CVN-74 HAZMAT Availability – Defense-Ready Optimization Project
Client: Naval Air Systems Command (NAVAIR)
A defense-ready optimization project using Lean Six Sigma Black Belt methods was conducted aboard the Nimitz-class nuclear-powered aircraft carrier USS John C. Stennis (CVN-74) to improve HAZMAT availability and reduce waste from expired materials. Carrier Air Wing Nine (CVW-9) squadrons reported that several ‘Never Out List’ items were frequently either missing from supply or issued near their expiration dates. The primary objective of the project was to reduce inventory waste, increase the availability of key items, and ensure readiness by implementing a more reliable and traceable supply system. The team consisted of shipboard personnel across supply and maintenance functions, coached by NOVACES Master Black Belts (MBBs).
Challenges
An analysis revealed that 35.9% of the HAZMAT inventory had fewer than 30 days of shelf life remaining (Chart A below). This inefficiency contributed to over $158,000 in annual waste, storage constraints, and potential delays in aircraft readiness due to unavailable or expired materials like RAM Coating. A key issue identified was the failure of the First-In-First-Out (FIFO) system to ensure the proper rotation of stock. Further testing demonstrated that training levels or personnel differences did not account for this failure, indicating that the system itself needed redesign.
Solutions Delivered
The project implemented several targeted solutions to address root causes:
- Introduced a color-tagging system to identify HAZMAT by month of manufacture.
- Marked shelving by National Item Identification Number (NIIN) and order of use (‘1st’, ‘2nd’, ‘3rd’) to enforce FIFO discipline.
- Improved database visibility to Hazardous Inventory Control System (HICS), enabling real-time inventory tracking.
- Required end-user inspections for Type II materials before approving shelf life extensions.
- Established a verification process to check shelf life at material receipt.
- These measures standardized processes and improved user compliance while reducing expired inventory.
Key Takeaways
Increased defense-readiness by reducing the risk of aircraft being grounded due to unavailable or expired HAZMAT.
Improved accuracy and visibility of HAZMAT inventory by 40%.
Standardized labeling and retrieval practices.
Minimized error and time spent locating materials.
Established a replicable model for HAZMAT inventory control applicable across similar shipboard environments.