It all started with an idea sparked by a need for a more efficient way to work with resilient mounts on the USS Rhode Island (SSBN 740) Project.

Hundreds of resilient mount hangers are used aboard Navy ships to support piping and they all require precision and accuracy during fabrication to ensure that they are positioned just right. Shop 56 prefabricates these resilient mount hangers through a very time-consuming process. Each hanger rod is held in position while a welder tack welds it in place. Rework was often a possibility.

"We wanted a tool we could use to make the process more efficient," said Mike Wells, Pipe Group (Code 960) Pipe Trades Zone Manager. "We needed to tackle the amount of hangers on the Rhode Island to ensure we got the job done right the first time."

Wells and Nuclear Test Mechanic John Gordon developed an initial prototype made from a toolbox top, washers and an angle iron. The initial prototype could be configured to support and align a hanger rod to the required height and angle before tack welding it in place. However, each resilient mount hanger assembly varies and making adjustments to the prototype configuration required disassembly.

"There's a 16th-inch difference between each rod diameter and we needed to set it up to work with a variety of sizes for the job," said Gordon. "So we took that initial design to the Rapid Prototype Center (RPC) to see what we could do to improve it."

RPC Toolmaker John Tate led the project and began sketching a complete solution to eliminate the hassle when making adjustments to the prototype for the different resilient mount hangers, rods and various angles required. "We used T-slot material, sheet metal, washers and clamps to create a more accurate design," said Tate. The new "all-in-one" prototype supports the various resilient mount hangers, rods and required angles. Making adjustments is easy with this new tool-less fixture.

The team is currently working on testing and improvements for the new product, named the G & W Hanger Rod Fixture, and it seems to be a welcome addition to the arsenal for NNSY.

"I think this device is awesome!" said Code 960 Superintendent John Tuthill. "This device makes the job a lot safer and steadier for our pipefitters. The safety and innovation behind this is tremendous. We're able to step away from the prehistoric way of getting things done and provide a tool a worker can use and perform the job with ease. Great work all around!"

Wells added, "We're very proud of what we were able to accomplish and it's been an excellent experience working with the RPC. They came through and were open to suggestions throughout the entire process. They were able to help us make our idea a reality."

"The RPC is built for the shipyard to aid in innovation and bringing new ideas to life," said Tate. "We are here to help make the worker's job easier. And if we accomplish that, it's a job well done."

If you have an idea that might improve your job, contact the RPC at 396-4950/4956/4758 or 778-4181.

For more information, visit www.navy.mil, www.facebook.com/usnavy, or www.twitter.com/usnavy.

For more news from Norfolk Naval Shipyard, visit www.navy.mil/.