Innovation does not always come from complex technology; it often comes from the people who use the tools every day. When a group of Newport News shipbuilders took a renewed look at a familiar device, the versatile weld gauge, or V-WAC gauge, they joined together and turned a small idea into an improved and cost-saving solution.

“They had a need, and the team came together and collaborated to develop the product, and all from different areas,” said Marcos Dalaney Sr. (O64), a Fleet Support superintendent.

Inspectors use V-WAC gauges to measure undercut, porosity and other critical weld characteristics. Because the average tool measures around 4 inches, it presents challenges in ease of use, particularly when trying to measure and inspect hard-to-reach places.  Recognizing this, the group of shipbuilders worked together to enhance the tool with a simple alteration, making it more efficient and easier to use, without sacrificing accuracy.

“I call these home remedies,” said Derrick Hicks (X67), a test inspection manager. “Whenever I got to a position where I needed to push or pull something, I just made it.”

The group’s solution included adding extra length options. The shipbuilders used scrap aluminum to create 6-, 12- and 18-inch plates to add on to the V-WAC gauge. Mitchell Bryant (O64), a construction supervisor, coordinated the material transfer and made arrangements with off-site shops to get the updated gauge fabricated in one day. He said, “We wanted to make a good product that would get the job done on time.”

The increase in length allows shipbuilders to reposition the scale to better suit the area, capture a more accurate measurement and also improves ergonomic posture while performing these duties. The new and improved gauge has not only increased efficiency but also reduced costs.

“Anytime we can assist in saving this company time and money the scrapyard does not hesitate in doing so,” said Courtland Myles (O53), a supervisor for material handling.

The team did not stop there. The group also discovered they could produce the point tip, or needle, of the gauge within the shipyard. While the gauge’s metal plate has an extended shelf life, the needle gets worn down after numerous uses. Being able to produce replacement tips themselves has allowed the team to increase productivity and save on costs.

With more than 100 years of experience and from various areas of the shipyard, this group of shipbuilders used their experience and knowledge to create an improved V-WAC gauge tool that is making a positive impact within Fleet Support. The group hopes to expand its uses to other areas of the shipyard.