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RickoverRickover’’ss Legacy: Legacy:

Secrets of the Nuclear NavySecrets of the Nuclear Navy’’ss

SuccessSuccess

Ken ReedKen Reed

Senior AssociateSenior Associate

System ImprovementsSystem Improvements

Why is Why is RickoverRickover’’ss methodology so methodology so

Important?Important?

Consequences of errors can be SEVEREConsequences of errors can be SEVERE

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About meAbout me

•• 21 years Nuclear Submarine Experience21 years Nuclear Submarine Experience

–– Retired Master Chief Electronics TechnicianRetired Master Chief Electronics Technician

–– Served on:Served on:•• Ballistic Missile BoatBallistic Missile Boat

•• Fast AttacksFast Attacks

•• Nuclear Research subNuclear Research sub

–– Last boat Last boat –– USS SEAWOLF (SSN-21) USS SEAWOLF (SSN-21)

What did I do?What did I do?

•• Operation and maintenance of ReactorOperation and maintenance of ReactorControl ElectronicsControl Electronics

•• Reactor operator and propulsion plantReactor operator and propulsion plantsupervisorsupervisor

•• Squadron Reactor OperatorSquadron Reactor Operator–– In charge of training and maintenanceIn charge of training and maintenance

oversight on 6 boats in the squadronoversight on 6 boats in the squadron

•• Last ship Last ship –– USS SEAWOLF USS SEAWOLF

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On board SEAWOLF:On board SEAWOLF:•• Senior Enlisted nukeSenior Enlisted nuke

•• In charge of training and maintenanceIn charge of training and maintenanceplanning for 4 engineering divisionsplanning for 4 engineering divisions

•• Ran training and drill programRan training and drill program

•• Earned highest possible grade (Excellent)Earned highest possible grade (Excellent)on 2 successive Operational Reactoron 2 successive Operational ReactorSafeguards ExaminationsSafeguards Examinations

A Little Nuclear HistoryA Little Nuclear History

•• Dec 2, 1942 - 1Dec 2, 1942 - 1stst ““nuclear reactornuclear reactor””

operated by operated by EnricoEnrico Fermi at University of Fermi at University of

ChicagoChicago

•• 1947 1947 –– Rickover trained in Nuclear Rickover trained in Nuclear

EngineeringEngineering

•• 1954 - USS NAUTILUS launched1954 - USS NAUTILUS launched

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From this:From this:

……to thisto this

In 12Years!!

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And since then:And since then:

•• As of 2004:As of 2004:

–– 103 reactors103 reactors

–– 82 ships82 ships

–– 5600 reactor-years of operation5600 reactor-years of operation

•• 2900 civilian reactor-years2900 civilian reactor-years

–– May be as many as 20 reactors in a singleMay be as many as 20 reactors in a single

portport

–– No major accidents or releasesNo major accidents or releases

How has this been accomplished?How has this been accomplished?

•• IntegrityIntegrity

•• TrainingTraining

•• DisciplineDiscipline

•• Root Cause AnalysisRoot Cause Analysis

•• InspectionsInspections

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Military Military vsvs Business Business

•• II’’ve heard it said that you canve heard it said that you can’’t run at run a

business like the militarybusiness like the military

•• I believe that there is a lot that can beI believe that there is a lot that can be

learned in both directionslearned in both directions

•• See what you may be able to apply to theSee what you may be able to apply to the

business modelbusiness model

•• Substitute Substitute ““companycompany”” for for ““commandcommand””

““GoodGood”” ships ships

•• Obviously, differences ship to shipObviously, differences ship to ship

•• As an inspector, I saw As an inspector, I saw ““goodgood”” ships and ships and

““badbad”” ships ships

•• I will highlight the differencesI will highlight the differences

•• NOTE: Even the NOTE: Even the ““badbad”” ships are held to ships are held to

minimum high standardsminimum high standards

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Nuclear Navy Bell CurveNuclear Navy Bell Curve

Belo

w A

vera

ge

Belo

w A

vera

ge

Above A

vera

ge

Above A

vera

ge

Avera

ge

Avera

ge

Exce

llent

Exce

llent

Sig

nifica

ntly

BA

Sig

nifica

ntly

BA

Unacce

pta

ble

Unacce

pta

ble

Does notexist

Perfo

rmance

Perfo

rmance

IntegrityIntegrity

•• Emphasized continuouslyEmphasized continuously

•• No second chancesNo second chances

•• Mistakes happen, but lack of integrity is aMistakes happen, but lack of integrity is aconscious actconscious act

•• You can include You can include ““responsibilityresponsibility”” here also here also

•• AdmAdm Rickover: Rickover:

““Half-truths are like half a brick - theyHalf-truths are like half a brick - theycan be thrown farthercan be thrown farther””

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IntegrityIntegrity

•• AdmAdm Rickover: Rickover:

–– ““Unless you can point the finger at theUnless you can point the finger at the

man who is responsible when somethingman who is responsible when something

goes wrong, then you never had anyonegoes wrong, then you never had anyone

really responsible.really responsible.””

–– DoesnDoesn’’t sound very TapRooT-t sound very TapRooT-ishish, does it?, does it?

•• Or Does It?Or Does It?

IntegrityIntegrity

•• Remember, TapRooT® never says thatRemember, TapRooT® never says that

you shouldnyou shouldn’’t hold someone responsiblet hold someone responsible

for a problem.for a problem.

•• It just isnIt just isn’’t always the operator who ist always the operator who is

responsible.responsible.

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TrainingTraining

•• Seems like this is the first thing cut in yourSeems like this is the first thing cut in yourbudgetbudget

•• Rarely does this end up being a goodRarely does this end up being a gooddecisiondecision

•• Training turns out to be the #2 priority,Training turns out to be the #2 priority,following only mission accomplishmentfollowing only mission accomplishment–– Even here, Even here, ““mission accomplishmentmission accomplishment”” usually usually

includes required training valueincludes required training value

““We donWe don’’t havet have

time for training!time for training!””

Typical Weekly Schedule (at sea)Typical Weekly Schedule (at sea)

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Notes on TrainingNotes on Training

•• Average of 5 hours / man / weekAverage of 5 hours / man / week

–– Classroom onlyClassroom only

–– Drills, OJT, qualification, study, etc countedDrills, OJT, qualification, study, etc counted

separatelyseparately

•• If training overridden, RESCHEDULEDIf training overridden, RESCHEDULED

•• EVERYONE went to trainingEVERYONE went to training

•• On watch 6, On watch 6, ““offoff”” 12 12

““Creeping Nuke-ismCreeping Nuke-ism””

•• Forward departments started doing sameForward departments started doing same

regimenregimen

–– DidnDidn’’t like itt like it

•• Nukes run forward and aft drill programsNukes run forward and aft drill programs

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To Investigate, or not toTo Investigate, or not to

investigateinvestigate……

•• Issues always ariseIssues always arise

•• Some are minor, some not so minorSome are minor, some not so minor

•• You must decide at what level anYou must decide at what level an

investigation is requiredinvestigation is required

Questions to ask:Questions to ask:

1.1. How serious was the problem?How serious was the problem?

2.2. Who knows about it?Who knows about it?

3.3. Who could find out about it?Who could find out about it?

4.4. Who else needs to know about it?Who else needs to know about it?

5.5. What are the consequences of notWhat are the consequences of notinvestigating?investigating?

6.6. Do I understand the problem, or is it prettyDo I understand the problem, or is it prettycomplex?complex?

7.7. Do I have all the information I need?Do I have all the information I need?

8.8. How much time is available for recovery?How much time is available for recovery?

IntegrityIntegrity

andand

TrainingTraining

take caretake care

of theseof these

Green BookGreen Book

EntryEntry

CritiqueCritique

Required?Required?

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Is a Critique Required?Is a Critique Required?

•• Separates Separates ““goodgood”” boats from boats from ““not sonot so

goodgood”” boats boats

•• Naval Reactors has rules for whenNaval Reactors has rules for when

problem is an Incidentproblem is an Incident

–– Rules not so clear on Rules not so clear on ““critiquecritique””

–– Up to discretion of Commanding OfficerUp to discretion of Commanding Officer

–– This separates the men from the boysThis separates the men from the boys

The Dreaded CritiqueThe Dreaded Critique

•• Always badAlways bad–– Outcomes:Outcomes:

•• DisqualificationDisqualification

•• Oral reprimandOral reprimand

•• Upgrade programUpgrade program

•• Loss of pay / rank?Loss of pay / rank?

•• TrainingTraining

•• New procedure / procedure changeNew procedure / procedure change

•• Rickover-inspiredRickover-inspired

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The New NavyThe New Navy

•• Perception has changedPerception has changed

–– No longer look bad at higher levelsNo longer look bad at higher levels

–– LessLess likelylikely to be blame-oriented to be blame-oriented

–– NR guidelines issued (based on NR guidelines issued (based on ““goodgood”” boats) boats)

–– Commands more likely to conduct critiquesCommands more likely to conduct critiques

–– Critique smaller issuesCritique smaller issues

–– ““Fact-findingFact-finding””

The Critique SequenceThe Critique Sequence

•• Involved parties assembledInvolved parties assembled

•• CO / XO / COB / EDMC / ENG conveneCO / XO / COB / EDMC / ENG convene

•• Timeline quickly developed (interviews)Timeline quickly developed (interviews)

•• Procedures referencedProcedures referenced

•• Further statements takenFurther statements taken

•• Involved parties excusedInvolved parties excused

•• Agree on root causes, STCA, LTCAAgree on root causes, STCA, LTCA

•• Involved parties informedInvolved parties informed

•• TrackingTracking

•• Incident report or Near Miss submitted if requiredIncident report or Near Miss submitted if required

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Why does this work?Why does this work?•• Integrity re-enforcedIntegrity re-enforced

–– Fair punishment can be expected for mistakes, but there is noFair punishment can be expected for mistakes, but there is notolerance for a lapse of integrity.tolerance for a lapse of integrity.

•• Military discipline can be easily enforced, so punishmentsMilitary discipline can be easily enforced, so punishmentscan be quickly meted out.can be quickly meted out.

•• No one goes home when you are underway.No one goes home when you are underway.

•• For the same reason, training can be quickly held.For the same reason, training can be quickly held.

•• There is a huge amount of outside oversightThere is a huge amount of outside oversight

•• The CO has ultimate authorityThe CO has ultimate authority

•• There is a large body of experience to draw upon whenThere is a large body of experience to draw upon whendetermining the root causes and corrective actions.determining the root causes and corrective actions.

•• A warship must be able to fulfill its assigned missionA warship must be able to fulfill its assigned mission

•• The CO is informed of almost all problems, keeping himThe CO is informed of almost all problems, keeping himabreast of the status of all his equipmentabreast of the status of all his equipment

Disadvantages:Disadvantages:

•• Personnel are usually all interviewed togetherPersonnel are usually all interviewed together

•• Interview held with the supervisor presentInterview held with the supervisor present

•• Due to limited manpower and time, critique onlyDue to limited manpower and time, critique onlythe the ““bigbig”” stuff stuff

•• The CO can quickly become overwhelmed by theThe CO can quickly become overwhelmed by thesheer number of issuessheer number of issues

•• The same people normally decide on the rootThe same people normally decide on the rootcauses and the corrective actions for everycauses and the corrective actions for everyincidentincident

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InspectionsInspections

•• Nuclear Propulsion Examination BoardNuclear Propulsion Examination Board

–– Conduct Operational Reactor SafeguardsConduct Operational Reactor Safeguards

ExamsExams

–– Previous Engineers, COPrevious Engineers, CO’’ss

–– Every 12-16 monthsEvery 12-16 months

–– Most announced (scheduled 6-9 months out)Most announced (scheduled 6-9 months out)

•• Several per year only 3 days noticeSeveral per year only 3 days notice

–– Answer directly to NAVSEA 08Answer directly to NAVSEA 08

ORSE Work-upORSE Work-up

•• Good boats need only moderateGood boats need only moderate

preparationspreparations

•• All need time in schedule dedicated toAll need time in schedule dedicated to

drillsdrills

•• Squadron personnel assist in Squadron personnel assist in w/uw/u, reviews, reviews

•• ““Good boatsGood boats””: integrated into daily ship: integrated into daily ship’’ss

scheduleschedule

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IntegrationIntegration

•• Audits by all levels of commandAudits by all levels of command

•• Drills whenever there is an openingDrills whenever there is an opening

–– Maybe only walk-Maybe only walk-throughsthroughs allowed allowed

–– ““MinorMinor”” drills any time drills any time

•• Training never to Training never to ““check the boxcheck the box””

•• Test, test, testTest, test, test

•• Internal audits of everythingInternal audits of everything

The ORSE InspectionThe ORSE Inspection

•• 2 Days2 Days

–– Day 1Day 1

•• Records ReviewsRecords Reviews

•• Written ExamsWritten Exams

•• Monitored EvolutionsMonitored Evolutions

•• Material InspectionMaterial Inspection

–– Day 2Day 2

•• DrillsDrills

•• Observe a training sessionObserve a training session

•• Oral interviewsOral interviews

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The ORSE InspectionThe ORSE Inspection

•• Inspection now includes an observation ofInspection now includes an observation of

ship control, piloting, navigation, etcship control, piloting, navigation, etc

•• Reactor safety includes things outside theReactor safety includes things outside the

engineroomengineroom

–– Tough for the reactor to be safe if the ship isTough for the reactor to be safe if the ship is

operated unsafelyoperated unsafely

Consequences can be severeConsequences can be severe

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Was this reactor safe???Was this reactor safe???

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Nuclear NavyNuclear Navy’’s Guiding Principless Guiding Principles

•• Integrity from Day 1Integrity from Day 1

•• Training is part of daily lifeTraining is part of daily life

•• Whole ship must be safeWhole ship must be safe

•• Procedural complianceProcedural compliance

–– Understand procedureUnderstand procedure

–– Question when it doesnQuestion when it doesn’’t make senset make sense

–– Get it fixedGet it fixed

•• Rising Standards of ExcellenceRising Standards of Excellence

•• Facing factsFacing facts

•• Learn from experienceLearn from experience

•• Total ResponsibilityTotal Responsibility

Nuclear NavyNuclear Navy’’s Guiding Principless Guiding Principles

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TagoutTagout System System

•• Navy LO/TO system seems much more rigorousNavy LO/TO system seems much more rigorous

•• StepsSteps–– One man researches and writes LO/TOOne man researches and writes LO/TO

–– Second man independently verifies boundariesSecond man independently verifies boundaries

–– Worker must prove boundaries to supervisorWorker must prove boundaries to supervisor•• Use printsUse prints

•• Prints must be correctPrints must be correct

–– Workers prepare systemWorkers prepare system•• Secure system, drain, ventSecure system, drain, vent

–– Supervisor authorizes hanging tagsSupervisor authorizes hanging tags

TagoutTagout System (cont) System (cont)

Steps:Steps:

–– First worker positions components, hangs tagsFirst worker positions components, hangs tags

–– Second worker verifies positions, signs tagsSecond worker verifies positions, signs tags

–– Supervisor approves commencement of workSupervisor approves commencement of work

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Why this worksWhy this works

•• Rigorously followedRigorously followed

•• Prints are correctPrints are correct

•• All components correctly labeledAll components correctly labeled

–– No deviations from label allowedNo deviations from label allowed

•• Rigorous auditingRigorous auditing

•• Walk-down NOT allowed as only checkWalk-down NOT allowed as only check

–– In fact, walk-down not even mentionedIn fact, walk-down not even mentioned

ConclusionsConclusions

•• RickoverRickover’’ss methods were required at the methods were required at thetime institutedtime instituted–– Over the years, minor modifications, butOver the years, minor modifications, but

basics have NOT changedbasics have NOT changed

•• Adoption of his exact methods by civilianAdoption of his exact methods by civilianbusinesses may not work businesses may not work in totalin total

•• However, his principles in generalHowever, his principles in generalwill work anywhere.will work anywhere.