An idea is a concept existing in the mind, a thought or notion that comes from a mental awareness of a want or need. Left in the mind, it’s simply a thought that may vanish in time. However, if the idea is shared and nurtured, it can become a reality.

The Norfolk Naval Shipyard Technology and Innovation Laboratory (NNSY T&I Lab) launched the Real Ideas Program in May with the desire to create a space where shipyard workers can submit and implement new ideas and technology to improve safety, cost, productivity, and quality of executed projects at NNSY. The program team collaborates with shipyard workers in understanding needs, researching what’s available, and breaking down barriers to bring together the folks that can help develop and deploy the ideas. The end goal is to either secure the desired process or technology, or develop it to fit the needs of the requestor.

The REAL Ideas program mission is to nurture and encourage workplace innovation to ensure the continuation to expand the advantage at America’s Shipyard. It focuses on bridging resource gaps to enable the workforce to become more innovative and creative in how work within their control is executed.

“When someone comes into the lab, we sit down with them and iron out exactly what they need and determine if it’s a viable idea depending on complexity,” said Real Ideas Program Manager Dale Berkley. “We look at the idea from every angle and do extensive research to ensure what we are able to come up with will improve the work being done and satisfy the needs of the workers. The process itself is a partnership and we’re with the workers every step of the way.”

Since the program’s launch, more than 40 ideas have come through the doors of the NNSY T&I Lab from employees who came have either toured the facility previously or had heard of previous ideas being developed at the lab.

For Nuclear Engineer Edward Henderson, he heard about the program from the coworker at a time he had a need to fill.

“I was designing a test plug and play module from old equipment that had areas with wires exposed,” said Henderson. “I wanted to cover up those areas with a label plate on them to not only protect the user but also ensure they understand what goes where. It would make the job safer and more efficient for those using the module.”

Henderson was introduced to the lab by a coworker who had recently toured the lab through their Learning Organization 101 (LO101) class so he came over to share his idea and see what options were available.

“They took down my information and listened to my idea,” said Henderson. “They brought everyone together that could help make this idea a reality and worked with me through the initial idea to creation. We were able to design and print the faceplate as needed and it works perfectly. When I initially came to the lab, I thought of my idea as something small. However, from its concept to creation, I see now that even the smallest ideas can make a big difference. I was thoroughly impressed with my experience and I encourage others to speak out when they have ideas. The NNSY T&I Lab is here to help!”

Another idea from Quality Assurance Specialist Tiffany Fuhs, who when testing as a welder found the need for an improved weld mask.

“When you have to work on welding pipes directly, you have to be able to have the right protection and fit into the spaces as needed,” said Fuhs. “Being a smaller girl, I knew I’d have to get into the smallest spots to do my welds. I needed to find ways to get in; however, the massive welding shield we use at the shipyard can be an obstacle in some of those tight spaces. At the time I needed to find a way to pass a GTAW weld test in a tight restriction without the use of a mirror, so I saw the need and went to work. I developed a lightweight, flexible welding shield out of heat tape and other materials. It was able to resist fogging and fit my needs with the space I had to enter and perform the work. And it worked perfectly!”

Once Fuhs had showed off her creation, she found other welders had a similar interest in her shield and wondered how they could obtain one of their own.

“I honestly never realized other people would be interested in the mask I made, I was simply making it to fit my needs. So when they came to me looking for how they could get one of their own, I sought ways we could produce them for our workforce,” she said. “I read about the lab in the Service to the Fleet and through videos on YardTube. I then took a tour during my LO101 class and saw what they could do firsthand. The next day I returned to the lab and pitched my mask idea to them and we’ve been working on ways to develop the design that can be produced for the shipyard and beyond. It’s been really exciting and seeing how passionate they are in helping make something tangible to help the workforce is really inspiring.”

Fuhs’ mask is currently in the draft stages, with the team working on a prototype to test and ensure it fits the needs of the welders who would be using the mask.

Boiler Shop (Shop 41) Trade Manager Anthony Britton said the NNSY T&I Lab is “helping to bring us into the 21st Century.”

Shop 41 has recently been bringing in new technology into the shop, including a Hydro Lance Water Jet System which uses lances which enter the tubes and shoot high-powered water jets to remove soft scale deposits, oils, and other materials.

“With the NNSY T&I Lab and the manufacturer of the machine, we’re working to make the device more automated and to utilize a laser mapping system,” said Britton.

Shop 41’s Hartwell Fitchett added, “We want to completely remove the worker from having to interact with lancing the tubes with high pressure water jetting operations on the job, protecting them from getting cuts, burns, or heat exhaustion. The system would make the job more efficient and keep our people safe.”

The team is currently in the early stages of developing the new system and is excited for its completion and other future innovations it can bring to the Boiler Shop.

For more information about the Real Ideas Program, contact the NNSY T&I Lab at 757-396-7180 or NNSY_REALIdeas@navy.mil.

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