First Time Quality of the Dockside Tests and Trials Process (Docktrials) (2015-407)
- Bollinger Shipyards
- BAE Systems Southeast Shipyards
- Sparkhound, Inc.
- Hepinstall Consulting Group
January 2015 - December 2016
NSRP ASE Investment: $744K
Industry Investment: $745K
This project streamlined the Dock Test and Trials Process through the development and implementation of First-time Quality shipbuilding processes, as well as electronic reporting enablers to reduce the rework inherent in the Dock Trials Process.
The Navy has experienced significant quality problems with several ship classes over the past several years. It has focused on reducing the number of serious deficiencies at the time of delivery, and GAO’s analysis shows that the number of deficiencies–particularly “starred” deficiencies designated as the most serious for operational or safety reasons–has generally dropped. Nonetheless, the Navy continues to accept ships with large numbers of open deficiencies. Accepting ships with large numbers of uncorrected deficiencies is a standard practice and GAO found that there are varying interpretations of Navy policy with regard to when the defects should be resolved.
This project was designed to shift the emphasis from an inspection-based detective quality control process to a more preventive “Quality at Source” process to ensure the quality and reliability of system components and equipment installation, and drive First Time Quality (FTQ) of all Dockside Tests and Trials. The process to provide objective quality evidence was standardized to promote real-time capture and documentation of test information.
This project delivered the following executable and implementable solutions to the U.S. Shipbuilding Industry:· a preventive, Quality-at-Source Program that includes standard process, production checksheets, statistical process control charts, leading indicators, metrics, and analysis tools;· a Quality At Source Master Database and Standard Report Templates; and a· Detailed Implementation Guide
The benefits of this project are measured in terms of reduced number of discrepancies at In-Process Inspections, Dockside Test and Trials, as well as at Acceptance Test and Trials. The QAS System, which provides an integrated, user-friendly view of all Test and Inspection information, applies to all government and commercial shipbuilding projects.
Point of Contact:
Brent Tompkins, Bollinger Shipyards
Request Final Report form NSRP– Limited Distribution Authorized to U.S. Shipbuilding, Repair Industry and NSRP Program Representatives