridium Antenna • Direction Finding, GPS, Image Processing, Storage and Retrieval • COMMUNICATION • Communication Sleeve • VPA Antenna • ESM • Signals ADF Intercept: • - Low Band Omni Bands • - Mid Band Omni Bands • - High Band Omni Bands PATRIOT Antenna Heated Head Window SUBIS Eyepiece Box

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