l1_1 - shipbuilding process

8/18/2019 L1_1 - Shipbuilding Process

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Kul-24.4130

Shipyard engineering

Lecture 1-1:

Shipbuilding process

Marine Technology

Appl ied Mechanics


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Lecture in course contentsIntroduction

Outfitting

Production

planning

Shipbuilding process and

ship yard productivity

Design process

and materials

managements

Hull production


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Objectives, contents and literature

• Learning objective: – Understand shipbuilding process – Recognise shipbuilding process stages – Know the basic terms of shipbuilding process

• Contents:

– Production strategy – Theoretical shipbuilding model – Shipbuilding process stages – Basic terminology

• Literature – Laivatekniikka. Räisänen toim., 2000, Kappale 30 – Ship production, Storch et al., SNAME, 1995, Chapter I-II


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Production strategy

• Main challenge of production strategy: – The aim of the production investment is to create a

competitive advantage for the company, not just the

best factory in the world

• If own factory does not create a competitive

advantage, it is better to buy a product than to

make yourself


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Product?

• Material versus immaterial (car vs. experience)• Product vs. Services (ship vs. repair service)

• Consumption vs. investment

• Part vs. product package

• One-off vs. standard part

• Standard, customized, personalized ...

• Product family, variation, extension

• Combination vs. selection


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Production objective

• The aim is to achieve at the same time a good – productivity (added value / cost,…)

– controllability (lead-time)

– flexibility (to manage overproduction)

– sensitivity

– capital efficiency (efficient use of capital)

– loaned capital / productivity -ratio (profit, cost)

– quality


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Production customisations level

Design intensity

and customisation

One-off-a kind

products or systems

Standard, volume products

Production efficiency/Repetition

Warehouse vs. design-to-order


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Customisations level

Customisation level

Volume vs. one-off production

Design

Fabrication

Assembly

Distribution

WAREHOUSE

Design

Fabrication

Assembly

Distribution

PACK-TO-ORDER

Design

Fabrication

Assembly

Distribution

ASSEMBLY-TO

Design

Fabrication

Assembly

Distribution

FABRICATE-TO

Design

Fabrication

Assembly

Distribution

DESIGN-TO-ORDER

Before order – After order


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Product and type of market

Characterics Demand stable Demand dynamic

Product life cycle Long (2+ Y) Short (


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Development trends of Finnish and European

marit ime industry

• Strong networking of the shipbuilding – Shipyards focuses on their core

business and utilize sub-contractors,

modular solutions and integrated

suppliers

– Extreme example is an assemble yardconcept

• Suppliers focus on developing their

own product and supportive activities

• The ship's owners look for new

solutions to reduce life cycle costs

and improve competitiveness


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Theoretical shipbuilding model

The production function

qt = q (Kt, Lt, Et)

qt = production rate at time tKt= capital utilization rate at time t

Lt= labour utilization rate at time t

Et= efficiency effects due to

production rate change at time t

C u

m u l a t i v e

p r o d u c t i o n

P r o d u c t i o n r a t e

m a n n i n g

Time

Time


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Labour util isation rate

• Labour utilization rate Lt is defined asquality-adjusted labour

– Ship sequence number (experience effect*)

– Number of workers (manning level)

– Change rate of the workers number

– Length of the work day (overtime)

– Workers' skill level

*) Experience curve effect (Experience Curve)

• Costs is reduced by a constant amount each time theaccumulated production is doubled

• In shipbuilding industry, this constant is normally 5-10%


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Efficiency effects

• Distractions affect the efficiency effects Et – Incomplete or missing plans

– Interruptions in the use of labour

– Interruptions in support functions – Worker morality


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Stages of Shipbuilding process

1. Concepts design

2. Initial design3. Basic design

4. Component definition andacquisition

5. Coordination design

6. Product hierarchy and work breakdown structure

7. Detail design

8. Material requisition9. Part fabrication (hull and outfitting)

10. Unit production (module, element, etc.)

11. Block outfitting (sis. Steel outfitting)

12. Painting of blocks

13. Block outfitting

14. Hull assembly15. Area outfitting

16. Commissioning, delivery


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Ship production terminology

• Block, sub-block, part assembly, and part

• Space and Area

• System, sub-system, and

equipment/part/component

• Product and pre-fabrication

• EMO, EM, and JM –outfitting

• Turn-Key -delivery


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Block, sub-block, part assembly, and part

• Block: the largest construction unit, a part of part of

the ship's hull or superstructure, applied in

production. For example, at the Turku shipyard

block can have dimensions of about 40x30x15 m

and weigh 600 t.

• Sub-block: The blocks are assembled from sub-

blocks. Sub-block typically includes some welded

equipment (bushings, pipes and cables),implemented before painting

• Part assembly: sub-blocks are assembled from

different part assemblies, such as bulkheads,

welded sections, floors, etc..

• Part: blocks and part assemblies are done from

components, such as plates, stiffeners, brackets,collars, collars. It is typical that the parts are made

by cutting a raw plate and profiles


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Space and Area

• Area: the combined space such as a cabin area or a nightclub. Thearea can also be a vertical entity such as a staircase or enginecasing. The area consists of one or more spaces. The essential thingis that the area is uniform and it is not composed of unconnectedspaces. The area definition is a yard-specific and it is affected severalfactors such as the location, shape, size, consistency, content and theamount of work.

• Space: a unique space of ship such as the cabin, bridge, engineroom, air conditioning room, etc.. Space alone or together with otherspaces compose the area.


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System, sub-system, and equipment/part/component

• System: a functional subsystem of the ship such as air

conditioning, power generation, propulsion system. Typically, thesystem extends more than one area, either by serving them, or just

passing through.

• Subsystem: The system consists of sub-systems (components of

the system). Subsystems such as air conditioning canal, cable

trays, a main generator, shaft.

• Equipment / part / component: Equipment are functional parts of

subsystems such as canal damper, main generator, support

bearing. Parts and components are smaller installation units such

as screws, nuts, fuses, etc. The definition of part and component is

not unambiguous.


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Product

• Product is the results of the productication i.e. the part of the ship or the

work task.• The product has always

– Content, definition

– Work unity

• The product is always associated with

– input and output:

– electrical, plumbing and heating, alarm, etc.

• The product has an interface or interfaces with other products.

– Interfaces are more and less physical. The product may be a part of

hull, space, area, system, or any combination of the above. – The product must be clearly understood, thus it can not be

indefinable or abstract thing.


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Pre-fabrication

• Pre-fabrication is a part or a set of parts which are

manufactured in the workshop, not onboard. Modules areprefabricated functional entities. The division is based on

the applied production technology:

– In machinery outfitting, the examples of the pre-fabrication are

separator unit, fuel pump unit, cooling equipment unit, piping set,

sewage treatment plant, control panels.

– In the interior outfitting, the prefabrication is call as a module. WC

and cabin units are sophisticated examples, where the installation

is completed at a workshop. The module is only connected to the

ship's systems in block or area outfitting stage.

– Other examples for interior outfitting are wall and roof modules,

large furniture for restaurants such as bar.


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EMO, EM, and JM –outf itting(Abbreviation applied in Finnish shipyards)

• EMO -outfitting – Sub-block outfitting done before the painting

• EM - outfitting

– Block outfitting done before the painting. Contains workphases, which might ruin the painting such as welding and

flame cutting. The installed outfitting equipment are selected

so that they will not damaged due to blasting and painting.

• JM - outfitting: – Block outfitting done after the painting


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Turn-Key -delivery

• Turn-key- delivery includes

– Design

– Material requisition

– Fabrication

– Implementation to the ship

– Testing and commissioning

• Sometimes, the term is applied broadly considering the

fabrication and installation as Turn-key delivery. The

trend of activity is towards the exact definition.

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