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Spinnaker Systems Smoke Stack Re-design

Spinnaker Systems Smoke Stack Re-design. Steven Eck. Company Overview. Spinnaker Systems is a Component of Southfork Industries Spinnaker Systems Produces Military Ships for the U.S. Air Force Spinnaker Systems Employs 15,000 People and has Annual Revenue of $4 Billion

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Spinnaker Systems Smoke Stack Re-design

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  1. Spinnaker Systems Smoke Stack Re-design Steven Eck

  2. Company Overview • Spinnaker Systems is a Component of Southfork Industries • Spinnaker Systems Produces Military Ships for the U.S. Air Force • Spinnaker Systems Employs 15,000 People and has Annual Revenue of $4 Billion • Southfork Industries is Defense Contractor that Employs 100,000 People With Annual Revenue of $10 Billion

  3. Current Smoke Stack Design • Current Design Contains Low Grade Structural Alloy With a Number of Circumferential Welds • Material Was Chosen Primarily Because of Availability and Weight • Quality of Welds is Inconsistent Throughout the Part • Inspection Techniques for Evaluating Part are Inadequate

  4. Service Failures • Each of the First Five Smoke Stacks have Cracked in Service • Cracks have been Analyzed with Poor Weld Quality Identified as Mode of Failure • Part Experiences Vibration in Service Which Would Contribute to Cracking • Improved Inspection Techniques Have Shown Additional Areas for Future Failures

  5. Criteria for Part Re-design • Repair of Part Requires Re-weld of the Part, Post-Process Inspection,and Forced Downtime of the Ship • Welding and Inspection Costs are $10,000 per repair procedure • Analysis of Cracked Part to be Performed to Determine if Unfixed Cracks Can Pose Safety Risk to Ship

  6. Criteria for Re-design • Re-design of Part Shall Keep Primary Components of Smoke Stack Constant • Curvature of Part • Overall Length and Diameter of Part • Weight of Part • Flatness Requirement of Mating Flange • Complete Non-recurring Portion of Project by End of Calendar Year 2002 • Select Design That Fits Within Project Budget

  7. Funding Source for Project • $100,000 IRAD Funding Available • Funding Would Cover the Following: • Identification of Design Component Improvements • Selection of New Supplier • Non-recurring Tooling Costs • Funding is Available Through End of Year

  8. Selection Process • Aim to Select Supplier That Can Provide Part With Identical Shape, Light Metal/Composite, Reduction in Quantity of Welds • Talked With Prospective Suppliers and Provided Each With RFQ • Received RFP from Suppliers • Selected Optimal Design by August 1 to Allow for Tooling Construction Prior to Year’s End

  9. Acquisition of First Part • Supplier Will Manufacture Tooling for Part • Spinnaker Will Create New Engineering Drawings • Supplier Will Provide First Article for Testing • Spinnaker Will Evaluate First Article Against Environmental and Functional Requirements • Supplier Will Manufacture First Production Part for Spinnaker • Spinnaker Will Install First Production Part on Ship by July 1, 2003

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