Rajeev Kumar S

Manager (Planning Dept.)

Cochin Shipyard Ltd
rajeevscea@gmail.com
9995804310 05 Oct ’17
 PROCESS PLANNING DETAILS
 Work Breakdown Structure
 Advantages

 PWBS & SWBS

 Top down & Bottom up approach

 PERT schedule for Ship construction

 Gantt Chart

 Network diagrams
 Activities
 Relationships
 Dates
 AOA / ADM and AON / PDM
 Lead , Lag, Float
 Critical path
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 PROCESS PLANNING DETAILS
 CPM, PERT concepts

 Forward & Backward Scheduling

 Crashing , Fast tracking

 Histograms

 Softwares used for Scheduling

 Theoretical ship building model

 S Curve analysis

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 SAMPLE NETWORK DIAGRAM
SL.NO. ACTIVITY PREDECESSOR DURATION
1 A - 0
2 B A 6
3 C A 5
4 D A 3
5 E C 1
6 F C 3
7 G C 2
8 H D 1
9 I B 4
10 J E 3
11 K G 1
12 L F,J,K 3
13 M H,L 5
14 N I,M 0
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 CPM & PERT
Basis for Comparison PERT CPM
PERT is a project management CPM is a statistical technique of
Meaning technique, used to manage project management that manages
uncertain activities of a project. well defined activities of a project.
A technique of planning and
What is it? A method to control cost and time.
control of time.
Orientation Event-oriented Activity-oriented
Evolved as Research &
Evolution Evolved as Construction project
Development project
Focuses on Time Time-cost trade-off

Estimates Three time estimates One time estimate

Appropriate for High precision time estimate Reasonable time estimate

Management of Unpredictable Activities Predictable activities

Nature of jobs Non-repetitive nature Repetitive nature

Research and Development Non-research projects like civil
Suitable for
Project construction, ship building etc.
Crashing concept Not Applicable Applicable

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 WHY CPM / PERT ?
 Project Completion date?

 On Schedule?

 Within Budget?

 Critical Activities?

 How can the project be finished early at the least cost?

 Crashing, Fast tracking

 Softwares used for Scheduling

 Histograms

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 SHIP BUILDING MODEL
• The production function
qt = q (Kt, Lt, Et)
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
– Labour productivity
• Experience effect
• Number of workers
• Change rate of the workers number
• Length of the work day (overtime)
• Workers skill level
– Efficiency effects
• Incomplete or missing plans
• Disruption of workers
• Disruption of support functions
• Worker morale
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S-CURVE ANALYSIS

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 ASSIGNMENT NO. 1

1. Explain in detail “Design for production” .

2. Differentiate between PERT and CPM. Draw Gantt charts and

network diagrams for ship building activities of a platform supply
vessel. Cycle time – 20 months, Quayside outfit time – 10 Months

3. Explain different work breakdown structures, scheduling of ship

construction activities and their importance.

Last Date of Submission – 10th Oct

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 ASSIGNMENT NO. 2

1. Explain ship building model

2. Explain productivity in ship building and productivity improvement

methods.

3. Explain use of computers in PP&C and application of CAD/CAM

Softwares.

Last Date of Submission – 19th Oct

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 SAMPLE QUESTIONS FOR INTERNAL 2
1. Explain capacity planning with reference to ship building work
centers.
2. Explain different ship building standards
3. Explain panel line production shop
4. Explain cost estimation and manhour estimation in ship building.
5. Explain an expansion plan for a ship building yard from 100000
DWT to 200000 DWT with necessary bar charts.

6. Explain the procedure for activities involved in establishing a new

ship building yard. Specify equipment and facilities/shops

7. Explain corporate planning, long range schedule and build strategy

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 CAPACITY PLANNING & PRODUCTIVITY
• Manhour Concept
– Concept
– Types of Capacity
• Manhour & cost estimation
– Direct costs & Indirect costs
– Top down (cost down / historical) and Bottom up (cost up/ engineering
analysis) approaches
– Historical costing , Parametric method, Standard ship approach, Direct
analysis
– Manhour per tonne * weight
• Capacity planning
– Work centers, parallel projects, Overload, Under load
– Resource levelling
– Outsourcing
• Productivity index
– DWT, Tonnes, CGT, total productive area, steel stock yard
– Productivity graphs: block assembly Mhr Vs Weight,
• Productivity estimation of series / similar projects
• Improving productivity

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 CAPACITY PLANNING & PRODUCTIVITY
• New ship building facility
– Market analysis : potential markets, market shares, labor , vendor
markets, environmental requirements, energy costs, land cost
– Geographic / urban factors : proximity to open sea, highway, rail
and water transportation, technical schools and universities
– Identify yard facilities and capacities reqd – dock, slipways, blasting
machines, CNC cutting machines, cranes etc
– Yard layout
• Storage areas (steel, blocks, equipment / machinery)
• Material flow
• Road ways and Transportation
• Area for sub contractors
• Shops (steel fab, pipe fab, sheet metal, paint, carpentry)
• Building sites
• Equipment / Machinery

• Future capacity estimation

– Market analysis, commercial and defence

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FUTURE CAPACITY ESTIMATION

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• Production capacity of shipyard is, in most case,
defined by the resource secured, the yard area, and
especially the proximity degree of each factories and
work stages.
• The problem is that most resources and factories are
hard to be changed from the initially installed and
built status even though the need for the increase of
the production capacity is taken place.
• Therefore, initial layout design of the shipyard has to
be conducted with a reasonable input data and a
logical methodology. 15
• This division is similar with that of the ship
design process. The target phase of this paper
is the preliminary design, which determine a
rough layout of the main shops & work stages
(Indoor shops, Painting shop, Outfitting shop,
Pre-Erection (PE) workstage, etc.) considering
the capacity of the dry-dock and the ship
construction cycle.

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 Input and output of shipyard
preliminary layout design
• the given geometry of land is used as a boundary condition
when each shop and each workstage is located along with a
layout design process.
• The block geometry of the target ships are required for the
area calculation, where the orthogonal area of each block is
summed and averaged.
• The target production volume and the production capacity of a
planning shipyard are also used for the area calculation
together with the block area coming from the block geometry.
• The required area and number of the shop and the workstage
is proportional with the block area and the production volume.
• On the other hand, the required area is in inverse proportion to
the production capacity, where the production capacity has
hour or day unit. 19
Input data
•Geometry of land as boundary condition.
•Block geometry of target ships - Number of blocks,
Dimension of block.
•Planned production volume.
•Planned production capacity - Block production and
steel fabrication.

Output
•Required maximum size of each shop and workstage.
•Optimized location of each shop and workstage.
•Allocation of unit work cell w.r.t. required production
capacity.

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 Production area calculation

• Most shipbuilding company has difficulties in area

planning because the roughly estimated plan area was
not adjustable for the actual shipbuilding process.
• Other production issues such as load evening,
production method, etc. could be improved locally
with given work conditions.
• However, less estimated area plan could not be
resolved. And, the insufficient production capacity by
area shortage has to be covered by the outsourcing the
block construction to the cooperative firm or the
subcontractor.

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• So, the reasonable area calculation with the
measurable input data and the systematic
method is the most critical point of preliminary
layout design.
• So, the first procedure is to estimate the
production area based on the target ship
information and planned production volume. The
basic principle of this procedure is to calculate
required total area of each production process.

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• the calculation of area for the blocks is based on
Little's law. Little's law says that the long-term
average number of customers in a stable system L is
equal to the long-term average effective arrival rate,
λ, multiplied by the average time a customer spends
in the system, W
• Time corresponds with the block staying period at
the work stage and the number corresponds with
the required holding capacity of workstage. Also,
arrival rate is the required production capacity per
unit time
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 COMPUTER INTEGRATED MANUFACTURING
• Computer Integrated Manufacturing
– Computer Aided Design (CAD)
• Designing
• CNC programs
– Computer Aided Manufacturing (CAM)
• Production machines
• Process planning, scheduling and monitoring
• Materials management
– Interfacing of CAD and CAM
– Computer Aided Production Management (CAPP)
• Capacity planning
• Cost planning and control
• Inventory management
• Production scheduling
• Materials requirement planning
• Shop floor control
• Inspection and testing
• Assembly (robot / NC mechanical hand)

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