Innovation is More Than Thinking > Naval Sea Systems Command > Saved News Module

PEARL HARBOR, Hawaii – How many times have we looked at a process or a project and complained that it could be done quicker? Sure, we may have suggested ways to improve the process, but did we truly advocate for our idea? It could have been easy for Andy Lieu, Pearl Harbor Naval Shipyard and Intermediate Maintenance Facility (PHNSY & IMF) Reactor Engineer, to fall into the same pattern; but instead he challenged the system, challenged the status quo, and helped save the shipyard hundreds of thousands of dollars.

Performed by the PHNSY & IMF Reactor Engineering Division, shield surveys are tests performed for maintenance work involving the removal and reinstallation of radiological shielding. This process ensures the Sailors’ exposure will be within the expected range of radiation levels. Shield surveys have been an extensive process for over 30 years with very few changes in procedures, despite technological advancements that render many of the requirements unnecessary. Despite that acknowledgment, the process remained unchallenged.

Lieu realized there was an opportunity for improvement; part of his job is to work with fleet designers to improve efficiencies within the bounds of safety. Lieu understood that safety would not be compromised by eliminating many testing requirements. With the advice of his supervisor, Scott Bonilla, who told him not to hesitate to share methods for improvement, he submitted a waiver proposal. Unfortunately, when he made his first attempt to alter the requirements, Lieu was initially met with rejection from Knolls Atomic Power Laboratory (KAPL), an organization dedicated to supporting fleet design and troubleshooting.

Though disappointed, rejection did not stop Lieu from trying again. In February 2020, he represented PHNSY & IMF at the structural corporate initiative located at KAPL. It was at this conference that Lieu met the person who initially rejected him. Lieu asked, “What can I do to help you help me?” The KAPL representative stated that there needed to be more time allotted for the engineering and administrative work that went into the proposal.

Lieu faced obstacles in trying to balance his daily workload with the administrative tasks needed to support his process improvement initiative. He knew it would be easier to continue the pre-existing process, and though excessive, he assured that the task would get accomplished. Whereas, by attempting to change the system, he recognized that it would require a lot more time and he could potentially get rejected again.

Despite his concerns, Lieu persevered and collaborated with the structural shielding branches at the Navy’s three other public shipyards. He then submitted the waiver once again in May of 2020 and by November 2020, Lieu received news that his request for the waiver was granted.

The waiver altered the technical requirements at the design of the survey, which allowed them to eliminate 88% of their initial planned work for the shield surveys on USS Columbia (SSN 771). That resulted in cost savings of about $125,000 and 1,900 resource hours for that project alone. Additionally, the waiver was granted for all upcoming Los Angeles-class submarine shield surveys, including the USS Charlotte (SSN 766) and the USS Tucson (SSN 770), as well as the Los Angeles-class submarine surveys at Portsmouth Naval Shipyard and Norfolk Naval Shipyard. Essentially, this waiver also set the precedence for work being done with aircraft carriers at Puget Sound Naval Shipyard. Overall, this change will benefit the entire corporation.

For more news from Pearl Harbor Naval Shipyard & IMF, visit navsea.navy.mil/Home/Shipyards/PHNS-IMF or facebook.com/PearlHarborNavalShipyard.