A.Y.Odaba 2009Product Work Breakdown StructureProduct Work Breakdown Structure(PWBS)(PWBS) A.Y.Odaba 2009Glossary Glossary Cycle time: the length of time it takes a process to cycle once Effectiveness : ability to use a resouce in best possible way (or ability to solve a problem in best possible way) Efficiency:the degree of effectiveness as it applied to a process Process: the blending and transformation of a specific set of inputs into a more valuable set of outputs Reliability : the consistency of an output Rework: any unnecessary, repeated operational steps Waste: all non-value adding process activities except those required to satisfy rules, regulations etc. Work : actions that move a process forward or directly add value Work efficiency : a mathematical expression of how much work versus waste exists in a process A.Y.Odaba 2009Work Efficiency Work EfficiencyWORKWORK + WASTEx100 % A.Y.Odaba 2009Utilization UtilizationRelation between the time when the equipment actually is used for productive time (machine time) and the total time availableWhat is AVAILABLE time ?Breakdowns and stops15 %Personal allowances 15 %Technical allowances 15 %Manual time 15 %Machine time 40 %Utilization40 % A.Y.Odaba 2009Definitions DefinitionsMACHINE TIMETOTAL AVAILABLE TIMEMachine UTILIZATION =Personnel PRODUCTIVITY=USED MANHOURSTOTAL QUANTITYProject PERFORMANCE =ALLOCATED MANHOURSUSED MANHOURS A.Y.Odaba 2009Process Re Process Re- -enginering engineringThe goal: is to decrease the the amount of waste in any work processBefore AfterAWork WorkWaste WasteBWork WorkWaste WasteWork WorkWaste WasteWork WorkWaste WasteMore workin the same amount of timeSame amount of workin muchless time A.Y.Odaba 2009Key Process Characteristics Key Process Characteristics Effectiveness : Do outputs meet customer requirements ? Efficiency : Is process cycle time acceptable ? Reliability : Do outputs always meet customer approval? Cost : Are process costs acceptable ?Customer wants Customer gets Customer always wantsCustomer usually gets Process cycle time is 3h 25 min.Process cycle time should be 1h 15 min.Process costs $ 55 per outputProcess should cost $ 36 per output A.Y.Odaba 2009Production FlowProduction Flow - - Shop Floor Shop FloorSteelStockyardShotblasting &PrimingPlateCuttingProfileCuttingPlateFormingProfileFormingMiscellaneousAssembliesBlockConstructionCurved PanelLineWeb & Comp.LineSmall PanelLineLarge Panel &Double BottomLine A.Y.Odaba 2009Main Activities in Ship ConstructionMain Activities in Ship Construction - - Functional Approach Functional ApproachFrameBody PlanProfile &ButtocksPiping MechanicalMainMachineryAuxiliaryMachineyDecksShellPlatingShipHull FormHullStructureMachinery Outfit - - - - - -Bulkheads - - - - - -- - - - - -Electrical HVAC - - - - - -- - - - - - A.Y.Odaba 2009Group Technology in ShipbuildingGroup Technology in Shipbuilding - - Definition DefinitionA technique for manufacturing small to medium lot size batches of parts of similar process,of somewhat dissimilar materials, geometry and size, which are produced on a committed small cell of machines, which have been grouped together physically, specially tooled and scheduled as a unit [Storch et el. 1995] A.Y.Odaba 2009Group Technology in ShipbuildingGroup Technology in Shipbuilding - - Benefits BenefitsReduction in engineering drawingsCompany standardizationReduction in design and engineering man-hoursBetter utilization of facilitiesSimplified and automated planningSimplified scheduling and production controlImproved productivity A.Y.Odaba 2009Build StrategyBuild Strategy - - A Group Technology Approach A Group Technology ApproachWhat is to be done?When is it to be done?How is it to be done?What resources are needed to do the task?Build StrategyAn agreed design, engineering, materials management, production, planning and testing planprepared before the work startsso as to identify and integrateall the necessary processes [T.Lamb, 1996] A.Y.Odaba 2009Product Oriented Work Breakdown Structure (PWBS) Product Oriented Work Breakdown Structure (PWBS)PWBS provides indentation levels within production tree structurePWBS classifies the shipon the basis of its interimproductParts and subassemblies are grouped by common characteristicsand classified by both design and manufacturing attributes.BenefitsProvide mechanism to enter into and come out of SWBSCommunicate amongst design, material procurement and production departments using a common framework and description of both the material and labor for a particular interim product.Stagewise testing and acceptanceAssistance in configuration and change management A.Y.Odaba 2009Product Oriented Work Breakdown StructureProduct Oriented Work Breakdown Structure - - Requirements RequirementsType of workResourcesControl ofProductionProcessHull constructionOutfittingPaintingMaterialManpowerFacilitiesProduct Structure (Zones)Work Type (or system based)Work Stage A.Y.Odaba 2009Components of Integrated Hull, Outfitting and Painting (IHOP) Components of Integrated Hull, Outfitting and Painting (IHOP)Product Work Breakdown Structure (PWBS)Zone Outfitting Method (ZOFM)Zone Painting Method (ZPTM)Hull BlockConstruction Method (HBCM)Pipe Piece Family Manufacturing(PPFM) A.Y.Odaba 2009Integrated Hull, Outfitting and Painting (IHOP) Integrated Hull, Outfitting and Painting (IHOP)HMCMZOFMZPTMUses same logic of group technology as employed in HBCM & ZOFMConsiders painting work as an assembly process with different painting work at different levelsPPFMClassifies pipe-piecesOrganized independently of the hull structural blockA fabrication process rather than the assembly work of HBCM/ZOFM/ZPTMThe ship is dived and subdivided into blocksBlocks are the basis for control of the productionBlocks are also used for ZOFM and ZPTMBlocks:simple & logical boundariesmin. number of blocksprovide min. scaffoldingprovide max. accessibilityWorks in conjunction with HBCMUses similar logic of zone division as in HBCMOutfit components are assembled either independent of the hull blocks or based on the hull blocksOn-unitOn-blockOn-board A.Y.Odaba 2009Integrated Hull, Outfitting and Painting (IHOP)Integrated Hull, Outfitting and Painting (IHOP) - - Benefits BenefitsHMCMZOFMZPTMThe ship is dived and subdivided into blocksBlocks are the basis for control of the productionBlocks are also used for ZOFM and ZPTMOutfitting and installation work in closed & covered areasBetter and safer work conditionsEasy supervision of workReduced idle time Maximum amount of down hand or vertical plane paint workBetter control of temperature and humidity for paint workSafer worker environmentUtilization of same scaffolding with block assemblyPPFMLarge variety pipe-piece parts with number of common elements can be grouped into families or batches having similar design and manufacturing attributesTesting and coating of pipes are done at the place where the final pipe piece assembly and pipe piece joining takes place A.Y.Odaba 2009Built up sectionsor stiffened bracketswork s.: assembly, bendingAssembled structural parts(e.g. transverses, girders, floors)work s.: assembly, back assy.Pre-block assembly stage;assists to assemble partial zones to main blockBLOCK = KEY ZONE Flat, curved, superstructure blocks;work stage:joining, assembly, back assemblyPost-block assembly stage;two or more block assemblies are joinedto create a larger block; work stage:joining, pre-erectionComplete hull is considered as a zone;fore, hull, aft hull, cargo hold, engine room, superstructure;work stage:erection, testProduce non-subdividablecomponents&piece parts;work stages: marking,cuting & bendingHull Block Construction Method (HBCM) Manufacturing Levels Hull Block Construction Method (HBCM) Manufacturing LevelsPartFabricationPartFabricationPartFabricationPartFabricationPartFabricationPartFabricationPartFabricationPartFabricationPartAssemblyPartAssemblyPartAssemblyPartAssemblySub-blockAssemblySub-blockAssemblySemi-blockAssemblyBlockAssemblyGrand-blockJoiningBlockAssemblyHullErectionMain Work Flow A.Y.Odaba 2009Production StagesProduction Stages Steel Hull Steel Hull A.Y.Odaba 2009Parts Fabrication Parts FabricationLine HeatingMarkingMarking & cutting -NC MachinePress Bending(courtesy NSNetShipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo) A.Y.Odaba 2009Sub Sub- -Block Assembly Block AssemblyPalletized sub-assembliesawaiting block assemblyWelding a sub-blockA completed sub-block being moved toa block assembly facilityAssembly of small sub-blocksby gravity-feed welding(courtesy NSNetShipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo) A.Y.Odaba 2009Block Assembly Block AssemblyBlock assembly shopwith process lanesCurved block assembly onan adjustable pin jigsBlock transportation withheavy-lift transportersThe first stage of flat-panelblock assembly(courtesy NSNetShipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo) A.Y.Odaba 2009Hull Erection Hull ErectionKeel laying - Past !!Pyramid erection system -outfitted and painted blocksErection of machinery-space blocksErection of stern block containingrudder horn(courtesy NSNetShipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo) A.Y.Odaba 2009 A.Y.Odaba 2009 A.Y.Odaba 2009 A.Y.Odaba 2009 A.Y.Odaba 2009 A.Y.Odaba 2009 A.Y.Odaba 2009 A.Y.Odaba 2009 A.Y.Odaba 2009 A.Y.Odaba 2009 A.Y.Odaba 2009 A.Y.Odaba 2009 A.Y.Odaba 2009 A.Y.Odaba 2009 A.Y.Odaba 2009UNIT = KEY ZONE Manufacturing level foron-unit outfitting workManufacturing level foron-unit outfitting work)Manufacturing level foron-unit outfitting workOn-unit and grand-unit outfitting assemblyare fitted to the structural blocksdefined by the HBCMOutfit work carried out on the hull of the shipeither during pre-launch erection stage or during the post launch outfitting stageTesting of outfitted unitsThe work packages andmaterial requisition forcomponent procurementare grouped by zone & areaZone Outfitting Method (ZOFM) Manufacturing Levels Zone Outfitting Method (ZOFM) Manufacturing LevelsMain Work FlowComponentProcurementComponentProcurementComponentProcurementComponentProcurementComponentProcurementComponentProcurementComponentProcurementComponentProcurementUnitAssemblyUnitAssemblyUnitAssemblyUnitAssemblyGrand-UnitAssemblyGrand-UnitJoiningSemi-blockAssemblyOn-blockOutfittingOn-boardOutfittingOperation & Test A.Y.Odaba 2009Outfit Components Outfit ComponentsCables; pre-cut, identified and palletizedVentilation ducts100 foot diameter LNG sphereNuts & bolts(courtesy NSNetShipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo) A.Y.Odaba 2009On On- -Unit Outfitting Unit Outfitting4) Completed pipe unitsready for landing on block3) Two nearly completed pipe units2) A pipe piece secured to supportswith U bolts1) Tack welded supports for pipe uniton a platen(courtesy NSNetShipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo) A.Y.Odaba 2009On On- -Block Outfitting Block OutfittingAn outfitted and painted blockView of outfitted blockFitting out ofventilation-duct piecesFitting out of electrical cable trays(courtesy NSNetShipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo) A.Y.Odaba 2009On On- -Board Outfitting Board OutfittingOn-board outfitting - traditional way On-board outfittingOn-board outfittingFlanges for large & medium diameterpipes are in alignment(courtesy NSNetShipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo) A.Y.Odaba 2009PWBSPWBS - - Outfit Units Assembly Outfit Units AssemblyOutfit units which are dissimilar in arrangement and in functions incorporated, have the same classification in a product-oriented work breakdown structure because the problems associated with their assembly are the same.(courtesy NSNetShipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo) A.Y.Odaba 2009PWBSPWBS - - Outfit Units Assembly Outfit Units AssemblyUnit : Standard Machinery UnitResources: 30 pipe pieces 5 walkway sections + handrail 8 supports a smaller unit consisting of 2 interconnected pumps on a common foundation.Time : 2 worker assembly team for one weekWeight : 10 tons(courtesy NSNetShipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo) A.Y.Odaba 2009Application ofanti-corrosive paintsPainting of various outfitting items(masts, cargo booms, hatch covers),application of anti-corrosive paintsFinal stage in the ZPTM;no block turnover,application of anti-corrosive paintsSurface preparationand primer coatingfor plates and sectionsZone Painting Method (ZPTM) Manufacturing Levels Zone Painting Method (ZPTM) Manufacturing LevelsShopPrimerShopPrimerShopPrimerPrimerPrimer PrimerFinishUnder-coatPaintFinishPaintFinishUnder-coatPaintPrimerUnitAssembly A.Y.Odaba 2009Zone Painting Zone PaintingAn extensivelt outfitted and painted blockPriming of steel plate(courtesy NSNetShipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo) A.Y.Odaba 2009Marking, cutting andmachining of pipesFlange and collar attachment(excludes joining of mainand branch assemblies)Joining of main pipe sub-assembly tobranch pipe sub-assemblyto produce pipe assemblyChecks for qualityof the assembled pipesPickling and coatingof pipe assembliesGrouping of pipes according to the requirements for a specific pallet(e.g. Hull, machinery, superstructure)Different arrivingmaterials are groupedaccording to thetype of materialPipe Piece Family Manufacturing Method (PPFM) Manufacturing Leve Pipe Piece Family Manufacturing Method (PPFM) Manufacturing Levels lsPipeReceivingPipeReceivingPipeReceivingPipeReceivingPipeReceivingPipeFabricationPipeFabricationPipeFabricationPipe PieceAssemblyPipe PieceAssemblyPipe PieceJoiningTestingCoatingPalletizingTesting A.Y.Odaba 2009Pipe Pipe- -Piece Family Manufacturing Piece Family ManufacturingPalletizing areasPPFMClassification: PenetrationsPPFM Classification :StraightPPFMClassification:Unit assembledPipe receiving area(courtesy NSNetShipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo) A.Y.Odaba 2009Integrated Schedule for Hull Construction, Outfitting and Painti Integrated Schedule for Hull Construction, Outfitting and Painting ngPrinciple EventScheduleIntegrated Hull ConstructionOutfitting & Painting Master ScheduleBlock AssemblyMaster ScheduleOn-unit OutfittingMaster ScheduleOn-board OutfittingMaster ScheduleOn-block OutfittingMaster ScheduleMonthly Schedule Monthly Schedule Monthly ScheduleWeekly Schedule Weekly Schedule Weekly ScheduleBlock ErectionMaster Schedule A.Y.Odaba 2009Hull Construction Progress Hull Construction Progress A.Y.Odaba 2009Producibility ProducibilityThe reduction in costsas a result of the effort put in tomake ship cheaper to buildbymaking it cheaper to constructwithout compromisingon its desired capabilitieslike size, speed, displacement, payload,stability, strength etc.Reducelabor cost by reducing number of steps to perform the taskReduce the number of piece parts varityIncorporate standardizationIncrease repetitive jobs A.Y.Odaba 2009 A.Y.Odaba 2009(courtesy NSNetShipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo)PWBS, statistical control and line heating are interdependent. In accordance with a product work breakdown blocks which are assembled on a flat panel are a distinct problem category regardless of their design differences. In Avondale Shipyards, Inc., they are assembled on a dedicated process lane. A.Y.Odaba 2009PWBSPWBS - - Erection Level Erection Level11(courtesy NSNetShipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo)Building Progression: Keel Laying +Building Progression: Keel Laying + days days A.Y.Odaba 2009PWBSPWBS - - Erection Level Erection LevelLanding the Block Landing the Block 13(courtesy NSNetShipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo)Building Progression: Keel Laying +Building Progression: Keel Laying + days days A.Y.Odaba 2009PWBSPWBS - - Erection Level Erection LevelEngine Engine- -room Tank room Tank- -top blocks top blocks 15(courtesy NSNetShipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo)Building Progression: Keel Laying +Building Progression: Keel Laying + days days A.Y.Odaba 2009PWBSPWBS - - Erection Level Erection LevelBlue sky outfitted controlBlue sky outfitted control console and diesel generators console and diesel generators19(courtesy NSNetShipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo)Building Progression: Keel Laying +Building Progression: Keel Laying + days days A.Y.Odaba 2009PWBSPWBS - - Erection Level Erection LevelLanding the Cant Block Landing the Cant Block 22(courtesy NSNetShipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo)Building Progression: Keel Laying +Building Progression: Keel Laying + days days A.Y.Odaba 2009PWBSPWBS - - Erection Level Erection LevelLanding the grand block Landing the grand blockBuilding Progression: Keel Laying +Building Progression: Keel Laying + day days s22(courtesy NSNetShipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo) A.Y.Odaba 2009PWBSPWBS - - Erection Level Erection Level24(courtesy NSNetShipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo)Building Progression: Keel Laying +Building Progression: Keel Laying + days days A.Y.Odaba 2009PWBSPWBS - - Erection Level Erection LevelLanding the main engine Landing the main engine 24(courtesy NSNetShipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo)Building Progression: Keel Laying +Building Progression: Keel Laying + days days A.Y.Odaba 2009PWBSPWBS - - Erection Level Erection LevelLanding the aft superstructureLanding the aft superstructure half half27(courtesy NSNetShipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo)Building Progression: Keel Laying +Building Progression: Keel Laying + days days A.Y.Odaba 2009PWBSPWBS - - Erection Level Erection LevelFinish paint application to theFinish paint application to the undersides of hatch undersides of hatch- -covers covers28?(courtesy NSNetShipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo)Building Progression: Keel Laying +Building Progression: Keel Laying + days days A.Y.Odaba 2009PWBSPWBS - - Erection Level Erection LevelAft half of superstructure beingAft half of superstructure being fitted fitted29(courtesy NSNetShipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo)Building Progression: Keel Laying +Building Progression: Keel Laying + days days A.Y.Odaba 2009PWBSPWBS - - Erection Level Erection LevelLanding the aft half ofLanding the aft half of superstructure on board superstructure on boardBuilding Progression: Keel Laying +Building Progression: Keel Laying + days days29(courtesy NSNetShipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo) A.Y.Odaba 2009PWBSPWBS - - Operation and Test Level Operation and Test Level(courtesy NSNetShipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo) A.Y.Odaba 2009IRON STURTIRON STURT - - Ship No: 2728, IHI Kure Shipyard Ship No: 2728, IHI Kure ShipyardLBP= 163.0m, B=22.9m, D=13.6m, d=10.0m, DWT=22,093, HP=9000 LBP= 163.0m, B=22.9m, D=13.6m, d=10.0m, DWT=22,093, HP=9000StartFabricationLaunching43workdays inbuilding dock !!!Keel LayingDelivery