ihop

© A.Y.Odabaşı 2009

IntroductionIntroduction

Week 1Week 1

İİ.T..T.ÜÜ. Faculty of Naval Architecture and Ocean Engineering. Faculty of Naval Architecture and Ocean EngineeringMethodsMethods of of ShipShip ProductionProduction –– GEM314EGEM314E


Objectives of the CourseObjectives of the Course

• The main aim of this module is to equip students with methods and tools forproduction of marine vessels. The objectives of the class are as follows:

• A good knowledge of methods and tools for production of marine vessels• An appreciation and good understanding of various issues in shipyard production operations.• An ability to analyse system requirements before choosing appropriate production methods and

tools

• Students will:• Be given an understanding through practice of ship production• Observe a shipyard in action through the site visits• Be given instruction• Experience the process of technical report writing

• On completing this course students should:• Be familiar with the concepts of ship production system design• Recognise the main hardware elements of shipyards• Appreciate the relative merits of differing systems• Understand the technical, and economic issues


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COURSE OUTLINE – Spring 2009

(Tuesdays-1330-1630) Title Subjects Lecturers

Week 13 February

Introduction, Shipbuilding Process and Project Network Analysis

Introduction to class. Building methods, ship structures, Product Work Breakdown Structure (PWBS), Group Technology Planning and scheduling Costing and value engineering

AYO

Week 210 February

Welding Basics and Welding in Shipbuilding Welding techniques and welding applications

in shipbuildingAYO

Week 317 February

Capacity Planning Calculations for Shipyards

Area requirements, tools utilization, pallet concept IHH

Week 424 February

Shipyard Layout and Facility PlanningSteel Prefabrication (Site visit)

Shipyard facilities, process lanesMaterial handling systemsSteel cutting and forming,Steel fabrication

Sedef TersanesiFahri ArısoySedef Gemi İnşaatı A.Ş.Tuzla/İstanbulTel.0216 395 4741Fax. 0216 395 4740

Week 53 March

Measurements and statistical accuracy control in ship production Applications on accuracy control in shipyards Tanju Köse

Week 610 March

Welding Procedures and Inspection(Site Visit)

Welding procedures,Inspection of hull welding, destructive and non-destructive testing etc.Activities of classification societies

Türk LoyduHasan HabiboğluTürk Loydu VakfıTuzla/İstanbulTel.0216 446 22 40Fax.0216 446 22 46

Week 717 March

Marine Equipments(Site Visit)

Production of cranes, rudders, Hatch Covers, Deck Equipments etc.

Gürdesan, GebzeMustafa Gürsoy,Tel.0262 724 8546Fax.0262 724 8554


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Week 8 EXAM Mid-Term examination(Multiple choice / Books open) D311 EXAM

Week 931 March Materials and Welding

Structural steels, non-ferrous alloys, non-metallic materials, welding and cutting methods.

OerlikonHacı DolutaşOerlikon Kaynak Elektrotları ve San.A.Ş.,Sefaköy/İstanbulTel.0212 411 1400Fax.0212 411 1114

Week 107 April Surface preparation and Painting Abrasive blasting and priming, finish coatings

Hempel Seyit Ali Dikerkol Esra ErbagiMarketing Department

Week 1114 April FRP Construction (Site Visit) Materials, methods of production

YONTECHEkber OnukYonca Teknik TersanesiTuzla/İstanbulTel.0216 392 9970Fax. 0216 392 9969

Week 1221 April Aluminum construction (Site Visit) Handling and storage,

forming, welding

Yıldız TersanesiBaki GökbayrakTel. 0216 395 4075Fax. 0216 395 1290

Week 1328 April Outfitting and Machinery installation

General outfitting,Subcontractor’s work, Installation priorities, shafting, propellers, piping, electrical installations

IHH, AYO

Week 145 May Review IHH


Other ConditionsOther Conditions

TERM-TIME ASSESSMENTS

Quantity Weight (@ points)Mid-Term Examination 1 %20Quiz 4 %20Assignment 2 %20Attendance Compulsory

Contribution of term work on achievemet scores : % 60Contribution of final exam scores on achievement scores : % 40

Prerequisites for attending final exam :

1) 70% attendance to class meetings.2) Submission of reports in full and on given deadlines


Product Work Breakdown StructureProduct Work Breakdown Structure(PWBS)(PWBS)

İİ.T..T.ÜÜ. Faculty of Naval Architecture and Ocean Engineering. Faculty of Naval Architecture and Ocean EngineeringMethods of Ship Production Methods of Ship Production -- GEM 314GEM 314--EE


GlossaryGlossary

• Cycle time : the length of time it takes a process to cycle once

• Effectiveness : ability to use a resouce in best possible way (or ability to solve a

problem in best possible way)

• Efficiency :the degree of effectiveness as it applied to a process

• Process : the blending and transformation of a specific set of inputs into a

more valuable set of outputs

• Reliability : the consistency of an output

• Rework : any unnecessary, repeated operational steps

• Waste : all non-value adding process activities except those required to satisfy

rules, regulations etc.

• Work : actions that move a process forward or directly add value

• Work efficiency : a mathematical expression of how much work versus waste

exists in a process


Work EfficiencyWork Efficiency

WORK

WORK + WASTEx 100 %


UtilizationUtilization

Relation between the time when the equipment actually is used for productive time (machine time) and the total time available

What is AVAILABLE time ?Breakdowns and stops15 %

Personal allowances15 %

Technical allowances15 %

Manual time15 %

Machine time40 %Utilization 40 %


DefinitionsDefinitions

MACHINE TIME

TOTAL AVAILABLE TIMEMachine UTILIZATION =

Personnel PRODUCTIVITY =USED MANHOURS

TOTAL QUANTITY

Project PERFORMANCE =ALLOCATED MANHOURS

USED MANHOURS


Process ReProcess Re--engineringenginering

The goal: is to decrease the the amount of waste in any work process

Before After

AWorkWork

WasteWaste

BWorkWork

WasteWaste

WorkWork

WasteWaste

WorkWork

WasteWaste More workin the same

amount of time

Same amount of workin muchless time


Key Process CharacteristicsKey Process Characteristics

• Effectiveness : Do outputs meet customer requirements ?

• Efficiency : Is process cycle time acceptable ?

• Reliability : Do outputs always meet customer approval?

• Cost : Are process costs acceptable ?

Customer wantsCustomer gets

Customer always wantsCustomer usually gets

Process cycle time is 3h 25 min.Process cycle time should be 1h 15 min.

Process costs $ 55 per outputProcess should cost $ 36 per output


Production Flow Production Flow -- Shop FloorShop Floor

SteelStockyard

Shotblasting &Priming

PlateCutting

ProfileCutting

PlateForming

ProfileForming

MiscellaneousAssemblies

BlockConstruction

Curved PanelLine

Web & Comp.Line

Small PanelLine

Large Panel &Double Bottom

Line


Main Activities in Ship Construction Main Activities in Ship Construction -- Functional ApproachFunctional Approach

FrameBody Plan

Profile &Buttocks

Piping Mechanical

MainMachinery

AuxiliaryMachiney

DecksShellPlating

Ship

Hull Form HullStructure Machinery Outfit - - - - - -

Bulkheads - - - - - -

- - - - - -

ElectricalHVAC - - - - - -

- - - - - -


Group Technology in Shipbuilding Group Technology in Shipbuilding -- DefinitionDefinition

A technique for manufacturing small to medium lot size batches of parts

of similar process,of somewhat dissimilar materials,

geometry and size, which are produced on a committed small cell of machines,

which have been grouped together physically, specially tooled and scheduled as a unit [Storch et el. 1995]


Group Technology in Shipbuilding Group Technology in Shipbuilding -- BenefitsBenefits

•Reduction in engineering drawings•Company standardization•Reduction in design and engineering man-hours•Better utilization of facilities•Simplified and automated planning•Simplified scheduling and production control•Improved productivity


Build Strategy Build Strategy -- A Group Technology ApproachA Group Technology Approach

•What is to be done?•When is it to be done?•How is it to be done?•What resources are needed to do the task?

Build StrategyAn agreed design, engineering, materials management,

production, planning and testing planprepared before the work startsso as to identify and integrate

all the necessary processes [T.Lamb, 1996]


Product Oriented Work Breakdown Structure (PWBS)Product Oriented Work Breakdown Structure (PWBS)

•PWBS provides indentation levels within production tree structure

•PWBS classifies the ship on the basis of its interim product•Parts and subassemblies are grouped by common characteristicsand classified by both design and manufacturing attributes.

Benefits•Provide mechanism to enter into and come out of SWBS•Communicate amongst design, material procurement and production departments using a common framework and description of both the material and labor for a particular interim product.•Stagewise testing and acceptance•Assistance in configuration and change management


Product Oriented Work Breakdown Structure Product Oriented Work Breakdown Structure -- RequirementsRequirements

Type of work

Resources

Control ofProduction

Process

Hull constructionOutfittingPainting

MaterialManpowerFacilities

Product Structure (Zones)Work Type (or system based)Work Stage


Components of Integrated Hull, Outfitting and Painting (IHOP)Components of Integrated Hull, Outfitting and Painting (IHOP)

Product Work Breakdown Structure

(PWBS)

Zone Outfitting Method (ZOFM)

Zone Painting Method (ZPTM)

Hull BlockConstruction Method

(HBCM)

Pipe Piece Family Manufacturing

(PPFM)


Integrated Hull, Outfitting and Painting (IHOP)Integrated Hull, Outfitting and Painting (IHOP)

HMCM

ZOFM

ZPTM•Uses same logic of group technology as employed in HBCM & ZOFM•Considers painting work as an assembly process with different painting work at different levels

PPFM•Classifies pipe-pieces•Organized independently of the hull structural block•A fabrication process rather than the assembly work of HBCM/ZOFM/ZPTM

•The ship is dived and subdivided into blocks•Blocks are the basis for control of the production•Blocks are also used for ZOFM and ZPTM

Blocks:simple & logical boundariesmin. number of blocksprovide min. scaffoldingprovide max. accessibility

•Works in conjunction with HBCM•Uses similar logic of zone division as in HBCM•Outfit components are assembled either independent of the hull blocks or based on the hull blocks

On-unit

On-block

On-board


Integrated Hull, Outfitting and Painting (IHOP) Integrated Hull, Outfitting and Painting (IHOP) -- BenefitsBenefits

HMCM

ZOFM

ZPTM

•The ship is dived and subdivided into blocks•Blocks are the basis for control of the production•Blocks are also used for ZOFM and ZPTM

•Outfitting and installation work in closed & covered areas•Better and safer work conditions•Easy supervision of work•Reduced idle time

•Maximum amount of down hand or vertical plane paint work•Better control of temperature and humidity for paint work•Safer worker environment•Utilization of same scaffolding with block assembly

PPFM•Large variety pipe-piece parts with number of common elements can be grouped into families or batches having similar design and manufacturing attributes•Testing and coating of pipes are done at the place where the final pipe piece assembly and pipe piece joining takes place


Built up sectionsor stiffened brackets

work s.: assembly, bending

Assembled structural parts(e.g. transverses, girders, floors)

work s.: assembly, back assy.

Pre-block assembly stage;assists to assemble

partial zones to main block

“BLOCK” = KEY ZONE Flat, curved, superstructure blocks;

work stage:joining, assembly, back assembly

Post-block assembly stage;two or more block assemblies are joined

to create a larger block; work stage:joining, pre-erection

Complete hull is considered as a zone;fore, hull, aft hull, cargo hold, engine room, superstructure;

work stage:erection, test

Produce non-subdividablecomponents&piece parts;

work stages: marking,cuting & bending

Hull Block Construction Method (HBCM) Manufacturing LevelsHull Block Construction Method (HBCM) Manufacturing Levels

PartFabrication

PartFabrication

PartFabrication

PartFabrication

PartFabrication

PartFabrication

PartFabrication

PartFabrication

PartAssembly

PartAssembly

PartAssembly

PartAssembly

Sub-blockAssembly

Sub-blockAssembly

Semi-blockAssembly

BlockAssembly

Grand-blockJoining

BlockAssembly

HullErection

Main Work Flow


Production Stages Production Stages –– Steel HullSteel Hull


Parts FabricationParts Fabrication

Line Heating

MarkingMarking & cutting -NC Machine

Press Bending

(courtesy NSNet Shipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo)


SubSub--Block AssemblyBlock Assembly

Palletized sub-assembliesawaiting block assembly

Welding a sub-block

A completed sub-block being moved toa block assembly facility

Assembly of small sub-blocksby gravity-feed welding



Block AssemblyBlock Assembly

Block assembly shopwith process lanes

Curved block assembly onan adjustable pin jigs

Block transportation withheavy-lift transporters

The first stage of flat-panelblock assembly



Hull ErectionHull Erection

Keel laying - Past !! Pyramid erection system -outfitted and painted blocks

Erection of machinery-space blocks Erection of stern block containingrudder horn



“UNIT” = KEY ZONE Manufacturing level foron-unit outfitting work

Manufacturing level foron-unit outfitting work)

Manufacturing level foron-unit outfitting work

On-unit and grand-unit outfitting assemblyare fitted to the structural blocks

defined by the HBCM

Outfit work carried out on the hull of the shipeither during pre-launch erection stage or

during the post launch outfitting stage

Testing of outfitted units

The work packages andmaterial requisition for

component procurementare grouped by zone & area

Zone Outfitting Method (ZOFM) Manufacturing LevelsZone Outfitting Method (ZOFM) Manufacturing Levels

Main Work Flow

ComponentProcurement








UnitAssembly

UnitAssembly

UnitAssembly

UnitAssembly

Grand-UnitAssembly

Grand-UnitJoining

Semi-blockAssembly

On-blockOutfitting

On-boardOutfitting

Operation & Test


Outfit ComponentsOutfit Components

Cables; pre-cut, identified and palletizedVentilation ducts

100 foot diameter LNG sphere

Nuts & bolts



OnOn--Unit OutfittingUnit Outfitting

4) Completed pipe unitsready for landing on block 3) Two nearly completed pipe units

2) A pipe piece secured to supportswith U bolts

1) Tack welded supports for pipe uniton a platen



OnOn--Block OutfittingBlock Outfitting

An outfitted and painted blockView of outfitted block

Fitting out ofventilation-duct pieces

Fitting out of electrical cable trays



OnOn--Board OutfittingBoard Outfitting

On-board outfitting - traditional wayOn-board outfitting

On-board outfitting Flanges for large & medium diameterpipes are in alignment



PWBS PWBS -- Outfit Units AssemblyOutfit Units Assembly

Outfit units which are dissimilar in arrangement and in functions incorporated, have the same classification in a product-oriented work breakdown structure because the problems associated with their assembly are the same.



PWBS PWBS -- Outfit Units AssemblyOutfit Units Assembly

Unit : Standard Machinery UnitResources:• 30 pipe pieces• 5 walkway sections +

handrail• 8 supports• a smaller unit consisting

of 2 interconnected pumps on a common foundation.

Time : 2 worker assembly team for one week

Weight : 10 tons



Application ofanti-corrosive paints

Painting of various outfitting items(masts, cargo booms, hatch covers),

application of anti-corrosive paints

Final stage in the ZPTM;no block turnover,

application of anti-corrosive paints

Surface preparationand primer coating

for plates and sections

Zone Painting Method (ZPTM) Manufacturing LevelsZone Painting Method (ZPTM) Manufacturing Levels

ShopPrimer

ShopPrimer

ShopPrimer

Primer Primer Primer

FinishUnder-coat

Paint

FinishPaint

FinishUnder-coat

Paint

Primer UnitAssembly


Zone PaintingZone Painting

An extensivelt outfitted and painted block

Priming of steel plate



Marking, cutting andmachining of pipes

Flange and collar attachment(excludes joining of main

and branch assemblies)

Joining of main pipe sub-assembly tobranch pipe sub-assemblyto produce pipe assembly

Checks for qualityof the assembled pipes

Pickling and coatingof pipe assemblies

Grouping of pipes according to the requirements for a specific pallet

(e.g. Hull, machinery, superstructure)

Different arrivingmaterials are grouped

according to thetype of material

Pipe Piece Family Manufacturing Method (PPFM) Manufacturing LevePipe Piece Family Manufacturing Method (PPFM) Manufacturing Levelsls

PipeReceiving

PipeReceiving

PipeReceiving

PipeReceiving

PipeReceiving

PipeFabrication

PipeFabrication

PipeFabrication

Pipe PieceAssembly

Pipe PieceAssembly

Pipe PieceJoining

Testing

Coating

Palletizing

Testing


PipePipe--Piece Family ManufacturingPiece Family Manufacturing

Palletizing areasPPFM Classification: Penetrations

PPFM Classification :Straight

PPFM Classification:Unit assembled

Pipe receiving area



Integrated Schedule for Hull Construction, Outfitting and PaintiIntegrated Schedule for Hull Construction, Outfitting and Paintingng

Principle EventSchedule

Integrated Hull ConstructionOutfitting & Painting

Master Schedule

Block AssemblyMaster Schedule

On-unit OutfittingMaster Schedule

On-board OutfittingMaster Schedule

On-block OutfittingMaster Schedule

Monthly Schedule Monthly Schedule Monthly Schedule

Weekly Schedule Weekly Schedule Weekly Schedule

Block ErectionMaster Schedule


Hull Construction ProgressHull Construction Progress


ProducibilityProducibility

The reduction in costsas a result of the effort put in tomake ship cheaper to build

bymaking it cheaper to construct

without compromisingon its desired capabilities

like size, speed, displacement, payload, stability, strength etc.

Reduce labor cost by reducing number of steps to perform the task

Reduce the number of piece parts varity

Incorporate standardization

Increase repetitive jobs

© A.Y.Odabaşı 2009 (courtesy NSNet Shipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo)

PWBS, statistical control and line heating are interdependent. In accordance with a product work breakdown blocks which are assembled on a flat panel are a distinct problem category regardless of their design differences. In Avondale Shipyards, Inc., they are assembled on a dedicated process lane.


PWBS PWBS -- Erection LevelErection Level 11


Building Progression: Keel Laying + Building Progression: Keel Laying + daysdays


PWBS PWBS -- Erection LevelErection LevelLanding the BlockLanding the Block 13




PWBS PWBS -- Erection LevelErection LevelEngineEngine--room Tankroom Tank--top blockstop blocks 15




PWBS PWBS -- Erection LevelErection LevelBlue sky outfitted control Blue sky outfitted control console and diesel generatorsconsole and diesel generators 19




PWBS PWBS -- Erection LevelErection LevelLanding the Cant BlockLanding the Cant Block 22




PWBS PWBS -- Erection LevelErection LevelLanding the grand blockLanding the grand block

Building Progression: Keel Laying + Building Progression: Keel Laying + daydayss

22



PWBS PWBS -- Erection LevelErection Level 24




PWBS PWBS -- Erection LevelErection LevelLanding the main engineLanding the main engine 24




PWBS PWBS -- Erection LevelErection LevelLanding the aft superstructure Landing the aft superstructure halfhalf 27




PWBS PWBS -- Erection LevelErection LevelFinish paint application to the Finish paint application to the undersides of hatchundersides of hatch--coverscovers 28

?




PWBS PWBS -- Erection LevelErection LevelAft half of superstructure being Aft half of superstructure being fittedfitted 29




PWBS PWBS -- Erection LevelErection LevelLanding the aft half of Landing the aft half of superstructure on boardsuperstructure on board


29



PWBS PWBS -- Operation and Test LevelOperation and Test Level



IRON STURT IRON STURT -- Ship No: 2728, IHI Kure ShipyardShip No: 2728, IHI Kure ShipyardLBP= 163.0m, B=22.9m, D=13.6m, d=10.0m, DWT=22,093, HP=9000LBP= 163.0m, B=22.9m, D=13.6m, d=10.0m, DWT=22,093, HP=9000

StartFabrication

Launching

43workdays in

building dock !!!Keel Laying

Delivery


End of Week End of Week 11

Questions ?Questions ?

ihop

Documents

ship production applications

practice of ship production

welding applications

shipyard production

good knowledge of methods

shipbuilding process

ship structures

course students