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Faculty of Naval Architecture and Ocean Engineering Methods of Ship Production GEM314E
Introduction
Week 1
The main aim of this module is to equip students with methods and tools for production 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
Title
Subjects Introduction to class. Introduction to ship production. A system view of the ship building. Rules of the game Statistical principles, overview, Applications Building methods, ship structures, Product Work Breakdown Structure (PWBS), Group Technology Planning and scheduing Costing and value engineering Welding in Shipbuilding (Theory)
Lecturers
Introduction
AYO
IHH
Week 3 1 March
AYO
Week 4 8 March
Welding Basics
AYO JOTUN Mehmet Ali Kamacolu Jotun Boya Sanayi ve Tic.A.. Tuzla/stanbul Tel. 0216 423 5170 Fax. 0216 423 5174 Sedef Tersanesi Cumhur Kurtel Sedef Gemi naat A.. Tuzla/stanbul Tel.0216 395 4741 Fax. 0216 395 4740 Yldz Tersanesi Baki Gkbayrak Tel. 0216 395 4075 Fax. 0216 395 1290
Week 5 15 March
Course Outline
Week 6 22 March
Shipyard facilities, process lanes Material handling systems Steel cutting and forming, Steel fabrication
Week 7 29 March
Aluminum construction
Handling and storage, forming, welding General outfitting, Subcontractors work, Installation priorities, shafting, propellers, piping, electrical installations Mid-Term examination (Multiple choice / Books open)
AYO
EXAM
D311
EXAM
Week 10 19 April
Welding and cutting methods, structural steels, non-ferrous alloys, non-metallic materials, non-destructive testing,
Oerlikon Hac Doluta Oerlikon Kaynak Elektrotlar ve San.A.. Sefaky/stanbul Tel.0212 411 1400 Fax.0212 579 3053 Trk Loydu Hasan Habibolu Trk Loydu Vakf Tuzla/stanbul Tel.0216 446 22 40 Fax.0216 446 22 46 YONTECH Ekber Onuk Yonca Teknik Tersanesi Tuzla/stanbul Tel.0216 392 9970 Fax. 0216 392 9969
Week 11 26 April
Welding
Week 12 3 May
FRP Construction
Other Conditions
Mid-Term Examination Quiz Assignment Attendance Contribution of term work on achievemet scores Contribution of final exam scores on achievement scores Prerequisites for attending final exam : 1) 2)
: :
70% attendance to class meetings. Submission of reports in full and on given deadlines
SHIP OWNERS SHIP OWNERS (BUYERS) (BUYERS) INTERNATIONAL INTERNATIONAL RULES AND RULES AND CONVENTIONS CONVENTIONS
NEW NEW SHIPYARDS SHIPYARDS (e.g. FAR EAST) (e.g. FAR EAST)
? ?
USA
Direction 1
JAPAN
<%1 ? ? ?
Direction 2
SOUTH KORE
% 40
TURKISH SHIPBUILDING INDUSTRY
FUTURE ?
RUSSIA POLOND UKRAINE NORWAY
Environment
% 20
% 17
CHINA VETNAM
EU
% 21
Direction .
Marketing Techniques
Right product Right market Right price and payment terms Right marketing tools Customer relations
Price and payment conditions Quality Delivery Time Shipyard reliability Customer relations
Ship production is a manufacturing operation whereby procured material, machinery and equipment is converted into a defined functional product (i.e. Ship, offshore platform, etc) through organized use of knowledge purchased material, labor and shipyard facilities. Knowledge manifests itself in design (especially through adopted design standards and productionkindly practices), production methodology, process engineering (methods, jigs & tools), production and procurement planning and programming and quality management. Information flow is a key issue in productivity management and improvement. Shipyard facilities dictate what is not possible. As such in the development of a production methodology available facilities play a significant role. Management of labor is both a technical and management issue. On the technical side topics such as information of construction logic, methods, labor skills and the design and use of appropriate jigs and tools play on important role. The management side involves the operational effectiveness of labor mix and their control. Flows Coordination of information, material and work flow are indispensable contribution in successful ship production.
CONCEPT DESIGN
The objective of the conceptual design stage can be stated to be: To establish overall features of a design to meet owner or mission requirements. The content of the stage can be defined as a series of inputs and outputs. Inputs may be presented in the form of an outline specification, or one may be developed as a basis for the conceptual design. Inputs and outputs are listed below: Inputs Service requirements Routes Market forecasts Technical change in ship components and equipment Outputs Preliminary general arrangement, midship section Preliminary specification Preliminary calculations (dimensions, capacities, etc) Preliminary body plan If at this stage a shipbuilder has been identified, the following production inputs and outputs are essential: Production Inputs Shipbuilding policy Type plan Facility dimensions Interim product types Production Outputs Preliminary block breakdown Zone identification
Production Inputs Shipbuilding policy Company standards and industry standards including: Material sizes Modules Service runs Block sizes Spatial analysis
Production Outputs
FUNCTIONAL DESIGN
Functional design follows contract signing and is intended to establish features of a design for the purposes of classification and other approval and material specification, The various inputs and outputs are listed below: Inputs Contract design Functional requirements Production Inputs Preliminary build strategy Standards Production Processes Facilities Outputs Ship design: hull form, capacities, etc Structural design: approval drawings, scantling plans Machinery installation: arrangements, piping diagrams electrical fittings, etc. Accommodation design Ship systems design Hull outfit Production Outputs - Contract build strategy - Schedules:erection/installation, assembly, manufacture - Production information - Purchasing information
TRANSITION DESIGN
Transition design is considered here as a distinct stage, although in some aspects it runs parallel to the functional design process through all the stages. The objective of transition design is to translate the features of the design from the system orientation, necessary to establish functional performance, to a planning unit orientation, necessary to establish production requirements. Transition design develops elements of systems into steel and outfit zone composites. It should be based on the spatial analysis of earlier design stages. However, for effective design for production to take place, production needs and capacities should be highlighted from the earliest stage: Inputs Conceptual design Contract design Functional design Outputs Process analysis Interim products Work package information Work station drawing information
DETAIL DESIGN
The objective of detail design is to establish the features of the design necessary to allow local purchasing, part manufacturing and subsequent assembly to be carried out. Detail design is carried out by planning unit, on those elements of the ship which have been developed to the stage where all functional and approval requirements have been satisfied. It can be defined in terms of inputs and outputs: Inputs Functional design Transition design Build strategy Standards Work station capacities Process analysis Outputs Work instructions Work station drawings Material lists Dimensional requirements
Preparing design with full cognition of production facilities and difficulties in fabrication and erection is known as design for production. The main issues of design for production are: o Reduction of variety and use of standard details o Use of standard components o Employment of modularity and cellularity concepts for distributed systems o Full knowledge of shipyard production facilities and capabilities
The main elements of design for production are establishment of shipyard standards and continuing dialogue between designers, planners, procurement and production personnel. .
Use of standard for plates & stiffeners Use of standard 2-D element Straight line brackets Reduction of lugs Asymmetric face flats Thin panel deflection avoidance Tolerance selection Co-ordination with HM & E design groups
A) Gross weight higher More difficult scrap arrangement Subject to buckling failure, failure often seen at early stage of hydrostatic test before ship leaves yard More difficult erection butt and face plate welding - use of alternative erection joints, e.g. laps B) Net weight higher
Lower production hours due to straight lines and machine application Subject to fatigue failure, failure seen after a number of years in service Good for fast erection, although accurate alignment should be maintained Lends itself to future more fundamental approach, e.g. plastic design or bracketless
Use of modular component Clash avoidance by design Design features to encourage pre-fabrication (e.g. use of common supports for pipe & cable highways)
Space allocation for cable support structures (Clash avoidance & Modularisation)
Contract Design Detail Design & Planning Component Production Product Integration
Progression
Correction
DEFINITION
STANDARD A standard is that which has been selected as a model to which objects or actions may be compared. In every case, a standard provides a criterion for Judgement and its form thus depends on what is to be Judged and how it is to be Judged. (From Encyclopedia Britanica)
STANDARDIZATION The process of developing and bringing about the utilization of standards. While standardization of some kind or degree is part of almost every human activity planned and systematic industrial standardization is meant in normal usage of the term. (From Encyclopedia Britanica) .
TYPE OF STANDARDS
INTERNATIONAL STANDARDS ISO (International Organization for Standardization) IEC (International Electrotechnical Committee) REGIONAL STANDARDS ASAC (Asian Standards Advisory Committee) CEN (European Committee for Standardization) NATIONAL STANDARDS JIS (Japanese Industrial Standards) BS (British Standards) DIN (Deutche Normen) ANSI (American National Standards) NF (Norm Franaise) Others INDUSTRIAL ORGANIZATION STANDARDS ASTM (American Society of Testing and Materials) ASME (American Society of Mechanical Engineers) SAE (Society of Automotive Engineers) Others COMPANY INTERNAL STANDARDS
1 2 3 4 5
Part and Product Standards Design Engineering Standards Production Process Standards Testing and Inspection Standards Accuracy and Tolerance Standards
THEME
FACTORS INFLUENCING ITS DEVELOPMENT Industrial labs and R&D organisations regarded as an aid to practical problem solving; dependent on the training and experience of supervisors and middle managers. Long and Short Term needs determine the research agenda; orientation of R&D personnel to practical affairs. Origins in chemical and electrical industries; existing equipment and methods considered always improvable. Complexity of products; systematic and integrative nature of innovation.
Technological development is evolutionary; progress occurs in steady and successive steps. A close and intimate interaction between technology development work and potential problems (in plant or market) is essential. Product and process innovation are intimately related. Progress occurs through organised effort; team-work and collaboration across functional boundaries and critical.
TECHNICAL SUCCESS :
Technical success refers to the successful implementation of a new operating technology which provides reductions in errors and effort requirements due to the elimination of paper driven steps, growth in enabling capability and functionality and improved change management.
ECONOMIC SUCCESS :
Economic success refers to the realisation of productivity increase, non-productivity benefits (e.g. reduced lead time, quality improvements, increased flexibility etc.) and translation of these benefits into cost reduction and competitive gain.
DESIGN AND DATA INTEGRATION CONTRIBUTE MAINLY TO TECHNICAL SUCCESS WITH TANGIBLE ECONOMIC GAINS REAL ECONOMIC SUCCESS IS ACHIEVED THROUGH DECISION AND ORGANISATION INTEGRATION
Engineering design Engineering drawing Process planning Methods, time and motion study Routing
Inventory control
Auxiliary services
Task :
to search, find and present the definitions of the following words in the context of GEM314E course
End of Week 1
Questions ?