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Recently, however, Bath has experienced more than its share of problems. In the view of its own management, the yard needs numerous improvements and changes to maintain efficiencies: better facilities, enhanced process procedures, more effective allocation of the workforce. Relations with craft unions at Bath are strained. Completion of the large destroyer Zumwalt (DDG 1000), first of a three-ship class of very advanced stealth destroyers, has run into numerous difficulties. All three ships of the class have fallen behind schedule, and delays reportedly are affecting the Arleigh Burke-class destroyers under construction in the yard.
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Unlike Ingalls, which at times has simultaneously built up to five different ship classes, Bath usually has only two designs in hand. The DDG 1000s, a program that, ironically, was originally won by Ingalls, represent one of the largest challenges in recent US shipbuilding history. Displacing nearly 16,000 tons and more than 600 feet long, the ships are the largest surface combatants built in the US since 1961, and certainly the most complex.
BIW made major improvements to build the ships, particularly construction in 2008 of a huge ultra hall so that major outfitting could be done indoors, protected from the harsh Maine winter. The yard was also reconfigured to install a land-level transfer facility, allowing entire hulls to be more easily moved inside the yard. A new expansion plan was approved by GD and the Navy in 2013.
But Bath also needed to eliminate older, less efficient facilities and streamline labor practices. And in September 2011, it received the first “restart” construction order for a new Arleigh Burke-class destroyer, the Rafael Peralta (DDG 115). More destroyer contracts were received over the next three years.
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Meanwhile, work to complete the Zumwalt has run into increasing difficulties. A recurring problem is the complexity of the integrated power plant, a design far beyond anything yet installed in a ship. With virtually every system connected to the 78-megawatt plant, sequencing systems tests has proved to be a recurring challenge, often leading to delays to bring on systems ahead of or different from planning schedules.
BIW has surged workers, particularly electrical workers, to the ship, leading to delays in the next two ships, Michael Monsoor (DDG 1001) and Lyndon B. Johnson (DDG 1002).
In March, the Navy announced the problems meant the Zumwalt’s planned delivery date of August 2015 would be delayed at least until November. But by mid-July, that goal was gone, and the Navy acknowledged it was hoping to begin the first sea trials in December. No new delivery date has been announced, but it clearly won’t happen this year.
Neither the Navy nor BIW would respond to queries about exactly how far behind schedule the DDG 51-class destroyers are.
“That’s something we would like to know,” one service official said with a sense of frustration. But it does appear that, like Ingalls a decade ago, every ship under construction in Bath’s yard is falling further behind schedule.
Assigning responsibility for the delays is also problematic. BIW is not solely responsible for the Zumwalt’s propulsion and combat systems, that’s on the Navy and its prime systems contractor, Raytheon. All bear significant responsibility for the delays.
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