SHIP PRODUCTION COMMITTEE

FACILITIES AND ENVIRONMENTAL EFFECTS

SURFACE PREPARATION AND COATINGS
DESIGN/PRODUCTION INTEGRATION
HUMAN RESOURCE INNOVATION
MARINE INDUSTRY STANDARDS
WELDING
INDUSTRIAL ENGINEERING
EDUCATION AND TRAINING
THE NATIONAL
SHIPBUILDING
RESEARCH
PROGRAM
September 1981
NSRP 0008
Proceedings of the REAPS
Technical Symposium
Paper No. 20: An Approach
to Successful Shipyard
Planning and Scheduling
U.S. DEPARTMENT OF THE NAVY
CARDEROCK DIVISION,
NAVAL SURFACE WARFARE CENTER
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Pr oceedi ngs
I REAPS Techni cal Symposi um
Sept ember 15- 17, 198l
Bal t i mor e, Mar yl and
I NSTI TUTE FOR RESEARCH AND ENGI NEERI NG FOR AUTOMATI ON AND PRODUCTI VI TY I N SHI PBUI LDI NG
I REAPS
AN APPROACH TO SUCCESSFUL SHI PYARD PLANNI NG AND SCHEDULI NG
St ephen M. Knapp
Spar Associ at es I nc
Annapol i s, Mar yl and
ABSTRACT
Cr i t i cal pat hs, "I - J " nodes, and act i vi t y dur at i on ar e al l wor ds of t he
net wor k desi gner . Al l ar e usual l y f or ei gn t o t he shi pyar d pl anner , and i n
gener al , shi pyar d pl anni ng per sonnel t end t o shy away f r om t he net wor ki ng
appr oach t o shi p const r uct i on pl anni ng. Net wor ki ng, however , can be used t o
pl an, and subsequent l y schedul e, t he pr oduct i on wor k or der s r equi r ed t o
compl et e t he const r uct i on of any vessel , r egar dl ess of i t s compl exi t y.
The f undament al appr oach t o successf ul shop pr oduct i on pl anni ng and
schedul i ng usi ng net wor ki ng t echni ques t hat have r educed pl anni ng t i me
dr amat i cal l y ar e descr i bed.
Two basi c cr i t er i a f or t he pl anni ng and schedul i ng net wor k ar e "si mpl i ci t y"
and "accur acy". Si mpl i ci t y i s concer ned wi t h t he cr eat i on, devel opment , and
mai nt enance of a pr oduct i on pl an. Accur acy def i nes t he manner i n whi ch t he
pl an r ef l ect s t he act ual const r uct i on of t he vessel i n quest i on.
443
Thi s i s not i nt ended t o be anot her di scussi on of some new and f ab-
ul ous pl anni ng t ool , or an i ndept h pr esent at i on of S A M E t h e o r e t . -
i cal concept t o i mpr ove your pl anni ng depar t ment , I t i s
t o demon-
st r at e an act ual , pr oven appr oach t o pl anni ng whi ch has been
us ed
successf ul l y on a number of vessel s, and t o br i ef l y descr i be t he
t echni ques and sof t war e t ool s used i n t hat appr oach.
The pl anni ng appr oach pr esent ed i s t he r esul t of a ser i ous, con-
cent r at ed ef f or t on t he par t of t he pl anni ng st af f of SPAR Assoc-
i at es, t o i mpr ove t he pl ans and schedul es of SPAR s c1i ent shi p-
yar ds. The appr oach cent er s ar ound a no- nonsense, pr agmat i c di s-
ci pl i ne whose pr i mar y obj ect i ve i s t o pr oduce r el i abl e and accur -
at e pr oduct i on wor kor der s, schedul ed i n such a manner as t o r epr e-
sent t he act ual bui l di ng phi l osophi es of t he shi pbui l di ng i nd-
ust r y.
SPAR' s pl anni ng appr oach cont i nues t o mat ur e, f ed by exper i ence
der i ved f r om pl anni ng al l or par t of si x i ndi vi dual vessel s over
t he past 12 mont hs, I n addi t i on, yar d gener at ed pl ans f or f our
ot her shi ps wer e r evi ewed, usi ng SPAR' s "St andar d Pl anni ng Gui de"
as cr i t er i a f or t he anal yses.
Most shi pyar ds deal wi t h a f i ni t e number and speci f i c t ype of ves-
sel t hat t hey nor mal l y bi d on. Pl anni ng becomes somewhat . mor e
di r ect , i n t hat pl anni ng per sonnel t end t o become accust omed t o
t he exact nat ur e of t he shi p, and event ual l y devel op an i nf or mal
st andar d f or pl ans and schedul es wi t hi n t hat yar d,
SPAR, however ,
444
must deal wi t h a l ar ger number of shi p t ypes, and sel domget s t he
l uxur y of l ear ni ng t he i nt er nal wor ki ngs of t he cl i ent . yar ds. As
a r esul t , SPAR s pl anner s bad t o r ep1ace t he yar d' s
pl anni ng
st andar ds wi t h a cl ear l y def i ned pl anni ng di sci pl i ne t o i nsur e t he
i nt egr i t y of t hei r pr oduct . Thi s di sci pl i ne has become so accur -
at e t hat cer t ai n cl i ent . yar ds have act ual l y begun t o i mpl ement . t he
di sci pl i ned appr oach i n l i eu of t hei r t r adi t i onal pl anni ng met hod-
ol ogi es.
To est abl i sh a basi s f or successf ul pl anni ng, cer t ai n pr el i mi nar y
r equi r ement s have t o be def i ned. I n shor t , a "pl anni ng- pl an" must
exi st t o gui de t he pl anner s t hr ough t he many pat hs necessar y t o
r eal i ze t he f ul l pot ent i al of t hei r exper i ence, use of comput er
t ool s, and t he cont i nual eval uat i on of t he vessel . Ther ef or e, t he
pl anni ng pr ocedur es must spel l out such i t ems as ki ck- of f meet -
i ngs, pl anni ng mi l est ones, and st andar d document s t o be pr epar ed,
The i ni t i al devel opment of t he pl an shoul d begi n as ear l y as pos-
si bl e wi t hi n t he const r uct i on cycl e of t he shi p. Pr ef er abl y, t he
pl anni ng ef f or t shoul d begi n when t he i ni t i al r equest . f or quot e
was pr esent ed t o t he yar d, r esul t i ng i n a schedul e of t he maj or
devel opment and const r uct i on mi l est ones, A good pr el i mi nar y pl an
at t hi s st age shoul d cont ai n r oughl y 10% of t he t ot al est i mat ed
number of wor kpackages t hat wi l l compr i se t he f i nal pl an, Thi s
f i r st publ i shed schedul e t hus f or ms t he backbone of t he over al l
Vessel s di r ect i on, i n t hat al l of t he yar d s r esour ces can be
f ocused on t he shi p. By compl et i ng t hi s hi gh- l evel schedul e wi t h-
i n weeks of t he RFQ, al l depar t ment s can r evi ew t hei r own abi 1i t y
445
t o per f or m. Engi neer i ng can vi ew t he t i mi ng of t he dr awi ng r e-
l ease sequence, Mat er i al can eval uat e any pot ent i al del i ver y pr ob-
l ems f or speci f i cat i on i t ems, and Management wi l l be af f or ded an
up- f r ont assessment of t he i mpact on t he yar d. Thi s schedul e may
al so cont ai n canned act i vi t i es t o di r ect t he devel opment of t he
quot e by i ndi cat i ng t he r equi r ed i nvol vement of Pr oduct i on, Engi n-
eer i ng, Mat er i al , and ot her depar t ment s,
Once Management deci des t o bi d on t he cont r act , Pl anni ng mus t
swi ng i nt o hi gh gear t o compl et e t he det ai l ed pr oduct i on schedul es
i n t i me t o suppor t t he const r uct i on, Her e i s wher e t he di sci pl i ne
of pl anni ng t akes i t s f ul l f or m. Pr i or t o st ar t of wor k, Pl anni ng
must pr epar e schedul es t o suppor t dr awi ng r el ease, mat er i al pr o-
cur ement , shop l oadi ng, st eel er ect i on, and t he f ul l compl ement of
wor kpackages r equi r ed by Pr oduct i on. Ever yt hi ng must be cover ed,
Shop f abr i cat i on and as s embl y of st eel and syst ems must be de-
f i ned. Test i ng schedul es must be r eady f or r evi ew by Qual i t y
Cont r ol . Al l const r uct i on mi l est ones must be pr epar ed and r evi ew-
ed by Pr oduct i on and Management .
Thi s appr oach i s def i ni t el y bol d, cal l i ng f or pl anni ng t o be i n
cont r ol of t he yar d, To r eal i ze t hi s ef f or t , pl anni ng must under -
st and al l of t he yar d s const r ai nt s, be f l exi bl e and r esponsi ve t o
t he needs of pr oduct i on, and be capabl e of adapt i ng i t s t echni ques
t o accomodat e t he changi ng cl i mat e of t he cont r act , dr i ven by
t he
cust omer , engi neer i ng, and t he envi r onment of t he year . To ac-
compl i sh t hi s f eat , t he shi pyar d must have set pol i ci es gover ni ng
446
pl anni ng and al l af f ect ed ar eas subj ect t o t he pl anni ng depar t -
ment , The pl anni ng depar t ment must . f unct i on f r om st r i ct pr oced-
ur al gui del i nes t o i nsur e t hat t hei r pl ans ar e accur at e and t he
schedul es ar e wor kabl e. To i nsur e t hi s, pl anni ng must . have a di s-
ci pl i ne whi ch must f ocus on t he f ol l owi ng poi nt s.
1. I ndi vi dual pl anner s, bot h SPAR' s and t he cl i ent
yar d s, have t hei r own t echni que t owar ds t he pr epar -
at i on of t he pl an. Ther ef or e, t he di sci pl i ne must .
est abl i sh t he compl et e gui de1i nes t o el i mi nat e r edund-
ant wor k, i nsur e t he i nt egr at i on of segment s pl anned
by di f f er ent peopl e, and t o cl ear l y def i ne each per -
son' s r esponsi bi l i t i es.
2. The r esul t ant pl an and schedul e must be easi l y vi suai -
i zed by al l depar t ment s wi t hi n t he yar d.
3. The syst ems or pr oduct wor k br eakdown st r uct ur e must .
be r ecogni zed, under st ood, and accept ed by al l depar t . -
ment s wi t hi n t he yar d,
4. The r esul t ant pl an and schedul e must be f l exi bl e t o
al l ow f or cust omer or engi neer i ng changes, pr eout f i t
ver sus nor mal out f i t t i ng const r uct i on, r ecover y pl an-
ni ng,
and r esour ce const r ai nt . eval uat i on.
447
5, Fi nal l y, a st andar d "Pl anni ng Document " must . be cr eat -
ed t o pr ovi de f or hi st or i cal anal yses, pl an and sched-
ul e mai nt enance, and as a basi s f or t he pl anni ng of
f ut ur e vessel s of t he same or si mi l ar t ype.
The pl anni ng met hodol ogy cent er s ar ound t he use of an
" I - J "
node
net wor k, Af t er di vi di ng t he shi p i nt o st andar d zones, each zone
i s encoded i nt o i t s nomi nal f or m and pl aced ont o SPAR' S PERT- PAC
syst em, under t he Mi cr onet l i br ar y, An exampl e of a nomi nal zone
woul d be one car go t ank wi t h act i vi t i es def i ned t o accomodat e t he
const r uct i on of any such car go t ank. A compl et e car go mi dbody can
t hus be net wor ked by r epet i t i ve "cal l s" t o t he Mi cr onet l i br ar y t o
t r ansf er i n t he car go t ank, changi ng such var i abl y def i ned i t ems
as t he zone number , l ead st eel uni t number , or t he user def i ned
"i ncr ement " number . Af t er t he t r ansf er , t hi s t ank can be cust om-
i zed by r emovi ng excessi ve act i vi t i es or by addi ng t hose act i vi t -
i es par t i cul ar t o t hi s car go t ank.
The PERT- PAC syst em' s Mi cr onet l i br ar y per mi t s t he
def i ni t i on of
act i vi t i es i n t er ms of var i abl es; . Thus, a wor kor der may be de-
f i ned as a combi nat i on of shi p' s account , shi p' s zOne,
and some
ar bi t r ar y di gi t , combi ned f or a si x <6> di gi t wor kor der number .
For exampl e, an act i vi t y on a Mi cr onet mi ght r ead "AAAZZW" wi t h an
account number assi gnment of 248,
Upon t r ansf er of t hi s mi cr onet
t o t he mast er net wor k, t he shi p' s
zone and t he ext r a di gi t woul d
be speci f i ed t o compl et e t he def i ni t i on of
t hi s wor kor der , For
exampl e, TRANSFER ( 12345) Z=25, W=8 woul d gener at e a wor kor der of
448
248258, Si nce subsequent t r ansf er s woul d r ef er ence a
di f f er ent .
zone, no dupl i cat i on of 248258 woul d occur .
The pl anni ng di sci pl i ne i nsur es t hat t hese zone t r ansf er s wi l l not
gener at e r edundant or conf l i ct i ng act i vi t i es, by di ct at i ng t he
wor kor der number i ng scheme and t he I - J node number i ng appr oach,
Dupl i cat e wor kor der def i ni t i ons ar e f l agged as an er r or and a r e
not l oaded t o t he mast er net wor k, The di sci pl i ne st at es t hat each
zone pl aced ont o t he Mi cr onet l i br ar y be sel f - cont ai ned. Each
zone const r uct , t her ef or e, must cont ai n act i vi t i es f or Engi neer -
i ng, Mat er i al pr ocur ement and cont r ol , Fabr i cat i on/ Assembl y, I n-
st al l at i on, component t est i ng, and t he necessar y net wor k l i nks t o
syst ems t est s and mast er net wor k cont r ol act i vi t i es, such as sea
t r i al s or del i ver y.
Whi l e t he r ul es f or wor kor der and node number i ng ar e r at her de-
t ai l ed, t he car ef ul USe of t he di sci pl i ne by t he pl anni ng gr oup
has demonst r at ed t hat one vessel can be pl anned by numer ous peopl e
wi t h no pr obl ems sur f aci ng when t he pi eces ar e i nt egr at ed i nt o a
f i nal net wor k. Even syst em5 t est i ng, whi ch must be "f ed" by
numer ous i nst al l at i on act i vi t i es t hr oughout t he net wor k, does not
cr eat e a pr obl em, si nce a si ngl e- act i vi t y Mi Cr onet i s Cr eat ed, and
i t s account . number i s l ef t . as a var i abl e, 80 When a pl anner needs
t o accomodat e syst ems t est s f or account 123, an addi t i onal Mi cr o-
net t r ansf er i s mer el y coded: TRANSFER <1154893> A=123. I f some
ot her pi anner has pr evi ousl y suppl i ed t hi s syst ems t est i ng act i v-
i t y,
t he PERT- PAC syst em wi l l r ej ect t he 1at t er def i ni t i on. The
449
pl anner i s t hus assur ed t hat hi s r equi r ed t est i ng act i vi t y i s i n
pl ace, whet her or not hi s t r ansf er act ual l y pl aced i t i nt o t he
mast er net wor k.
Pl anni ng by zone i s a ver y i mpor t ant par t 0f t hi s appr oach. The
t ot al net wor k pi c t ur e need never be dr awn. I nst ead, gr aphi cal
pr esent at i ons of t he nomi nal zone mi cr onet s and an over vi ew sket ch
of t he mast er net wor k pr ovi des enough vi si bi l i t y i nt o t he pl an t o
make i t wor kabl e. The capabi l i t i es of t he PERT- PAC Mi cr onet f ac-
i 1i t y t hus augment s t he nat ur al pl anni ng met hods associ at ed wi t h
z one or i ent ed pr oduct i on. T h e combi nat i on of net wor k phi l -
osophi es, t he PERT- PAC comput er syst em, and t he wr i t t en pr ocedur es
f or t he pl anni ng endeavor i nsur es t hat t he r esul t ant schedul es ar e
accur at e, si mpl i f i ed, and compl et e.
SPAR Associ at es has def i ned a pl anni ng appr oach based on:
* NETWORKS - f or desi gn and vi sual i zat i on of t he
pl an
* PERT- PAC - f or mai nt ai ni ng t he net wor k and
gener at i ng schedul es
* DI SCI PLI NE - t o i nsur e accur acy and si mpl i ci t y
of t he ent i r e pl anni ng oper at i on
The di sci pl i ne, bei ng t he cont r ol l i ng el ement , has
r ecei ved t he
most at t ent i on i n t er ms of devel opment and r evi ew, Whi l e t he
450
St andar d Pl anni ng Gui de cannot be consi der ed compl et e, i t s COn-
t i nued use f or pl anni ng t he cl i ent ' s vessel s pr ovi des an excel l ant
f i el d- t est i ng envi r onment ,
Compl et e Pl ans
* Engi neer i ng dr awi ngs
* Mat er i al Requi r ement s by CWBS and Zone
* Fabr i cat i on of St eel and Syst ems
* Assembl y of St eel and Syst ems
* St eel Er ect i on
* syst ems i nst al l at i on
* Test i ng by Zone, Syst em, Compar t ment
* Maj or Mi l est ones
451
PERT- WC Mi cr onet s
I - - - - - - - - - - - - - - - c-
* Var i abl e Def i ni t i ons
* Repet i t i ve Use Wi t hout Dupl i cat ed Packages
* Easi l y Removed f or Subst i t ut i ons
* can Be "Cl oned" f or Al t er nat i ve Pl anni ng
* Aut omat i c Node Li nki ng t o For m Chai ns
( St eel , Er ect i on)
452
St andar d Pl anni ng Gui de: Tabl e of Cont ent s
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
1, 0 I nt r oduct i on and Ter mi nol ogy
2, 0 Pl anni ng and Net wor ki ng Phi l osophy
3 , 0 Shi pyar d Dat a Requi r ement s
4, 0 Del i ver bl e I t ems
5, 0 Manpower and Faci l i t i es Loadi ng Opt i on
6, 0 Labor Cont r ol Opt i on
7. 0 Pl anni ng and Net wor ki ng Techni ques
7, 1 Engi neer i ng
7. 2 Mat er i al
7, 3 Pr eout f i t t i ng/ Post out f i t t i ng
7, 4 Test i ng act i vi t i es
7, 5 St eel Er ect i on Sequence and Cont r ol
7. 6 Auxi l i ar y Machi ner y
8, 0 Mast er Net wor k Cont ent and Const r uct i on
9 , 0 Mi l est ones and Hol i days
APPENDI CES
Sampl e Li st of Mi cr onet Number Assi gnment s
Sampl e Mi cr onet Pi ct or i al s
Pl anni ng Ser vi ces Pr i ci ng
Sampl e Pl anni ng Dat a For ms
FI GURES
4, 0, 1
4, 0, 2
4, 0, 3
4, 0, 4
4. 0. 5
Sampl e PERT- PAC Maj or Mi l est one St at us Repor t
sampl e PERT- PAC Cr i t i cal Pat h Repor t
Sampl e PERT- PAC Act i vi t y Li st i ng
Sampl e PERT- PAC Act i vi t y Schedul e Bar char t
( Mont hl y Ti me Scal e)
Sampl e PERT- PAC act i vi t y Schedul e Bar char t
( Weekl y Ti me Scal e)
453
S, P, G, : Tabl e of Cont ent s, cont i nued
5. 0. 1 Sampl e Manpower Requi r ement s Repor t
Labor Per f or mance By Pr oj ect Wor k Br eakdown
St r uc t ur e
6. 0, 2 Labor Per f or mance by Tr ade Gr oup
6, 0, 3 l abor Per f or mance By Wor k Cent er
6. 0. 4 Labor Per f or mance By Shi p Zone
6. 0. 5 Pr oj ect Per f or mance Tr end Repor t
7, 1, 1 Engi neer i ng Act i vi t i y Requi r ement s
7. 2. 1 Mat er i al Act i vi t y Requi r ement s
7. 3. 1 Sampl e Node Number i ng Scheme
9. 0. 1 Sampl e Mi l est one Li st
454
Pl anni ng Document at i on
SPAR wi l l del i ver t o t he cl i ent shi pyar d a document
descr i b-
i ng t he gener al pl anni ng appr oach used, pr obl ems encount er ed,
br i ef anal ysi s of schedul es, const r ai nt s encount er ed or used,
and r equi r ed mai nt enance necessar y t o suppor t t he n e t w o r k
The document s var y f r om shi p- t o- shi p, bot h i n cont ext and
scope, dependi ng pr i mar i l y upon t he compl exi t y of t he vessel .
The f ol l owi ng out l i ne pr esent s t he maj or poi nt s i n t he Shi p' s
Pl anni ng Document at i on.
1, Pr e- Pl anni ng
A. Revi ew of shi pyar d management st r uct ur e
1 , Pl anni ng Depar t ment
2, Pr oduct i on Deapr t ment s
3, Engi neer i ng/ Dr awi ng Of f i ce
4. Mat er i al Pr ocur ement and Cont r ol
5. Pr oj ect Management
B. Obser vat i ons r egar di ng t he vessel
1, St eel and syst ems compl exi t y
2, Ur gency of needed schedul es
3, Quant i t y/ Qual i t y of pl anni ng done by
yar d
4. Ext ent of cust omer changes, past and
cur r ent
5, Ext ent of pr e- out f i t i nst al l at i on t o
be done
6, Ext ent of pr e- out f i t pai nt i ng t o be
done
7, Ext ent of equi pment modul ar i zat i on t o
be done
C, Anal ysi s of exi st i ng pl anni ng on t hi s ves-
sel
I , St r engt h of exi st i ng wor kor der number -
i ng scheme
2, Qual i t y of zone assi gnment s
3. Ext ent of pl anni ng per - f or med t o- dat e
4, Any obser vabl e pr obl ems
455
A. Wor kor der i dent i f i cat i on
1. Fabr i cat i on
2. Assembl y
3. Er ect i on
4, On- shi p Wel di ng
5. Mi scel l aneous suppor t
B. Mi cr onet conf i gur at i on
C. Pr e- out f i t "hot " and "col d" conf i gur at i on,
i f appl i cabl e
D, Pr e- out f i t pai nt consi der at i ons, i f appl i c-
abl e
E. Er ect i on sequence const r ai nt s
1, Pr i mar y; bui l d di r ect i on
2. Secondar y; geogr aphi c r el at i onshi ps
3, Desi gn; par t i al shi p movement , pl anned
del ays, et c
F. Pr obl ems
I I I , syst ems
A, Wor kor der i dent i f i cat i on
1, Pur chased i t ems
2, Shop f abr i cat i on
3. Shop/ shi p assembl y
4, Shi p i nst al l at i on
5, Pr e- out f i t i nst al l at i on
B. Mi cr onet conf i gur at i ons, by shi p' s zone
C. I nst al l at i on sequence const r ai nt s
1. Suppor t ed mat er i al
2, Suppor t ed engi neer i ng
3, St eel st r uct ur e; bul kheads, over heads,
et c
4, Pl anned del ays
456
A, Zone or Uni t t est i ng
Wor kor der i dent i f i cat i on
2. Scope
3. Pr obl ems
B, I ndependent t ank t est i ng
1. Wor kor der i dent i f i cat i on
2, accur acy based on knowl edge of hul l
st r uct ur e
3, Accur acy based on r equi r ed suppor t
t est i ng equi pment
4, Pr obl ems
c. syst ems t est i ng
1, Wor kor der i dent i f i cat i on
2, Mi cr onet conf i gur at i on
3, Test i ng pl an
4, Pr obl ems
v. Net wor k/ Schedul e Mai nt enance
A. Change of bui l d di r ect i on
B. Change of pr e- out f i t quant i t y/ qual i t y
C. Er r or det ect i on and cor r ect i on
1. Bad dur at i ons or l ead t i mes
2, bad act i vi t y r el at i onshi ps
3. Loops
D. Schedul e pr obl ems
1, Del i ver y t oo l at e
2, Mi ssed mi l est one dat es
3. Lat e mat er i al or engi neer i ng
4. Fai l ed t est s
5, Cust omer changes
6. Engi neer i ng change not i ces
457
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http://www.nsnet.com/docctr/
Documentation Center
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Transportation Research Institute
Marine Systems Division
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Ann Arbor, MI 48109-2150
Phone: 734-763-2465
Fax: 734-763-4862
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