grouptech121798 - hcmut.edu.vnvtcang/course/kctau-106/course-from web/na2… · of all parts...
TRANSCRIPT
10/15/98 1
MODERN SHIPBUILDING PRACTICE
GROUP TECHNOLOGY/PWBS/IPC
• GT is not new• Has only had limited application in shipyards.• Typical uses have been structural part variety reduction and
development of pipe piece families.• Many shipyards say they use it but they only think so as they use
Work Breakdown Structures, classification and coding. This isnot GT.
• GT is necessary if a shipyard wants to utilize automated pipeshop, Computer Aided Process Planning and/or robotics.
• However, GT is not for everyone. It should not be used unless a• clear understanding of why they need it.• Many people need a classification and coding system but not
GT.
10/15/98 2
10/15/98 3
10/15/98 4
10/15/98 5
10/15/98 6
10/15/98 7
10/15/98 8
10/15/98 9
10/15/98 10
10/15/98 11
10/15/98 12
10/15/98 13
10/15/98 14
MODERN SHIPBUILDING PRACTICE
GROUP TECHNOLOGY/PWBS/IPC (Continued)
• Work Breakdown Structures (WBS) have been used for manyyears in many industries.
• WBSs are a convenient method to show desired tasks and/orprocesses to be used to build a product.
• A WBS can be Custom, Group Technology or Standard based.Custom based is when the product and its components are alldifferent and no attempt is made to group the tasks or processes.Group Technology based is when, even though the endproducts may be different the tasks or processes can be groupinto similar categories based on work requirements.Standard based is when the product is completely made up ofstandard components in the same way every time.
10/15/98 15
MODERN SHIPBUILDING PRACTICE
GROUP TECHNOLOGY/PWBS/IPC (Continued)• A Product Breakdown Structure is a graphic representation of an
indented Bill of Material, where the indentations reflect theorder in which the components are assembled.
• The term Product-oriented Work Breakdown Structure (PWBS)refers to the specific case where the product, work andorganization are combined into a system to address a specificindustrial product, like ships.
• The concept was introduced into U.S. shipbuilding by the IHITechnology Transfer in 1982 by the NSRP Report “Product-oriented Work Breakdown Structure.”
• Since then most U.S. shipbuilders have adopted the concept tosome level, but not to the extent or the way that the reportdescribed. In fact the report is confusing in many ways and hascaused implementers considerable trouble.
10/15/98 16
MODERN SHIPBUILDING PRACTICE
GROUP TECHNOLOGY/PWBS/IPC (Continued)
• A PWBS can be one of the most important tools in a shipyard’sattempt to improve it’s performance. This is because when it isdeveloped correctly and applied to assist in the integration of themany systems in a shipyard, the benefits are significant.
• Some shipyards develop a more detailed breakdown in the formof an Interim Product Catalog. The catalog can range from afew basic interim product types to a very comprehensive catalogof all parts through to erection. It can also identify work stationsand processes used to manufacture the interim products as wellas manhour budget and manning.
10/15/98 17
MODERN SHIPBUILDING PRACTICE
BREAKDOWN STRUCTURES
• A breakdown structure is a structured representation ofhierarchical information related to products of work.
• Bills of Material (BOM) are tabular representations of thecomponents that are required to assemble a product. BOM canbe simple sequential lists of all material or they can be indentedto represent what components go into higher level components.
• A PRODUCT Structure (PS) is formed by making a hierarchicaltree in place of the indented BOM. For convenience it is usuallyturned 90 degrees to present a vertical cascade.
10/15/98 18
MODERN SHIPBUILDING PRACTICE
BILL OF MATERIAL
>>Assembly 1>>Assembly 2>>Sub-Assembly 1>>Sub-Assembly 2>>Sub-Assembly 3>>Sub-Assembly 4>>Part 1>>Part 2>>Part 3>>Part 4>>Part 5>>Part 6>>Part 7
10/15/98 19
MODERN SHIPBUILDING PRACTICE
INDENTED BILL OF MATERIAL
>>Assembly 1Sub-Assembly 1
Part 1Part 2
Sub-Assembly 2Part 3
>>Assembly 2Sub-Assembly 3
Part 4Part 5
Sub-Assembly 4Part 6Part 7
10/15/98 20
MODERN SHIPBUILDING PRACTICE
WORK BREAKDOWN STRUCTURE
• Work Breakdown Structure (WBS) have been used for manyyears in many industries
• WBS are a convenient way to show desired tasks and/orprocesses to be used to build a product
• A WBS can be standard, group technology or custom basedStandard is when the product is completely made up of standard components I the same way every time.
Group technology is when, even though the end products may be different, the tasks or processes can be grouped into similar categories based on work requirements.
Custom is when the product and its components are all different and no attempt is made to group the tasks or processes.
10/15/98 21
MODERN SHIPBUILDING PRACTICE
WORK BREAKDOWN STRUCTURE (continued)
• There are many other types of breakdown structures used in ashipyard such as Labor Charging Structure and Cost AccountingStructure.
• Combining product and work in the same breakdown structure isillogical and confusing.
• However, there is normally a relationship between the product,the work that is required to manufacture it and the stage in theoverall process at which it is done. If these standardrelationships are identified and documented in an InterimProduct Catalog, then only the product structure is required toidentify the work required to produce the product. The workand stage naturally “fall out” of the system.
10/15/98 22
MODERN SHIPBUILDING PRACTICE
WORK BREAKDOWN STRUCTURE (continued)
• A WORK Breakdown Structure (WBS) is a hierarchicalrepresentation of the work that is required to produce a productor interim product.
• A WBS divides the total work into all the tasks to beaccomplished in building a product. The tasks are arrangedshowing their dependencies of the sequence in which theyshould be performed.
10/15/98 23
MODERN SHIPBUILDING PRACTICE
WORK BREAKDOWN STRUCTURE (continued)Block Erecting
On-Block Outfitting
Block Painting
Block Constructing
Assembling
Fabricating
Preparing
10/15/98 24
MODERN SHIPBUILDING PRACTICE
OTHER BREAKDOWN STRUCTURES
• Product Breakdown Structures (PBS) is a graphic representationof an indented bill of material, where the indentations reflect theorder in which the components are assembled.
• The term Product-Oriented Work Breakdown Structure (PWBS)refers to the specific case where the product, work andorganization are combined into a single system to address aspecific industrial product, like a ship.
• Since the PWBS concept was introduced into U.S. shipbuildingby the 1982 NSRP Report, most shipbuilders have adopted theconcept to some level, but not to the level suggested by theNSRP report.
10/15/98 25
MODERN SHIPBUILDING PRACTICE
PRODUCT BREAKDOWN STRUCTURE
Ship
Grand Block or Construction Zone
Block or Outfitting Zone
Assembly or Unit
Sub-Assembly
Part
Material/Equipment
10/15/98 26
MODERN SHIPBUILDING PRACTICE
INTERIM PRODUCTS
• Product Any finished (company deliverable object).
• Interim Product An in process object which is the output of awork stage (process) and is complete in and of itself.
• Interim Product A library of all interim products withCatalog complete description of physical properties,
cost data, manufacturing process, task duration, and resource requirements.
10/15/98 27
MODERN SHIPBUILDING PRACTICE
PWBS/IPC REQUIREMENTS
• Based on shipyard practices
• Satisfy as many individual group needs as possible
• Support computer-aided systems throughout company
• Integrate all shipbuilding information
• As simple as possible - easy to understand
• At learning level of all users
10/15/98 28
MODERN SHIPBUILDING PRACTICE
IDENTIFICATION IMPORTANCE
• Identification system has a direct and SIGNIFICANT impacton performance of any manufacturing company
• Identification system must be the INTEGRATOR forinformation management system
10/15/98 29
MODERN SHIPBUILDING PRACTICE
IDENTIFICATION NEEDS
EstimatingDrawingsManufactured and purchased partsBills of materialPurchase specificationsIn process interim productsDesign and production zonesWork packagesWork sequenceMaterial kittingLabor planningActivity schedulingMaterial controlProduction controlBudgeting
10/15/98 30
MODERN SHIPBUILDING PRACTICE
POTENTIAL APPROACHES
• Product/Work Station Structure
• Interim Product Catalog - Product based
• Interim Product Catalog - Process based
10/15/98 31
MODERN SHIPBUILDING PRACTICE
PRODUCTS/WS STRUCTURESPRODUCT WORK STATION/PROCESS
PRODUCTION SUPPORTBlocks- Bottom Stockyard Engineering
Bilge Blast & Prime PlanningSide Plate Plasma Cut PurchasingBulkhead Plate Oxy Cut Material Cont.Deck Profile Cut & Mark Production Cont.Loopbelt Tower Plate Flange TransportationBelt (M) Plate FormLower Bow Profile FormUpper Bow Sub-AssemblyLower Stern Robot WelderUpper Stern Panel Line- Plate Butt TackMach Space Bottom Plate Butt WeldMach Space Sides Etc.Mach Space Flats Block ConstructionMach Space Deck Block Hot OutfitDeckhouse Block Clean and Pain
Block Cold OutfitOutfitting Zones Dock Block Erection, Fit & Weld
Package Unit AssemblyZone OutfitSystem TestDock TrialSea TrialDelivery
10/15/98 32
10/15/98 33
MODERN SHIPBUILDING PRACTICE
INTERIM PRODUCT CATALOGPRODUCT BASED PROCESS BASEDDesign DesigningEngineering EngineeringPurchase Equipment PlanningRaw Material - Plate Controlling - Material/Production
Profiles Handling - Plate/Profiles/Pipe/EquipmentCastings Blasting & Priming - Plate/Profile/PipeForgings Flame PlaningPipe Contour Cutting - Insulation Profile Cutting - Manual/RoboticPaint Plate FormingElectric Cable Profile Bending
Parts- Structure Sub-AssemblingMachinery AssemblingElectrical Block ConstructingAuxiliary Block PaintingHull Outfit Package Unit Outfitting
Sub-Assemblies Block OutfittingBlock ErectionBlock Erection Welding
Assemblies Zone OutfittingTesting
Blocks Dock TrialingSea Trialing
Ship Delivering
10/15/98 34
10/15/98 35
10/15/98 36
10/15/98 37