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SOUTHAMPTON SOLENT UNIVERSITY

BEng (Hons) YACHT PRODUCTION & SURVEYING LEVEL 6 YACHT MANUFACTURING MANAGEMENT

Date: May / June 2012

Time: 00.00-00.00

INSTRUCTIONS TO CANDIDATES Time allowed for this examination is TWO hours. This paper contains FIVE questions. Candidates are required to answer ALL QUESTIONS in SECTION A and TWO QUESTIONS from SECTION B The allocation of marks is indicated on the paper.

SPECIAL STATIONERY PROVIDED Graph Paper.

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Exam Ref Number: YEP121/P2/2011-12/E1

SECTION A Candidates are required to answer ALL questions in this section. QUESTION ONE A Workboat manufacturer building in Aluminium Alloy that has been established for 15 years inland on the South Coast is committed to an expansion into a newly converted split dry-dock, which can be made operational in the next 6 months. To date the company has built 12 vessels of 18 25m for single or twin vessel orders, for which they have excellent production records. The last two vessels were 25m sister ships, both built in 2 years and involved approximately 40,000 man hours each. The Yard has secured an order for a limited-series production run of 4 vessels of 35m LOA, which are all to be built inside a 4 year period, effective immediately. The new facility has a split-dock build berth, so once fabricated in the Build Berth area the vessel build can be moved along on rails, past the Caisson (Inner dock gate) and into the Wet Dock area, then can be independently launched via flooding the Outfit Berth. An example Yard Plan view if shown in FIGURE ONE below.

WORKSHOPS

BUILD BERTH

OUTFIT BERTH

CAISSON
WORKSHOPS

CAISSON

FIGURE ONE Plan View of Yard showing Build Berth and Outfit Berth The following facts should be noted: 1. 2. 3. 4. a) Management have proposed that a Production Prototype philosophy be used Current Staff is 2 in Admin, 16 Metal Production & Engineering and 8 Outfitting Each vessel build-time has been set at 18 months after the Prototype The Four Vessel order is to be largely constructed in the New Facility

Propose how the Management Team might approach a Work & Method Study project, to assist the move to a new facility and achieve the increase in productivity required.

QUESTION ONE continued

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Exam Ref Number: YEP121/P2/2011-12/E1

QUESTION ONE continued Consider in your answer the following aspects: i. ii. iii. iv. v. b) Build History Current Productivity vs Required Transition to new Facility Training Prototype application (20 Marks) Draw out on Graph Paper a High Level Gantt Chart Production Programme for the next four years production to illustrate the Build Programme. Annotate the Gantt chart with relevant comments on: i. ii. iii. iv. Build Duration with concurrency and overlaps Milestones for Moving and Launching Periods of maximum resource requirement. Show how a single Generic Vessel Project Model looks

The Vessel 18 month individual Production Programme is as follows: 9 months at the single Build Berth Move into Outfit Bay for 6 months (+3 months pre-outfit work at Build Berth) Launch for Finishing, Trials and Commissioning in last 3 months (20 Marks)

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Exam Ref Number: YEP121/P2/2011-12/E1

SECTION B Candidates are required to answer no more than TWO questions from this section. QUESTION TWO Material Requirements Planning (MRP) systems have become popular as the Yacht Manufacturing industry moves towards higher volume production. a) Describe the fundamental concept of a generic MRP system using a Flow Chart diagram of the principle of operation clearly labelling the various aspects and the inputs involved with a particular emphasis on the flow of procedures through the system. (10 Marks) Explain the function and role of the following aspects: Master Schedule Bills of Materials Purchasing / Purchase Orders Works Orders (10 Marks) c) MRP Systems have moved forward in recent years to MRP2 and a more widespread system embracing the requirements for the company as a whole. Name the system that had been developed to take over from classic MRP based systems and explain the following features: The Underlying philosophy The Database concept The Modular design concept of the system (10 Marks)

b)

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Exam Ref Number: YEP121/P2/2011-12/E1

QUESTION THREE The process of Plant Location & Factory Planning and Layout Design falls into different levels. If a new Production & Repair Facility for a composite Superyacht Manufacturer is being planned for a Coastal location, discuss the main design points you as a Production Manager for the new facility would be likely to consider. Consider the options of a Green-Field site Under each of the following headings, discuss the issues and what information is needed to support decisions that will need to be addressed in considering establishing the new marine business venture, before moving planning on to the next level: a) b) c) d) e) General considerations for locating a new business in on the Coast and how a Business Mix may be achieved to maximise the opportunity. (10 Marks) Proximity to market (5 Marks) IT / Communications changes (5 Marks) Availability of Labour (5 Marks) Other considerations (5 Marks)

QUESTION FOUR Assessing the utilisation of labour and completeness of work in the various stages throughout a project is assisted by the process of Earned Value Analysis (EVA) a) b) Explain and illustrate the term Budget Cost of Work Performed (5 Marks) Produce an EVA sketch diagram if the project is running behind in terms of progress and at a higher then planned cost. (10 Marks) Detail the three basic questions which EVA poses and how data in answer to these questions is gathered in a production project (9 Marks) Consider an approach to bring a project back on target that has an EVA sitting below the BCWP line at the 60% point in the project by 15%. (6 Marks)

c)

d)

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Exam Ref Number: YEP121/P2/2011-12/E1

QUESTION FIVE Quality Systems in the Marine Industry are commonplace and often used as an indication to the potential client that the manufacturer is committed to excellence and the long term supply of good and services. Describe various aspects of a Quality System under the headings given below: a) Outline the two key principles that characterise a QA system and list what aspects within a typical Production system it attempts to address (5 Marks) Describe underlying concept on which a modern QA system if founded and describe the four Key Areas of activity in any QA system (5 Marks) Describe the QA Certification process a company has to go through in order to gain QA accreditation, include the type of documentation required and definition or processes. Use the following Main Headings: 1. 2. 3. 4. 5. 6. 7. The Standards Certification Agent Training Manual Other Documentation Implementation Pre-Assessment (20 Marks)

b)

c)

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Exam Ref Number: YEP121/P2/2011-12/E1