NSRP ASE Projects

The active projects are listed by technology area for the primary focus of the project. However, many of the projects include work in more than one technology area.

Shipyard Production Process Technologies
Business Process Technologies
Product, Design & Materials Technologies
Systems Technology
Facilities, Tooling, Risk Management
Crosscut Initiatives

Shipyard Production Process Technologies

Principal manufacturing process, equipment, planning, and other activities used to transform purchased materials and systems into completed products

Large Scale Computer Simulation Modeling System
Develop and deploy a yard-wide computer simulation modeling system that will enable analyses of the effects of current and new ship production work on the shipyard’s operations. Performing Activities: General Dynamics NASSCO, Atlantec Enterprise Solutions, Bender Shipbuilding and Repair Company, Shipconstructor Software USA, TranSystems/Automation Associates Duration: April 2008 – December 2009
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Remote Climbing Robot for Automated Welding Processes
Continue development of a proven climbing robot technology by developing and integrating a non-contact weld-seam tracking and feature extraction sensor system coupled with a novel navigation and welding control algorithm. Performing Activities: Robotic Technologies of Tennessee, Bath Iron Works, Tennessee Technological University Duration: April 2008 – March 2010
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Customization of Web- Based Planning and Production Engineering Tools
Develop and implement innovative planning and production engineering technologies to improve the planning and execution at mid-tier shipyards. The web-based tool will integrate planning, design, production control, material control, and daily scheduling with production processes.Performing Activities: Bollinger Shipyards, Atlantic Marine, Hepinstall Consulting Group Inc., Strategic Project Solutions, CBS Consulting Duration: April 2008 – July 2009
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Manufacturing and Assembly Technology for Low Cost Pultruded Composites
To apply new joining methodology to four joint configurations (flat, “L”, “T”, and cruciform), plus develop a panel edge feature, designed to mate with any joint configuration.Performing Activities: Northrop Grumman Shipbuilding, Material Sciences Corporation, Kazak Composites, West Virginia University Duration: April 2008 – June 2011
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Improved Affordablility for Composite Structures
Develop and demonstrate a low cost joining capability for pultruded composite panels to be used in place of the Vacuum Assisted Resin Transfer Molding processed panels.Performing Activities: Northrop Grumman Ship Systems, KaZaK Composites, and Naval Surface Warfare Center--Carderock Division.Duration: January 2007 – September 2008. NSRP ASE Investment: $991K Industry Investment: $991K
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Gas Metal Arc Welding and Distortion Mitigation
To develop GMAW procedures using unique technology that allows one to program the wave form for a variety of arc characteristics that can lower the effective heat input to the base plate and minimize distortion, enhance weld deposition rate for higher productivity, and allow for an increase in welding speed when welding over primed steel surfaces. Performing Activities: BMT Fleet Technology Limited, Marinette Marine Corp, ESAB, and Hobart Brothers. Duration: January 2007 - July 2008. NSRP ASE Investment: $243K Industry Investment: $243K
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Portable Automated Bulkhead and Hull Straightener
Modify the current technology used in straightening deck plate to remove distortion from out-of-position bulkheads and ship hull plating. Performing Activities: Northrop Grumman Ship Systems, Native American Technologies, and Bender Shipbuilding and Repair Co., Inc. Duration: January 2007 – February 2009. NSRP ASE Investment:$825K Industry Investment: $825K
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Portable Automated Deckplate Straightener
Develop a portable automated plate straightener to remove bulkhead and deck distortion caused by fitting and welding. Performing Activities: Northrop Grumman Ship Systems, Native American Technologies, Bollinger Shipyards. Duration: February 2005 – January 2006
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Variable Balance Submerged Arc Welding
Utilize recent technological advancements in submerged arc welding power source and consumable design to improve productivity rates and reduce the construction costs of both commercial and naval vessels in U.S. shipyards.Performing Activities: BMT Fleet Technology, LTD., Northrop Grumman Ship Systems, Naval Surface Warfare Center Carderock Division, Miller Electric, Hobart Brothers, DRDCA Duration: February 2005 – January 2006.download a one-page project summary
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Extended Lean Enterprise
To complete a comprehensive model for the application of Lean manufacturing concepts to the extended value chain of the U.S. shipbuilding and repair industry. Performing Activities: Atlantic Marine, Todd Pacific Shipyards, Bath Iron Works, Puget Sound Naval Shipyard, SUPSHIP Puget Sound, V2R Consulting, P. Jaquith & Associates, Malone Consulting Services, Hagemeyer North America, Moran Environmental Recovery, Namasco, Steve Streifer & Associates Duration: August 2003 - December 2004
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Lean Enterprise Model
Complete a comprehensive model for the application of lean manufacturing concepts to multiple market segments of the U.S. shipbuilding and repair industry. Performing Activities: Atlantic Marine, Todd Pacific Shipyards, Bath Iron Works (a General Dynamics company), Puget Sound Naval Shipyard, V2R Consulting, Optiprise, P. Jaquith& Associates, Malone Consulting Services, Penn State ARL (Advisory). Duration: July 2001 – December 2003.
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Development and Commercialization of Laser Assisted Oxygen Cutting (LASOX)
Develop and exploit an experimental technology for laser-assisted, oxygen cutting of thick-section steel plates. Performing Activities: Bender Shipbuilding& Repair Co. Inc., Caterpillar, BOC Gases, Alabama Laser Systems and General Dynamics Electric Boat. Duration: October 2001 – September 2004
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Advanced Structural Joining Methods
Reduce the time spent in both fitting and welding of structural steel using laser cutting, new joining strategies, precision forming and laser welding. Performing Activities: Bender Shipbuilding& Repair Co. Inc., Caterpillar, Inc., Edison Welding Institute, IPSCO Steel, Inc. Duration: August 1999 - December 2003.
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Ultra High-Pressure Water Blasting
Reduce the cost of ultra-high pressure water blasting as well as reduce the potential storm water contamination that is associated with this process. Performing Activities: Atlantic Marine Holding Co., Todd Pacific Shipyard Corp., Munro& Associates, Inc., Dana M. Austin Environmental Consulting, Inc. Duration: April 2000 - February 2002.
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AUTOGEN: Automatic Generation of Control Programs for Robotic Welding
Develop breakthrough concepts for automating generation of robotic welding control programs directly from computer-aided design (CAD) data, weld process parameter tables, and production planning rule sets. Performing Activities: Northrop Grumman Ship Systems Ingalls Operations, Sandia National Laboratories. Duration: August 1999 - December 2003.
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"World Class" Manufacturing Model
Develop and implement an advanced manufacturing system for U.S. commercial and naval ship construction based upon best world class shipbuilding and lean manufacturing principles. Performing Activities: NASSCO (a General Dynamics company), Bath Iron Works (a General Dynamics company), Northrop Grumman Newport News, General Dynamics Electric Boat, Todd Pacific Shipyards, First Marine International, Japan Technology Management Program, Munro& Associates, NIST, University of Washington, and University of Michigan. Duration: September 1999 - January 2001.
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Knowledge-Based Modular Repair
Leverage expertise, technologies and best manufacturing practices from other leading-edge manufacturing industries and apply them to ship repair and conversion at Atlantic Marine. Performing Activities: Atlantic Marine Holding Company, National Institute of Standards and Technology. Duration: September 1999 - September 2002.
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Line Heating System
To develop a complete line heating system that can be used by shipyards to efficiently and accurately form complex shapes in typical plate sections. The line heating method will convert what is essentially an art form practiced by skilled craftsmen into a predictable metal forming method. Performing Activities: Atlantic Marine, Edison Welding Institute Duration: July 1999 - January 2002
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Business Process Technologies

All principal business processes, from initial business strategy development through post-delivery customer service

Shipbuilding Partners and Suppliers (SPARS) 701
To continue development of a proven internet based shipyard-to-supplier business process. The additional capabilities are Supply Chain Management, Information Security, and continued operation of the SPARS Pilot Test Bed. Performing Activities: National Industrial Information Infrastructure Protocols (NIIIP), Bath Iron Works, General Dynamics Electric Boat, IBM Software Group, Northrop Grumman Shipbuilding Duration: April 2008 – June 2010
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Shipbuilding Partners and Suppliers (SPARS) 601
Re-engineer and replace manual, labor intensive, paper based, error prone, and long cycle business processes amongst shipyards, suppliers and the US NAVY with electronic, Internet-based business processes managed by an electronic workflow manager. Previous efforts have resulted in the reduction of labor costs, cycle time, and error rates. Performing Activities: Bath Iron Works, General Dynamics Electric Boat, Newport News Shipbuilding, Northrop Grumman Ship Systems, IBM Software Group, and NIIIP. Duration: January 2007 – June 2009. NSRP ASE Investment: $2.9M Industry Investment: $3.4M
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Shipbuilding Partners and Suppliers (SPARS)
Re-engineer and replace manual, labor-intensive, paper based, error prone and long cycle interactions amongst shipyards, suppliers and the U.S. Navy with web-enabled shipbuilding virtual enterprise business processes. Performing Activities: NIIIP, IBM, Electric Boat, Bath Iron Works, Northrop Grumman Newport News, Northrop Grumman Ship Systems, Todd Pacific Shipyards, Bollinger Shipyards, Bender Shipbuilding& Repair, VT Halter Marine, IBM e-Design, IBM Software Group, Altarum Center for Electronic Commerce, Portsmouth Naval Shipyard, Marine Machinery Association and shipbuilding suppliers. Duration: March 2000 – January 2006. NSRP ASE Investment: $8.6M Industry Investment: $11M
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Shipway 2.0: Developing Lean Best Practice for Business and Information
Develop Lean best practices in ship construction and repair for business and information processes involving the shipyard customer by analyzing, streamlining and mapping out a best-practice process for 12 business-critical value streams. Performing Activities: Atlantic Marine Holding Company, Todd Pacific Shipyards Corporation, Bollinger Shipyards, Inc., General Dynamics Electric Boat, Trident Refit Facility Kings Bay, Puget Sound Naval Shipyard& Intermediate Maintenance Facility, Southeast Regional Maintenance Center, V2R Consulting Group, and Hepinstall Consulting Group. Duration: January 2007 – December 2008. NSRP ASE Investment: $1.9M Industry Investment: $1.9M
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SHIPWAY: Lean in Business & Info Processes
Develop the lowest total cost, shortest cycle time, highest performing business processes for accomplishing naval ship new construction and repair. Performing Activities: Atlantic Marine, Todd Pacific Shipyards, Bath Iron Works (a General Dynamics company), Bollinger Shipyards, NAVSEA Northwest Regional Maintenance Center, NAVSEA Southeast Regional Maintenance Center, NAVSEA Trident Refit Facility - Kings Bay, V2R Consulting Group, NG Ship Systems. Duration: February 2005 - January 2006.
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Ship Check Data Capture
Deliver a process to capture ship check data in digital format, process the digital data, and create and/or validate 3D CAD models from that data cost effectively. Performing Activities: General Dynamics Electric Boat, Bender Shipbuilding& Repair, Gulf Coast Region Maritime Technology Center, Intergraph Corporation, Direct Dimensions, Inc., ShipShaper LLP, Woolpert LLP. Duration: February 2005 - January 2006.
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Product Design and Material Technologies

Parametric design rules, materials standards, engineering data, and advanced product designs and materials to support rapid and efficient ship designs

Design Producibility for Mid-Tier Shipyards
Incorporate Design for Production (DFP) methodologies into the ship design process for the participating mid-tiered shipyards, to reduce costs through simplification of the ship design process and vessel construction requirements. Performing Activities: Bollinger Shipyards, Todd Pacific Shipyards, Atlantic Marine, Hepinstall Consulting Group, Inc., and Vicky Dlugokecki, P.E. Duration: January 2007 – September 2008. NSRP ASE Investment: $742K Industry Investment: $742K
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Common Parts Catalog
Perform full-scale testing and refinement of shipyards' previous work on a Common Parts Catalog to provide solutions to the issues of inefficient part searches, lack of established part data standards inability to support part standardization of the IPDE programs, non-standard and duplicate parts proliferation and absence of inter-shipyard part commonality. Performing Activities: General Dynamics Electric Boat, Bath Iron Works (a General Dynamics company), Northrop Grumman Ship Systems. Duration: September 2003 - December 2004.
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more information    
CPC Central Configuration Control Group Procedures

"World Class" Material Standards and Parametric Design Rules
Develop and implement a rule-based methodology for ship design and material selection. Performing Activities: NASSCO a General Dynamics company), Bath Iron Works (a General Dynamics company), General Dynamics Electric Boat, VT Halter Marine, NG Newport News, NGSS Ingalls Operations, AMSEC LLC, Proteus Engineering, Vibtech, First Marine International, Munro & Associates, ABS Americas, SPAR Associates, Hopeman Brothers, Integration Partners, University of Washington, Webb Institute, and University of Michigan. Duration: September 1999 - March 2004.
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Structural Fire Protection
Test intumescent systems and their ability to meet U.S. Coast Guard, IMO and regulatory body requirements. Performing Activities: Nichols Brothers Shipbuilding, University of California San Diego, Gladding-Hearn Shipbuilding, VTEC, Incorporated. Duration: September 1999 - February 2001.
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Systems Technologies

Underlying systems infrastructure required to support the other initiatives

Practical Applications of Design for Producibility
Develop the capability of creating standard assemblies with appropriate material identification and build sequences in a manner that they can be instantiated into a design within the ShipConstructor product. Performing Activities: Bollinger Shipyards, Northrop Grumman Shipbuilding - Gulf Coast, VT Halter, Marinette Marine, Shipconstructor Software USA Inc. , ShipConstructor Software, Genoa Design International Ltd. Duration: April 2008 – March 2009
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Smart "As-Built" Models
To efficiently create an “as-built” model that includes all manufacturing and installation data for use in repair planning and design. Performing Activities: Bollinger Shipyards, Northrop Grumman Shipbuilding - Gulf Coast, VT Halter, Marinette Marine, Shipconstructor Software USA Inc. , ShipConstructor Software, Genoa Design International Ltd. Duration: April 2008 – March 2009
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Improved Methods for Generation of Full-Ship Simulation/Analysis Models 2
Develop modeling and simulation tools to reduce costs associated with current ship structural testing and analysis. Performing Activities: General Dynamics Electric Boat, Northrop Grumman Shipbuilding, Engineous Software, Inc., Product Data Services Corp., TechnoSoft, Inc. Duration: April 2008 – April 2009
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Improved Methods for Generation of Full-Ship Simulation/Analysis Models
Develop methods for more rapidly generating large scale, full-ship analysis models for strength, stress, shock, and acoustic simulation and assessment ; and engage with the Navy Full Ship Shock Trial Integrated Process Team to examine cost effective alternatives to replace open-ocean, large-scale shock trials of Naval ships. Performing Activities: General Dynamics Electric Boat, Northrop Grumman Ship Systems Duration: January 2007 - June 2008. NSRP ASE Investment: $1M Industry Investment: $1M
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Ship Design Tool Enhancement III
Build a common, interoperable 3D computer-aided ship design capability based on the AutoCAD platform as augmented by the ShipConstructor software product – a 3D modeling application. This phase of the project series focuses on Electrical, Weld Planning and Education& Training Modules Performing Activities: Bender Shipbuilding& Repair, Austal USA, Inc., Bollinger Shipbuilding, Marinette Marine, Northrop Grumman Ship Systems, Todd Pacific Shipyards, VT Halter Marine, Atlantic Marine, Elliot Bay Design Group, Genoa Design International, Gibbs& Cox, Murray& Associates, Ltd., ShipConstructor Software, Inc., ShipConstructor Software USA, Inc., Autodesk, University of Wisconsin at Marinette, University of South Alabama. Duration: January 2007 – February 2009. NSRP ASE Investment: $4.4M Industry Investment: $4.99M
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Shipyard Design Tool Enhancement
Develop the design software of choice for second tier shipyards (ShipConstructor) into a robust and fully integrated design solution, enhancements to streamline and maximize efficiency. Performing Activities: Bender Shipbuilding& Repair, Bollinger Shipbuilding, Electric Boat, Marinette Marine, Northrop Grumman Ship Systems, VT Halter Marine, Gibbs& Cox, Elliot Bay Design Group, Genoa Design, Murray& Associates, ShipConstructor Software USA, Inc., Albacore Research, Anteon Corporation (Proteus Engineering), Alan C. McClure Associates, Atlantec – Enterprise Solutions, Vexcel Corporation, Shipconstuctor Software Inc., Knowledge Based Systems. Duration: August 2003 – December 2006. NSRP ASE Investment: $2.84M Industry Investment: $4.75M
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Enabling Shipbuilding Interoperability (ISE-6)
Deploy information technology systems that meet the shipbuilder’s interoperability requirements in the area of life cycle support and post-delivery operations. Performing Activities: Integrated Shipbuilding Environment Consortium, General Dynamics Electric Boat, Northrop Grumman Ship Systems, Intergraph Corporation, Atlantec Enterprise Solutions, Industrial Planning Technology, Knowledge Systems Solutions Inc., Naval Surface Warfare Center-Carderock Division, Northrop Grumman Information Technology, and Product Data Services Corp. Duration: January 2007 – April 2009. NSRP ASE Investment: $1.9M Industry Investment: $1.9M
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Integrated Shipbuilding Environment (ISE)
Define, develop and deploy plans to provide information technologies to enable interoperability, design/build integration and business interaction among shipyards, equipment developers and vendors. Performing Activities: Electric Boat, Northrop Grumman Ship Systems, Northrop Grumman Newport News, Bath Iron Works, NASSCO, Intergraph Corp., IBM, NIIIP, Naval Surface Warfare Center - Carderock Division, STEP Tools Inc, SENER Ingenieria Y Sistemas, SIMSMART, Atlantec – Enterprise Solutions, Northrop Grumman Information Technology, Product Data Services Corp., Proteus Engineering, M. Information Engineering, Knowledge Systems Solutions, SAIC, Altarum, Gulf Coast Region Maritime Technology Center, Marine Machinery Association, University of Michigan, American Bureau of Ships, Kockums Computer Systems, ERIM – Center for Electronic Commerce. Duration: September 1999 - March 2007. NSRP ASE Investment: $23.9M Industry Investment: $27.4M
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Integrated Steel Processing Environment
Develop technologies and integrate a pilot system that will enable CAD-neutral interchange of steel fabrication work packages among associate shipyards. Performing Activities: Northrop Grumman Ship Systems Avondale/Ingalls Operations, NG Newport News, General Dynamics Electric Boat, NGIT/DES, STEP Tools, Inc., Sigmatek, AeroHydro, NIST. Duration: June 2002 - April 2003.
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Harvest: Finishing the Ship Product Models
Complete the international standardization of the shipbuilding Application Protocols (APs): AP-218 (Ship Structures), AP-216 (Ship Moulded Forms), and AP-215 (Ship Arrangements). Performing Activities: STEP Tools, General Dynamics Electric Boat and Product Data Services. Duration: October 2001 - June 2003.
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Facilities, Tooling and Risk Management

Functions of providing and maintaining a physical plant capable of assembling, modifying, and repairing ships in an efficient, safe, controllable and ecologically acceptable manner

Prepare for and Comply with the Air Emissions Residual Risk Ruling
Develop a cost-effective compliance strategy for a costly regulatory issue affecting the entire shipbuilding and repair industry by proactively engaging in the rule making process to minimize the cost, production, and organizational impact to commercial and Navy shipyards. Performing Activities: Concurrent Technologies Corporation, Bath Iron Works, Puget Sound Naval Shipyard, Atlantic Marine Alabama, Northrop Grumman Ship Systems, NASSCO, Norfolk Naval Shipyard, BAE Systems, Northrop Grumman Newport News, SofTek Systems Inc., Naval Surface Warfare Center--Carderock Division, Scientific Resources Associated, Applied Research Laboratory (ARL) - Penn State Univ., and Kelley Drye Collier Shannon. Duration: January 2007 – March 2009. NSRP ASE Investment: $1.125M Industry Investment: $125K
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Wireless Equipment Monitoring and Control System (WEMACS)
Integrate existing commercial systems and newly developed technologies to provide a comprehensive solution for the monitoring, control and utilization analysis of shipyard material handling equipment. Performing Activities: ID Systems, NASSCO (a General Dynamics company), Northrop Grumman Ship Systems, Portsmouth Naval Shipyard, RLW Inc., ARL Penn State University. Duration: August 2003 - September 2003.
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Welding Emissions
Improve worker safety and environmental performance while sustaining shipyard productivity and minimizing added cost. Performing Activities: Edison Welding Institute, Northrop Grumman Ship Systems Avondale/Ingalls Operations, Bath Iron Works (a General Dynamics company), General Dynamics Electric Boat, Lincoln Electric Co., NG Newport News, NASSCO (a General Dynamics company), ESAB Welding Products, Naval Surface Warfare Center (Carderock), and Kura Environmental Consulting. Duration: June 2000 - February 2003.
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Five S
Implement and measure the results of the Five-S methodology at two repair shipyards, Todd Pacific (Seattle) and Atlantic Marine (Jacksonville), while creating a shipyard-focused implementation program to assist U.S. shipyards in implementing Five-S programs quickly and effectively. Performing Activities: Todd Pacific Shipyards Corporation and Atlantic Marine Holding Company. Duration: March 2000 - September 2001.
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Ergonomic Guidelines
Determine if the implementation of ergonomic interventions within the domestic shipbuilding and ship repair industry can increase produce quality and productivity, while reducing injuries, illnesses and worker's compensation costs to the point of being beneficial to the industry's position in the global marketplace. Performing Activities: NIOSH, MEMIC, Bath Iron Works (a General Dynamics company), Continental Marine, VT Halter Marine, NGSS Ingalls Operations, Jeffboat, Puget Sound Naval Shipyard, Todd Pacific Shipyards, and university researchers coordinated by NIOSH. Duration: September 1999 - February 2003.
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Shipyard Stormwater Mop-Up
Evaluate a new technology under development for remediation of groundwater contamination (MOP-UP) for potential applications in shipyard stormwater runoff treatment. Performing Activities: Biopraxis, Inc., Chester Engineers, NASSCO (a General Dynamics company), and three or more additional shipyards located in different regions of the United States. Duration: June 1999 - February 2001.
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Treatment of Shipyard Stormwater
Evaluate a low -cost, treatment option that consists of passive filtration of stormwater in underground vaults to remove metals and suspended solids. Performing Activities: NASSCO (a General Dynamics company), Hart Crowser, and Stormwater Management, Inc. Duration: April 2000 - June 2003.
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Crosscut Initiatives
(Education, Human Resources, Organizational Change & Technology Transfer)

People and organizational issues that "cut across" each of the other major initiatives affecting organizational change, human resources, education and training, workforce development and retention, and technology transfer

Modern Shipbuilding Design Courses
To continue the development of a marine design education structure by adding 4 additional advanced marine design courses - Structure, Piping & HVAC, Electrical, and Design for Manufacturing & Producibility. Performing Activities: Bender Shipbuilding and Repair, Bollinger Shipyards, Northrop Grumman Shipbuilding-Gulf Coast, Genoa Design International, Gibbs & Cox, Murray & Associates, ShipConstructor Software, Art Anderson Associates, University of Wisconsin-Marinette, University of South Alabama Duration: : April 2008 – March 2009
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Low-Cost Virtual Reality Welder Training System
Develop a virtual welding system through innovative uses of: robust artificial intelligence technology, new real-time processing system and new, low cost, wired and wireless sensor technology. Performing Activities: Bender Shipbuilding and Repair, N.A. Tech, General Dynamics Electric Boat Duration: April 2008 – March 2010
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Shipbuilding and Repair Career Day Events
Introduce middle and high school students, as well as guidance counselors, to career possibilities in the shipbuilding and repair industry, introduce them to Lean manufacturing concepts and promote the industry in a positive manner. Performing Activities: Old Dominion University Research Foundation, Northrop Grumman Newport News, Northrop Grumman Ship Systems, and Colonna’s Shipyard. Duration: January 2007 – July 2008. NSRP ASE Investment: $213K Industry Investment: $213K
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key deliverables    
project website

Lean Enterprise Simulation Exercises
Develop industry-specific Lean simulation exercises and associated training programs for shipbuilding and repair. Performing Activities: Old Dominion University, Northrop Grumman Newport News, South Tidewater Association of Ship Repairers. Duration: August 2003 - November 2004.
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Crosscut Resource Center
Assemble the best data, practices, and processes for people and organizational issues in an online environment readily accessible to shipbuilding professionals. Performing Activities: General Dynamics Electric Boat, NGSS Avondale, Bath Iron Works (a General Dynamics company), Cascade General, Todd Pacific Shipyards Corporation, Jeffboat LLC, University of Michigan Transportation Research Institute, and Penn State University - Advanced Research Lab.. Duration: July 1999 - February 2003.
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Last Update: 10/3/08