SIB | Page 1

2021 | Volume 5 | Issue 4 | Supplier Information Bulletin

An In-Depth Supplier As-

sessment (ISA) Year in Re-

view. NDT Liquid Pene-

trant Testing Best Practic-

es. Supplier Quality In-

spection Survey request.

Available Training for De-

fense Manufacturing posi-

tions.

Please let us know what you think

about this bulletin!

Send questions about any article, con-

tent suggestions and comments to

Ken Mason at 860.433.4834 or email

EBSIB@gdeb.com

Update

LETTER TO THE SUPPLIERS

_______________________________________________________________________________________________________________________

In This Issue...

Contact Electric Boat re-

garding questions you have

about anything related to

Covid mandates for your

employees coming to our

facility or our employees

coming to yours.

As 2021 draws to a close, I would like to take the opportunity to thank our supply

base for the warm welcome I have received since taking over for Blair and for all of

the hard work and dedication you have shown through another challenging year.

The Delta Variant has caused additional difficulties for our suppliers that were ex-

pecting to get back into a standard operating schedule. Natural disasters such as

Hurricane Ida and the seemingly annual fire season in the western US remind us

that all of the processes and procedures within the facility can be upended over the

course of a single day by forces outside of our walls. The demands of delivering two

Virginia class submarines a year while meeting schedule for the Department of De-

fense’s top priority; the lead ship of the Columbia class, are indeed great. While we

rise to this challenge, Electric Boat’s expectation of first-time quality must remain

our top priority. This is not simply to avoid re-work or because it checks a box on a

purchase order; it is necessary to ensure our Sailors come back home to their fami-

lies each and every time these extraordinary ships we build go to sea. With your

support, I am confident we can continue to show our NAVY customer that we are

willing and able to meet those demands. I have enjoyed getting to meet many of you

in 2021 and I look forward to meeting with more of you throughout 2022 either at

your facility or here at Electric Boat as we continue to work together to provide the

quality materials required to build and maintain the most complex and critical plat-

form for the US Navy. Together, we will continue to deliver the advantage that pro-

tects our sailors, our families, and our freedom.

Enjoy the holiday season with your family and

friends. We have a lot to be thankful for.

Sincerely,

Beth Rafferty –

Vice President and Chief Supply Chain Officer

SIB | Page 2

LESSONS LEARNED

In-Depth Supplier Assessment Year-in-Review

Electric Boat (EB) introduced In-Depth Supplier Assessments (ISAs) in 2018 to enhance EB’s oversight of critical suppli-

ers following identification of significant supplier issues that impacted submarine construction. ISAs are a multi-day, on-

site audit tailored to each supplier to identify strengths, weaknesses, and risks with a supplier’s processes and implemen-

tation of requirements. EB has conducted over 70 ISAs at key suppliers since the program’s inception.

As we approach the end of 2021, we want to share some of the results of these ISAs with our valued suppliers and high-

light some of the trends we are seeing within the supply base. As can be seen in the chart below, we have identified nu-

merous opportunities for improvement in some key areas; most notably Non-Destructive Testing (NDT), Welding, and

Heat Treatment, which account for nearly 58% of ISA team findings.

Specific examples of ISA team findings regarding NDT programs in the supply base include NDT examinations not meet-

ing requirements:

Exam questions are verbatim from publically available question and answer books

Practical exams do not include checklists with at least ten different checkpoints

Continued on Page 3

SIB | Page 3

LESSONS LEARNED

ISA Year In Review (Continued)

Additional findings regarding NDT examinations included:

Practical exam checklists did not include critical attributes where failure to successfully complete will result in failure

of the exam.

Exam documentation is missing required elements such as the testing procedures used, materials used (such as pen-

etrant), the signature of the inspector or the signature of the examiner.

Level III Examiner recertified using points vice recertification by examination.

Findings regarding NDT Inspector and Examiner certification records not meeting requirements included:

Records missing statements that Level II Inspectors satisfactorily completed training requirements.

Records missing statements that the Level III Examiner approved training programs.

Missing signatures for the Level III Examiner.

Experience hours are not recorded, missing relevant aspects, or are inadequate to support qualification require-

ments.

On the job hours recorded do not have a qualified inspector listed for oversight required for a Level I or non-certified

trainee.

Other NDT Findings

Liquid penetrant materials utilized for testing did not match the procedure, penetrant procedure listed materials that

are no longer available (Magnaflux SKL-SP, SKL-SP1, SKL-WP, and SKL-WP1). Make sure you are using materials

listed in AMS 2644.

Local NDT procedures were missing relevant requirements:

Procedure is out of date to current revisions of requirements

Does not list all of the minimum technical knowledge and skillsets for the Level III Examiner

Does not address the education training and experience for the NDT methods in which NDT personnel are being

“considered for certification.”

Does not include all of the required testing.

Does not include how exams will be graded.

In many cases, these problems have been found at a sub-tier NDT house that a supplier has hired to administer and per-

form NDT on a supplier’s product. It is important to remember that you, the supplier, are ultimately responsible for the

quality and acceptability of testing and material provided by your sub-tier suppliers. Volume 5, Issue 1 of the Supplier

Information Bulletin also discusses sub-tier accountability.

If you are scheduled for an ISA in 2022, take some time to review your NDT program prior to the ISA. Questions regard-

ing this article can be sent to EBSIB@gdeb.com for adjudication.

SIB | Page 4

LESSONS LEARNED

Prohibited Surface Preparation Processes for Items

Requiring Liquid Penetrant Testing (PT) Electric Boat’s NDT team have compiled some best practices regarding the identification of surfaces that are prohibited

for use prior to liquid penetrant testing.

Liquid penetrant testing shall not be performed on surfaces which have been peened, sand, grit, or vapor blasted. Addi-

tionally, for NAVSEA 250-1500-1 and MIL-STD-2132 applications, power wire brushing is also prohibited. The use of

any of these operations on an inspection surface will require skim grinding to remove all evidence of smearing or peening

prior to performing a liquid penetrant inspection.

Sand blasting and power wire brushing may smear or obscure discontinuities and obscure their true size.

Hand Wire Brushing: Characteristics may include noticea-

ble scratches generally oriented circumferentially along the

weld and adjacent base metal. ALLOWABLE

Sand Blasting: Characteristics may include a dull gray/

silver color. The surface finish may appear “speckled.”

UNACCEPTABLE

Power Wire Brushing: Characteristics may include noticea-

ble scratches generally oriented circumferentially along the

weld and adjacent base metal and has a polished (very

shiny) and slightly pitted appearance. UNACCEPTABLE

Chemical Etching Testing

Solutions for electrochemical etching per MIL-STD 792 have a detrimental control requirement that requires testing be

performed at the supplier:

5.2 Type II, electrochemical etching. The electrolyte used shall be compatible with the base material to be marked.

Electrolyte containing bromine, fluorine, sulfer, and lead in excess of 250 parts per million (p/m) each shall not be

used. Certified test results shall be submitted with each batch or mix of electrolyte to establish compliance with this

limit. The certified test report shall also identify the analysis method(s) utilized. Etching shall be covered by a writ-

ten procedure which includes as a minimum the specification of the electrolyte and cleaning methods. The procedure

shall be made available to the authorized representative of NAVSEA concerned upon request. The depth of marking

by electrochemical etching should be approximately 0.0005 inch deep or greater.

If you perform electrochemical etching, ensure you are performing the required testing. Contact us at EBSIB@gdeb.com

or your cognizant Supplier Quality engineer with any questions..

SIB | Page 5

BEST PRACTICES

USS THRESHER (SSN 593) 58th Anniversary

Commemoration Special Recognition

The most recent issue of the SIB profiled retired submariner Chris Yaras’ presentation to NAVSEA as part of the USS

THRESHER Commemoration ceremony.

In recognition for his efforts Rear Admiral E.L. Anderson; Deputy Commander for Undersea Warfare, presented Chris

with a Letter of Appreciation.

Within the letter, Rear Admiral Anderson states, “Your message serves as an important reminder of the significance of

our day-to-day decision making, and of the implicit contract between the Navy and our Sailors’ families…..Thank you for

reinforcing the importance of lessons learned and the need to maintain the high-quality standards that are integral to

the SUBSAFE program….”

Mr. Yaras is available to present his “Supplier Quality and Integrity Brief” at your facility. Email us at EBSIB@gdeb.com

if you’re interested.

The Submarine Industrial Base Council (SIBC)

invites all suppliers to the submarine industry

to become members. There is no cost to join.

Go to submarinesuppliers.org to learn more.

In line with our commitment to continuously improving our processes, EB has requested feedback on your inter-actions with our Supplier Quality Inspection processes. Please take the time to submit the survey that was sent in late October. We value and appreciate your participation and feedback.

Procedure Review Checklist for Non-Destructive Test (NDT)

Methods Available

In an effort to reduce the number of disapproved Vendor Procedure Approval Requests (VPARs), a Procedure Review

Checklist has been generated for suppliers who need to submit VPARs for NDT methods completed at your facility. This

checklist has been designed to provide guidance on what is needed in the NDT procedures for Tech Pub 271 across the

Liquid Penetrant, Magnetic Particle, Visual, Ultrasonic, Radiographic, and Eddy Current testing methods.

The checklist will allow you to double check that all information required is included in the NDT procedures before they

are submitted for review by Electric Boat. As always, carefully review your contract requirements and contact Electric

Boat with any questions.

On October 2nd the Seawolf-class

nuclear attack submarine USS Con-

necticut (SSN 22) experienced an

underwater collision while operat-

ing in international waters.

As of October 7th, there were no re-

ported “life-threatening” injuries

and that the submarine is in a “safe

and stable condition.” This is a tes-

tament to the quality material our

supply base produces for Electric

Boat.

When we achieve excellence, sailors

return home.

SIB | Page 6

WORKFORCE INITIATIVES

South Yard Assembly Building Update From EB Communications:

As of early October, the building is now almost 50% structurally complete and on track to re-ceive the first Colum-bia module in Decem-ber 2023. Moorings for the new Ocean Transport Barge HOLLAND are also complete. The barge will be deliv-ered in early Novem-ber.

Follow EB Social Media Facebook:

General Dynamics Electric Boat

Twitter:

@GD Electric Boat

Instagram:

gdelectricboat

YouTube:

GD Electric Boat

LinkedIn:

General Dynamics Electric Boat

EB Landing:

www.EBlanding.com

Accelerated Training in Defense Manufacturing (ATDM)

ATDM is a prototype training platform for rapidly training skilled workers in key trades such as CNC machining and

welding for employment in the defense industry. ATDM was developed as a public-private consortium in consultation

with the defense industry. The Institute for Advanced Learning and Research (IALR) is leading a multi-year pilot project

to test and evaluate ATDM as a training platform for regional training centers supporting the Defense Industrial Base

(DIB). The pilot project is funded through the National Imperative for Industrial Skills initiative which was launched in

2020 by the Industrial Base Analysis and Sustainment Program Office (IBAS) in the office of the Undersecretary of De-

fense for Acquisition and Sustainment.

ATDM is a fast-track, intensive, and targeted program for training workers to defense industrial base skill gaps rapidly

and at-scale. Key attributes are:

Rigorous four-month training program providing 600+ hours of training.

Students drawn from veterans’ programs, transitioning military, industry, and other pools of “mature learners.”

Training aligned with national, industry-recognized credentials and certifications.

Curriculum customized to meet the specific skills and needs of the defense industry.

Student placement aligned with employment opportunities in the defense industry.

Trainings have already begun in 2021 in CNC machining, welding, metrology, and additive manufacturing. Trainings are

scheduled to begin in April and August 2022. The curriculum is customized to the skills and training needs of the naval

shipbuilding and sustainment sector

of the DIB. Training takes place in

Danville, Virginia.

For more information, please visit

www.atdm.org