Kul-24.

4130

Shipyard engineering
Lecture 1-1:
Shipbuilding process

Applied Mechanics
Marine Technology

Lecture in course contents

Production
planning

Introduction

Shipbuilding process and

ship yard productivity
Outfitting

Design process
and materials
managements
Hull production

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. Risnen toim., 2000, Kappale 30
Ship production, Storch et al., SNAME, 1995, Chapter I-II

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

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

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

Production customisations level

Design intensity
and customisation

Warehouse vs. design-to-order

One-off-a kind
products or systems

Standard, volume products

Production efficiency/Repetition

Customisations level
Volume vs. one-off production

Before order After order

Design

Design

Design

Design

Design

Fabrication

Fabrication

Fabrication

Fabrication

Fabrication

Assembly

Assembly

Assembly

Assembly

Assembly

Distribution

Distribution

Distribution

Distribution

Distribution

WAREHOUSE

PACK-TO-ORDER

ASSEMBLY-TO

FABRICATE-TO DESIGN-TO-ORDER

Customisation level

Product and type of market

Characterics

Demand stable

Demand dynamic

Product life cycle

Long (2+ Y)

Short (<1.5 Y)

Product variety

Low

High

Forecasting error

Small (5-10%)

Big (40%)

Contribution to
margin

Small (5-10%)

Big (30-60%)

Lead-time for make6-12 months

to-order

1-14 days

Development trends of Finnish and European

maritime 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 yard
concept

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

Theoretical shipbuilding model

Time

Production rate
manning

qt = production rate at time t

Kt = capital utilization rate at time t
Lt = labour utilization rate at time t
Et = efficiency effects due to
production rate change at time t

Cumulative
production

The production function

qt = q (Kt, Lt, Et)

Time

Labour utilisation rate

Labour utilization rate Lt is defined as
quality-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 the

accumulated production is doubled
In shipbuilding industry, this constant is normally 5-10%

Efficiency effects
Distractions affect the efficiency effects Et

Incomplete or missing plans

Interruptions in the use of labour
Interruptions in support functions
Worker morality

Stages of Shipbuilding process

1.
2.
3.
4.

Concepts design
Initial design
Basic design
Component definition and acquisition

5. Coordination design
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.

Product hierarchy and work breakdown structure

Detail design
Material requisition
Part fabrication (hull and outfitting)
Unit production (module, element, etc.)
Block outfitting (sis. Steel outfitting)
Painting of blocks
Block outfitting
Hull assembly
Area outfitting
Commissioning, delivery

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

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 subblocks. 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

Space and Area

Area: the combined space such as a cabin area or a nightclub. The
area can also be a vertical entity such as a staircase or engine
casing. The area consists of one or more spaces. The essential thing
is that the area is uniform and it is not composed of unconnected
spaces. The area definition is a yard-specific and it is affected several
factors such as the location, shape, size, consistency, content and the
amount of work.
Space: a unique space of ship such as the cabin, bridge, engine
room, air conditioning room, etc.. Space alone or together with other
spaces compose the area.

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

System: a functional subsystem of the ship such as air
conditioning, power generation, propulsion system. Typically, the
system 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.

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.

Pre-fabrication
Pre-fabrication is a part or a set of parts which are
manufactured in the workshop, not onboard. Modules are
prefabricated 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.

EMO, EM, and JM outfitting

(Abbreviation applied in Finnish shipyards)
EMO -outfitting
Sub-block outfitting done before the painting

EM - outfitting
Block outfitting done before the painting. Contains work
phases, 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

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.