ship construction- high school teacher’s manualaverma/nsf/marine kits... · ·...

Ship Construction- High School

Teacher’s ManualContents

• Teacher’s Instructions

• Assessment Sheet

• Bill of Materials & Cost Estimation Sheets

• Construction Activity

• Answer Key

Marine Kit – 2

This activity was developed under a grant from National Shipbuilding Research Program (NSRP)

Ship Construction Activity High School

Teacher’s Instructions This activity deals with construction of a Clipper Ship. Kit Contents

• Activity kit consists of Knex Parts, 2-Rulers, Student Handout and Teacher’s manual.

• Students need to bring calculator.

Set Up: • The activity requires two days. (Day-1 and Day-2) • Each session can be completed in a 55min class period. • Please use first 10-15 min to explain the activity using power point presentation

provided on the website. • The kit contains only one copy of the student handout. Please make copies for

additional groups.

Day 1: • Students should be divided into groups of four. • After the presentation the students are given the bill of materials form and the

student handout to count the number of parts required and to estimate the total cost of the ship.

• Teacher serves as the supplier of parts and collects money from each group for parts.

Day 2:

• Please give each group bills worth $290,000 provided in the kit. Students buy the estimated parts from the teacher using this money.

• Parts and student handout are provided to construct the Clipper Ship. Supplier (teacher) should only provide the number of parts as stated by each group in their bill of materials form.

• In case the students require additional parts while constructing the Clipper Ship, the same can be given to them but at double the original price, which will in turn increase their construction cost.

MarineTech Project Construction Activity Lean Institute, ODU AUG 2008

• In case a group has ordered extra parts they can return the parts for 20% restocking fee which means that the group will get 80% of the actual cost of the parts back (Group will only receive 80% of actual cost of parts instead of full refund)

• At the end of the activity, please ask students to count and place all the parts in their respective zip lock bags and arrange them back in the box.

• Please use the assessment sheet to evaluate work of each group. The group with maximum number of point wins.

MarineTech Project Construction Activity Lean Institute, ODU AUG 2008

Group No:

Names

1)

2)

3)

4)

Poor Fair Good Very Good Excellent

Quality Characteristics 1 2 3 4 5

Least construction cost

No missing parts

Least time for construction

Correct part counts

No restocking fee

Date(mm/dd/yy):

Construction Activity Assessment Sheet

This Assessment sheet is to be used by Teacher to evaluate the accuracy of Construction activity

MarineTech Project Construction Activity Lean Institute,ODU AUG 2008

Total Points

MarineTechAlok K. Verma 8/08 1

Bill of Material / Cost EstimationDay 1


Bill of Materials / Cost Estimation

The teacher is the supplier & the students are the employees of ABC Yards.

• A bill of materials form is provided and the students identify the number and type of parts needed to build the ship

• Photographs of the ship and sub assemblies are provided to identify and count the number of parts

• Students calculate the cost of building the ship• The students buy the material from the teacher (Supplier)• Students will be initially given $290,000 to buy the parts.• If the parts are not purchased with Bill of Materials, they can be

purchased later at double the price.• If parts are left over after final assembly, parts can be returned with a

20% restocking fee. (The team receives only 80% of cost of the part)

3

Material View Material Name

Quantity

Material Unit Price

Estimated Material

Cost=

Total Quantity * Material

Unit Price

Left Over Parts

Extra Parts Needed

Restocking Fee

=Left Over

Parts * 80% of

Material Unit Price

Extended Material Cost

=Restocking

Fee+( Extra Parts Needed * 2 * Material Unit

Price)

Bow

MidShipSection

STERN

TOTAL

75 Degrees Support –

Light Gray Granite

$1,000

90 Degrees Support –Dark Gray

Granite

$ 2,000

135 Degrees Support -

Green$2,000

Bill of Material & Cost Estimation - WorksheetGroup No. _____

4

180 Degrees Joint -Silver

$2,000

180 Degrees Support -Yellow

$2,000

360 Degrees Joint -Blue

$ 3,000

Hanging Clip -Black $500

Flat Joint -Brown $1,000

16mm Bar - Black $1,000

32mm Bar - White $2,000

52 mm Bar - Blue $3,000

5

85 mm Bar – Dark Gray $ 38000

187 mm Bar –Light Gray $10,000

Material Costs Estimated Material

CostReimbursed Amount

Cost of Extra Parts

Total Material Cost (Estimated material Cost – Reimbursed Amount = Cost of extra parts)

Total Labor Hrs/year/person

Total labor Cost (Labor hrs/ person × 3yrs × 4 persons × Labor rate)

Equipment Cost (Use 250% of the material cost)

Total Cost (Labor, Material , Equipment)

Assumptions: Number of people in a company-4. One Clipper Ship is completed in 3 years. ! Year has 52 weeks and workers work 5 days a week and 8hrs per shift. Hourly labor rate is $15/hr


SBRCD ProjectConstruction Activity

High SchoolPresentation


Activity Description

• The activity includes two modules• Students work in groups of 4• Each module can be completed within one class

period (55 min.)• Students build a clipper ship


Clipper ShipBOW MID SHIP SECTION STERN


Clipper Ship Cargo Ship

Clipper ship is a very fast multiple-masted sailing ship. Generally narrow for its length, limited in its bulk freight carrying capacities, the clipper ships have a large relative sail area.

A Cargo ship or freighter is any sort of ship or vessel that carries cargo, goods, and materials from one port to another. Cargo ships are usually specially designed for the task, often being equipped with cranes and other mechanisms to load and unload, and come in all sizes.


Stern:

The stern is the rear or aft part of a ship or boat.

The stern area has always been the location near the steering apparatus, and by extension became the domain of the ship's captain and other officers

Bow:

The bow is the forward part of the hull of a ship or boat, the point that is most forward when the vessel is underway.

The bow is designed to reduce the resistance of the hull cutting through water and should be tall enough to prevent water from easily washing over the top of it.

Definitions:


Construction of Ship

Day 2


Construction of Ship

• After buying the material each team starts constructing the ship.

• Handouts are provided to each team to construct the ship.• If the parts are not purchased with Bill of Materials, they can

be purchased later at double the price.• If parts are left over after final assembly, parts can be

returned with a 20% restocking fee. (The team receives only 80% of cost of the part)


Bow Stern

Ship Mid Section - LeftBow Sub Assembly 1 Bow Sub Assembly 2

Ship Mid Section - Right

Assembly Steps

2

39

51

10

4

6

7 8Clipper Ship


Stern Sub AssemblyTWO PARTSExploded View

Assembled Part

1

135 Degrees Support-Green16mm Bar-

Black32mm Bar- White


Bow Sub Assembly Section 1Exploded View

Assembled Part

2

180 Degrees Support-Yellow

90 Degrees Support –dark Gray Granite

Hanging Clip - Black

16 mm Bar- Black

32mm Bar- White


Bow Sub Assembly Section 2

Exploded View

Assembled Part

3 90 degrees Support-Dark Gray Granite

52mm Bar - Blue

Hanging Clip- Black

32mm Bar -White

180 Degrees Support- Yellow


Ship Mid Section-LeftExploded View

Assembled Part

4

180 Degrees joint- Silver

187mm Bar –Light Gray

360 Degrees Joint- Blue

Flat Joint- Brown


Ship Mid Section-RightExploded View

Assembled Part

5180 Degrees Joint- Silver

Flat Joint- Brown

135 Degrees Support- Green


Assembly of Bow

Front section of BowBow with Sub Assembly Section 1

6

Flat Joint - Black


Assembly of Bow Bow with Sub Assembly Section 27

16mm Bar- Black

Flat Joint - Brown85mm Bar-Dark Gray

75 Degrees Light Gray Granite

187mm Bar- Light Gray


Final Assembly of

Ship Mid Section

Left & Right

8


Final Assembly of Ship Mid Section & Bow9


Final Assembly of Ship Mid Section, Bow & Stern10


Bow

Ship Mid Section - RightBow with Sub Assembly 1

Bow with Sub Assembly Section 2

Ship Mid Section

Assembly Steps

Assembly of Ship Mid Section, Bow & Stern

23

9

51

10

4

6

7

8

Bow Sub Assembly 1 Bow Sub Assembly 2

Assembly of

Ship Mid Section with Bow

Ship Mid Section -Left

Stern Sub Assembly


Side View

Top View

75 Degrees Support – Light Gray Granite

85 mm bar-Dark Gray

Hanging Clip- Black

90 Degrees Support – Dark Gray Granite

16 mm Bar- Black Flat Joint

- Brown

360 Degrees joint- Blue

187mm Bar– Light Gray 52 mm Bar

- Blue

180 Degrees Support- Yellow

32 mm Bar- White

135 Degrees Support- Green

180 Degrees Joint - Silver

Part Names & Color List

26

Material View Material Name

Quantity

Material Unit Price

Estimated Material

Cost=

Total Quantity * Material

Unit Price

Left Over Parts

Extra Parts Needed

Restocking Fee

=Left Over

Parts * 80% of

Material Unit Price

Extended Material Cost

=Restocking

Fee+( Extra Parts Needed * 2 * Material Unit

Price)

Bow

MidShipSection

STERN

TOTAL

75 Degrees Support –

Light Gray Granite

1 1 $1,000 $1,000

90 Degrees Support –Dark Gray

Granite

2 3 5 $2,000 $10,000

135 Degrees Support -

Green4 4 $2,000 $8,000

Bill of Material & Cost EstimationGroup No. _____

27

180 Degrees Joint -Silver

4 4 $2,000 $8,000

180 Degrees Support -Yellow

4 8 12 $2,000 24,000

360 Degrees Joint -Blue

4 4 $ 3,000 $12,000

Hanging Clip -Black 4 4 $500 $2,000

Flat Joint -Brown 5 2 7 $1,000 $7,000

16mm Bar - Black 6 2 4 12 $1,000 $12,000

32mm Bar - White 8 20 2 30 $2,000 $60,000

52 mm Bar - Blue 1 14 15 $3,000 $45,000

28

85 mm Bar – Dark Gray 2 1 3 $ 38000 $12,000

187 mm Bar –Light Gray 2 3 5 $10,000 $50,000

Material Costs $281,000Estimated Material

Cost

Reimbursed Amount

Cost of Extra Parts

Total Material Cost (Estimated material Cost – Reimbursed Amount = Cost of extra parts) $281,000

Total Labor Hrs/year/person2080 hrs

Total labor Cost (Labor hrs/ person × 3yrs × 4 persons × Labor rate)$374,400

Equipment Cost (Use 250% of the material cost)$702,500

Total Cost (Labor, Material , Equipment)$1,357,900

Assumptions: Number of people in a company-4. One Clipper Ship is completed in 3 years. ! Year has 52 weeks and workers work 5 days a week and 8hrs per shift. Hourly labor rate is $15/hr


Assessment

Ship construction will be assessed for following five quality characteristics.

1. Least construction cost2. No missing parts3. Least time for construction4. Correct part counts5. No restocking fee


Wrap up

• After completing the construction activity, place the components back into their respective zip lock bags.

• Each zip lock bag is marked with a label.• Count all the parts and match with the number

on the label.• Place all zip lock bags in the box.

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