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Internship Report

Dawood College of Engineering and Technology, Karachi

Department Of: Industrial Engineering and Management

Submission Date: 15/03/2011

Copy to:1. DGM (HRD)

2. GM (Q. C)3. D.Sp (S. B Hall)

4. College (Chairman IND Department)

Muhammad EhsanD-08-IND-314

Shahid AliD-08-IND-337

Muhammad OwaisD-08-IND-336

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cknowledgment

By the Grace of Almighty Allah, We have been able to complete our INTERNSHIP atKarachi Shipyard and Engineering Works. All this become possible only due to thesupport of the following employees. They help us in understanding the different workbeing carried out in KS & EW, to enhance our technical skills. We really believe that ourinternship at KS & EW would never be possible without the support of all these people.We also appreciate the cordial co-operation from all our concern Managers in alldepartments; Especially:

Lt Cdr Mola MadadPN DGM (HRD) Mr. M. A Wadood

Q. C Supervisor (UT)

Mr. Abdul Majid BillooGM (Q. C)

Mr. Irfan AhmedQ. C Supervisor (UT)

Mr. Ghufran AshrafASP (NDT)

Mr. Rashid RiazQ. C Supervisor (MPT)

Mr. Qutubuddin Bhatti(Q .C Officer Hull)

Mr.Obaid-ur-RahmanQ. C Supervisor (RT)

Mr. Zeeshan AzizQ. C Supervisor

Mr. Abdul RahmanD.Sp (Ship-Building Hall)

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S. No. # Department # Page No. #

1. Introduction to KS&EW 4 to 6

2. Quality Control

7 to 22

Shipbuilding Quality Control (SQC)

Ship Repair Quality Control (SRQC)

Engineering Quality Control (EQC)

Quality Assurance

3. Ship Building Hall 23 to 25

4. Conclusion 26

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Introduction to K S & E W:

The Karachi Shipyard & Engineering Works Limited (KSEW), is Situated at WestWharf in Karachi, Sindh Pakistan. KSEW was established in early 1950's as a project ofPIDC. It was incorporated as a public limited company in 1957. The shipyard spread overan area of 29 hectares (71 acres).

Karachi Shipyard is the oldest Heavy Engineering Works of Pakistan which is cateringfor its Ship Building, Ship Repairing, Submarine/Warship Construction andHeavy/General Engineering requirements. KSEW has a large Ship Building Hall, threeShip Building Berths, two Dry Docks, three Foundries (Iron, Steel & Non-Ferrous),Fabrication Shops, one machine shop and other supporting facilities like Carpentry, PipeFitting and Light Steel Fabrication Shop. KSEW is working as an autonomouscommercial organization under the Ministry of Defense, Government of Pakistan.Karachi Shipyard is the only shipbuilding company in Pakistan. It has built numerouscargo ships, tugboats and support vessels, naval vesselsand submarines.

It has played a historical role in transferring of technologies and broadening the industrialbase of the country. KSEW is the only shipyard in Pakistan and has two dry docks of18,000 TDW (Tons Dead Weight) and 26,000 TDW capacities respectively. It has thecapability for building large vessels including Cargo Ships, Oil Carriers, Bulk Carriersand Warships, and Marine Craft including Tugs, Barges, Ferries, Fishing Trawlers,Dredgers and Special Crafts. Furthermore, KSEW has the facilities to produce a widerange of heavy engineering products including Heavy Steel Structures, Pressure Vessels,LPG Storage Tanks, Industrial Boilers, Overhead and Portal Cranes, complete Sugar andCement Plants, etc.

Since 1957 when it commenced its commercial production, it has built over 430 vesselsof different types and sizes for different nations. KSEW possesses an elaborate ShipRepair setup where it has so far repaired over 5000 Vessels, both of national as well asforeign origin. Many renowned Navies of the world including Pakistan Navy and variousShipping lines and Port authorities are KSEW's regular customers.

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KSEW has experience in handling a wide variety of steel construction work. Power housebuilding / Boiler structure, pedestrian overhead bridge, steel frame buildings, platforms,gantries for cranes, bridges, girders, towers for power transmission, broadcasting andtelecommunication etc. are some of the examples. Similarly hydraulic steel work such assluice, radial, flap, regulator gates, tunnel shafts, penstocks etc. for dams, barrage andheadwork is also carried out.

KSEW offers complete sugar plants on turnkey basis. So far KSEW has manufacturedvarious plants in the range of capacities from 2000 to 500 TCD which are based onFIVES-CAIL BABCOCK (FCB) FRANCE design. These plants are fully automatic andhave the latest technology. KSEW is a major source of supply of steel structures,conveyors, hoppers; bucket elevators, piping, and manganese steel lining plate and caststeel components for kiln, ball mills etc. for the cement factories.

KSEW can rightly be called “the first major steel industry of Pakistan ". Although it isdesigned for series production of ocean going vessels, its role in the support of industryand developmental engineering is very well known and prominent. It has a long record ofservice to industry and during slump in the shipping industry, has promoted furtherdiversification of its General Engineering activities. It has one of the largest and well-equipped engineering workshops of the country, the foundry (15 metric ton a piece) SteelFoundry (3 metric ton a piece) and Non-Ferrous Foundry (750 Kg. a piece) are workingin conformity to ASTM, BSS and DIN norms.

***** *****

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Quality Control:Quality control is a process by which entities review the quality of all factors involvedin production. This approach places an emphasis on three aspects:

Elements such as controls, job management, defined and well managed processes,performance and integrity criteria, and identification of records.

Competence, such as knowledge, skills, experience, and qualifications Soft elements, such as personnel integrity, confidence, organizational

culture, motivation, team spirit, and quality relationships.

The quality of the outputs is at risk if any of these three aspects is deficient in any way.Quality control emphasizes testing of products to uncover defects, and reporting tomanagement who make the decision to allow or deny the release, whereas qualityassurance attempts to improve and stabilize production, and associated processes, toavoid, or at least minimize, issues that led to the defects in the first place. For contractwork, particularly work awarded by government agencies, quality control issues areamong the top reasons for not renewing a contract.

Total quality control:

"Total quality control" is a measure used in cases where, despite statistical qualitycontrol techniques or quality improvements implemented, sales decrease. If the originalspecification does not reflect the correct quality requirements, quality cannot be inspectedor manufactured into the product. For instance, the parameters for a pressure vesselshould include not only the material and dimensions, but also operating,environmental, safety, reliability and maintainability requirements.

The Quality control department of KS&EW ensures the quality of work done, weather itis ship building, ship repairing, or other engineering project.

Quality Control department of KS&EW has the following objectives: Carries out inspection and testing related to inspection (during processes and after

developing the finish goods) in accordance with the quality plans, procedures, andwork instructions and customers requirements.

Handles non conforming products Maintain inspection records Maintains and controls the measuring and test equipments and calibrates or

arranges for calibration. Co-ordinates with ship design, engineering design departments, ship repair and

marketing department for preparing quality plans, and technical procedures &work instructions

Closely study the different requirements of the industry and the workers (i-earrange highly efficient and sophisticated equipments and also fulfill the trainingrequirements of the personnel’s as well by providing training wheneverrequired).

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Quality control department of KS&EW has to maintain the quality of work at thefollowing sections:

Shipbuilding Quality Control (SQC) Ship Repair Quality Control (SRQC) Engineering Quality Control (EQC)

Shipbuilding Quality Control (SQC):

Shipbuilding is the construction of ships. It normally takes place in a specialized facilityknown as a shipyard. Shipbuilders, also called shipwrights, follow a specializedoccupation that traces its roots to before recorded history. Shipbuilding and ship repairs,both commercial and military, are referred to as the "naval engineer". The construction ofboats is a similar activity called boat building. The dismantling of ships is called shipbreaking.

In the 20th century, shipbuilding (which encompasses the shipyards, the marineequipment manufacturers, and many related service and knowledge providers) grew as animportant and strategic industry in a number of countries around the world. Thisimportance stems from:

The large number of skilled workers required directly by the shipyard, along withsupporting industries such as steel mills and engine manufacturers;

And

A nation's need to manufacture and repair its own navy and vessels that supportits primary industries.

18th century perspective: 148 ship parts, 18 labeled hull sections(From Cyclopedia, Volume 2, 1728)

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Modern shipbuilding manufacturing techniques:

Modern shipbuilding makes considerable use of prefabricated. Entire multi-decksegments of the hull or superstructure will be built elsewhere in the yard, transported tothe building dock or slipway, and then lifted into place. This is known as "blockconstruction". The most modern shipyards pre-install equipment, pipes, electrical cables,and any other components within the blocks, to minimize the effort needed to assembleor install components deep within the hull once it is welded together. This was firstintroduced by Alstom Chantiers de l'Atlantique when they built the largest Ocean Linerin the world Cunard's RMS Queen Mary 2.

Ship design work, also called naval architecture, may be conducted using a ship modelbasin. Modern ships, since roughly 1940, have been produced almost exclusivelyof welded steel. Early welded steel ships used steels with inadequate fracture toughness,which resulted in some ships suffering catastrophic brittle fracture structural cracks(see problems of the Liberty ship). Since roughly 1950, specialized steels such as ABSSteels with good properties for ship construction have been used. Although it iscommonly accepted that modern steel has eliminated brittle fracture in ships, somecontroversy still exists.[15] Brittle fracture of modern vessels continues to occur from timeto time as the use of grade A and grade B steel of unknown toughness or fractureappearance transition temperature (FATT) in way of ships' side shells can be less thanadequate for all ambient conditions.

Construction of prefabricated module blocks of HMS Dauntless at BAE'sPortsmouth Shipyard.

Shipbuilding department of KS&EW work continuously to develop and build new shipskeeping in view of the requirements of the country and the private firms, givingindependent orders. Currently KS&EW are developing or working on a new Ship (F22Frigate) for Pakistan Navy, with the cooperation of China.The main aim of Shipbuilding Quality Control (SQC) is to check and control the differentprocesses or procedures carry out in the manufacturing of a ship, As shipbuilding demandan accurate, precise and accident free work, so that to minimize the wastages ofmaterials, instruments and tools. QC put efforts to make possible efficient working byproper inspection of equipments, tools, and various tests for materials, so that to use highquality of materials during manufacturing.

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Some important terminologies regarding F22 Frigate ship are:

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Ship Repair Quality Control (SRQC):

All ships need maintenance and repairs. A part of these jobs must be carried out under thesupervision of the Classification Society. A lot of maintenance it is carried out while atsea or in port by ship's staff. However a large number of repair and maintenance workscan only be carried out while the ship is out of commercial operation, in a ShiprepairYard. Prior to undergoing repairs, tankers must dock at a Deballasting Station for ifnecessary completing the tank cleaning operations and pumping ashore its slops (dirtycleaning water and hydrocarbon residues) ashore.

Modern and well-planned facilities exist in KSEW for undertaking above water & underwater repairs of Ships and off shore Drilling Rigs. The ancillary facilities include Shoreelectric supply, Compressed air, Oxygen, Acetylene gas and Natural gas in pipelines andcylinders as well as Fresh and Sea water supply lines and Fire fighting system. The well-equipped Machine Shop is in attendance besides other readily available facilities forsupporting Ship repairs of all kind.

For above-water repairs of Vessels, Quay Walls of 500 meter on the northern side and165 meter on the southern side are available. Above water repairs for Vessels of any sizeand dead weight can be undertaken not only at KSEW premises but also in KarachiHarbour and even at outer anchorage. Similarly any alteration/conversion on hull/ superstructure can be undertaken. For marine boilers, insulation, lagging, flooring, brickworkcan be carried out at the yard. Facilities also exist for repairs of Steam and Motor Vessels,both Main and Auxiliary machinery and all types of marine and stationary Boilers. Shipshaving draught of about 20 feet can be accommodated in graving docks, while vesselswith draught of up-to 15 feet can be berthed at the quay walls.

In the repair or replacement of parts or materials in a ship, QC tries to use high qualitymaterials, therefore reducing risk to a high percent.

Engineering Quality Control (EQC):

The quality check for the all the steel works carried out in KS&EW are properly checkedand controlled in EQC. The different manufacturing works carried out consist ofdeveloping/manufacturing high pressure vessels, rollers for sugarcane and cementindustries, etc........................................................................................................................

In all the above production departments of KS&EW, Quality is checked with thehelp of the following two main methods:

1. Destructive Testing (DT)

2. Non Destructive Testing (NDT)

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1. Destructive Testing (DT):

In Destructive Testing, tests are carried out to the specimen's failure, in order tounderstand a specimen's structural performance or material behavior under differentloads. These tests are generally much easier to carry out, yield more information, and areeasier to interpret than nondestructive testing.

Destructive testing is most suitable, and economic, for objects which will be massproduced, as the cost of destroying a small number of specimens is negligible. It isusually not economical to do destructive testing where only one or very few items are tobe produced (for example, in the case of a building).Some types of destructive testing:

Stress tests Crash tests Hardness tests Metallographic tests

2. Non Destructive Testing (NDT):

Nondestructive testing or Non-destructive testing (NDT) is a wide group of analysistechniques used in science and industry to evaluate the properties of a material,component or system without causing damage.

NDT plays an important role in the quality control of finished goods as well as rawmaterials. Outside the manufacturing field it is also widely used for routine control ofvarious items during operation to check that whether the quality is detoriated with time ornot.

Common NDT methods used at KS&EW are:1. Visual Inspection2. Magnetic-particle Test (MPT)3. Dye penetrant Test (DPT)4. Radiographic Test (RT)5. Ultrasonic Test (UT)

1. Visual Inspection:Often overlooked in any listing of NDT methods, Visual Testing inspection is one of themost common and most powerful means of non destructive testing. It is done byobserving the test material by naked eye or under a magnifying glass. Other NDTmethods such as MPT and DPT are indeed simply scientific ways of enhancing theindication to make it more visible to naked eye.Visual Inspection cannot deduct defects under the surface that’s way other methods/testsare performed to ensure the quality of test piece or material.

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2. Magnetic-particle Test (MPT):Magnetic particle inspection (MPI) is a non-destructive testing (NDT) process fordetecting surface and subsurface discontinuities in ferroelectric materials such as iron,nickel, cobalt, and some of their alloys. This method is capable of detecting open sourceor just below the surface flaws.The process puts a magnetic field into the part. The piece can be magnetized by direct orindirect magnetization. Direct magnetization occurs when the electric current is passedthrough the test object and a magnetic field is formed in the material. Indirectmagnetization occurs when no electric current is passed through the test object, but amagnetic field is applied from an outside source. The magnetic lines of force areperpendicular to the direction of the electric current which may be either alternatingcurrent (AC) or some form of direct current (DC).The presence of a surface or subsurface discontinuity in the material allows the magneticflux to leak. Ferrous iron particles are applied to the part. The particles may be dry or in awet suspension. If an area of flux leakage is present the particles will be attracted to thisarea. The particles will build up at the area of leakage and form what is known as anindication. The indication can then be evaluated to determine what it is, what may havecaused it, and what action should be taken if any.

3. Dye penetrant Test (DPT):Dye Penetrant Test (DPT), also called Liquid Penetrant Test (LPT) or PenetrantTesting (PT), is a widely applied and low-cost inspection method used to locate surface-breaking defects in all non-porous materials (metals, plastics, or ceramics). The penetrantmay be applied to all non-ferrous materials and ferrous materials, but for inspection offerrous components magnetic-particle inspection is also preferred for its subsurfacedetection capability.LPI is used to detect casting, forging and welding surface defects such as cracks, surfaceporosities, and leaks in new products, and fatigue cracks on in-service components.First the surface to be test is cleaned with a dry cloth or cotton piece to remove the dustparticles. The penetrant usually red in color is applied and allowed to set. The particles ofthe penetrant get into the cracks on the surface. The surface is cleaned again this putting asmall quantity of cleaner on a piece of cloth or cotton and then smoothly cleaning thesurface with it. The contrast color usually white is applied on the surface and allowed to

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dry out. This material brings out penetrant red particle from with-in cracks and the whitecontrast makes it easy to observe.

1. Penetrant application to the Section of materialwith a surface-breaking crack that is not visibleto the naked eye.

2. Excess penetrant is removed.3. Developer is applied to the surface.4. Inspection for the presence of discontinuities.

Advantages:

1. The main advantages of DPI are the speed of the test and the low cost.

2. Limited training is required for the operator — although experience is quitevaluable.

Disadvantages:

1. The main disadvantages are that it only detects surface flaws and it does not workon very rough surfaces. Also, on certain surfaces a great enough color contrastcannot be achieved or the dye will stain the work piece.

2. Proper cleaning is necessary to assure that surface contaminants have beenremoved and any defects present are clean and dry. Some cleaning methods havebeen shown to be detrimental to test sensitivity, so acid etching to remove metalsmearing and re-open the defect may be necessary.

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4. Radiographic Test (RT):Radiographic Testing (RT), or Industrial Radiography (IR), is a Non-DestructiveTesting (NDT) method of inspecting materials for hidden flaws by using the ability ofshort wavelength electromagnetic radiation (high energy photons) to penetrate variousmaterials.

Either an X-ray machine or a radioactive source (Ir-192, Co-60, or in rare cases Cs-137)can be used as a source of photons. Neutron radiographic testing (NR) is a variant ofradiographic testing which uses neutrons instead of photons to penetrate materials. Thiscan see very different things from X-rays, because neutrons can pass with ease throughlead and steel but are stopped by plastics, water and oils.

Since the amount of radiation emerging from the opposite side of the material can bedetected and measured, variations in this amount (or intensity) of radiation are used todetermine thickness or composition of material. Penetrating radiations are those restrictedto that part of the electromagnetic spectrum of wavelength less than about 10 nanometers.

The Radiographic Testing (RT) method is used for the detection of internal flaws in manydifferent materials (especially in joints between materials i-e welding). An appropriateradiographic film is placed behind a test specimen and is exposed by passing either X-Rays or Gamma-Rays through it. The intensity of the X-Rays or Gamma-Rays whilepassing through the product is modified according to the internal structure and thicknessof the specimen and thus exposed film, after processing, reveals the shadow picture,known as Radiograph of the product. It is then interpreted to obtain data about the flawspresent in the specimen. This method is used on wide variety of products such asforgings, castings and weld-ments.

Safety:

Industrial radiography appears to have one of the worst safety profiles of the radiationprofessions, possibly because there are many operators using strong gamma sources (> 2Ci) in remote sites with little supervision when compared with workers withinthe nuclear indu

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Weld Position: FlatMaterial: SteelWeld Process: Arc WeldingRadiography: ≤145 KVType of Discontinuity: Slag inclusion

5. Ultrasonic Test (UT):

In Ultrasonic Testing (UT) a high frequency sound waves are introduced into thematerial being inspected. Most ultrasonic inspection is done at frequencies between 0.5and 20 MHz, Well above the range of human hearing which is about 20 to 20,000 KHz.

The sound waves travel through the material with some attendant loss of energy(attenuation) due to material characteristics. The intensity of sound waves is eithermeasured, after reflection (Pulse Echo) at intensities (or Flaws) or is measured at oppositesurface of the specimen (Pulse transmission). The reflected beam is detected and

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analyzed to define the presence and location of flaws. The degree of reflection dependslargely on the physical state of matter on the opposite side of the interface, and to a lesserextent on specific physical properties of that matter, for instance, sound waves are almostcompletely reflected at metal-gas interfaces. Partial reflection occurs at metal liquid ormetal solid interfaces.

Ultrasonic testing has a superior penetrating power than radiography and can detect flawsdeep in the specimen, almost up to 6 to 7 meters of steel. It is quite sensitive to smallflaws and allows the precise determination of the location and size of the flaws.

Ultrasonic testing is often performed on steel and other metals and alloys, though it canalso be used on concrete, wood and composites, albeit with less resolution. It is a formof non-destructive testing used in many industries including aerospace, automotive andother transportation sectors.

Advantages:1. High penetrating power, which allows the detection of flaws deep in the part.2. High sensitivity, permitting the detection of extremely small flaws.3. Only one surface need be accessible.4. Greater accuracy than other nondestructive methods in determining the depth of

internal flaws and the thickness of parts with parallel surfaces.5. Some capability of estimating the size, orientation, shape and nature of defects.6. Nonhazardous to operations or to nearby personnel and has no effect on

equipment and materials in the vicinity.7. Capable of portable or highly automated operation.

Disadvantages:

1. Manual operation requires careful attention by experienced technicians2. Extensive technical knowledge is required for the development of inspection

procedures.3. Parts those are rough, irregular in shape, very small or thin or not homogeneous

are difficult to inspect.4. Surface must be prepared by cleaning and removing loose scale, paint, etc.,

although paint that is properly bonded to a surface need not be removed.5. Inspected items must be water resistant, when using water based couplants that do

not contain rust inhibitors.

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Quality Assurance:

Quality assurance, or QA for short, is the systematic monitoring and evaluation of thevarious aspects of a project, service or facility to maximize the probability that minimumstandards of quality are being attained by the production process. QA cannot absolutelyguarantee the production of quality products.Two principles included in QA are: "Fit for purpose" - the product should be suitable forthe intended purpose; and "Right first time" - mistakes should be eliminated. QA includesregulation of the quality of raw materials, assemblies, products and components, servicesrelated to production, and management, production and inspection processes.

Works Of QA:1. The QA department does the following:2. Monitoring the implementation of Quality Management System through out the

organization.3. Planning and scheduling of internal and external audits.4. Initializing NCR IQA (Non Conformity Report of Internal Quality Audit).5. Arranging follow up audit through auditors to verify the implementation and

correctiveness of the corrective actions.6. Planning and scheduling the Quality Council meeting to review.7. Customer’s feedback.8. Follow up of previous management review.9. Changes that could affect the Quality Management System

And10. Weak areas and recommendations for improvement.

Steps for a typical quality assurance process:There are many forms of QA processes, of varying scope and depth. The application of aparticular process is often customized to the production process.A typical process may include:

test of previous articles plan to improve design to include improvements and requirements manufacture with improvements review new item and improvements test of the new item

Company Quality:During the 1980s, the concept of “company quality” with the focuson management and people came to the fore. It was realized that, ifall departments approached quality with an open mind, success was possible if themanagement led the quality improvement process.

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The company-wide quality approach places an emphasis on four aspects:-

i. Elements such as controls, job management, adequate processes, performance andintegrity criteria and identification of records

ii. Competence such as knowledge, skills, experience, qualificationsiii. Soft elements, such as personnel integrity, confidence, organizational

culture, motivation, team spirit and quality relationships.iv. Infrastructure (as it enhances or limits functionality)

The quality of the outputs is at risk if any of these aspects is deficient.QA is not limited to the manufacturing, and can be applied to any business or non-business activity:

Design work Administrative services Consulting Banking Insurance Computer software development Retailing Transportation Education

It comprises a quality improvement process, which is generic in the sense it can beapplied to any of these activities and it establishes a behavior pattern, which supports theachievement of quality.This in turn is supported by quality management practices which can include a numberof business systems and which are usually specific to the activities of the businessunit concerned.In manufacturing and construction activities, these business practices can be equated tothe models for quality assurance defined by the International Standards contained inthe ISO 9000 series and the specified Specifications for quality systems.In the system of Company Quality, the work being carried out was shop floor inspectionwhich did not reveal the major quality problems. This led to quality assurance or totalquality control, which has come into being recently.

ISO 9000:

KS&EW has pioneered implementation of Quality Management System ISO 9000 inPakistani industry. The decision of ministry of defense to build AGOSTA 90B submarinein Pakistan with the collaboration of French shipyard encouraged KS&EW managementto obtain ISO 9000 International Quality Standard Certification for SWCD, which hasnow merged with Ship-Building (SB) division. After effective implementation of ISO9000 Quality Management System in SWC Division which was certified in 1997,KS&EW Management decided to extend the coverage of ISO 9000 QMS scope to otherdivision of KS&EW.Therefore the next divisions which qualified for ISO certification were GED (GeneralEngineering Division) certified in 1999, SBD (Ship-Building Division) in 2000, and

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finally SRD (Ship-Repair Division) in February 2002. Now the ISO 9001:2008certification for all above division has been renewed in November 2008.

Certification:ISO does not itself certify organizations. Many countries have formed accreditationbodies to authorize certification bodies, which audit organizations applying for ISO 9001compliance certification. Although commonly referred to as ISO 9000:2000certifications, the actual standard to which an organization's quality management can becertified is ISO 9001:2008. Both the accreditation bodies and the certification bodiescharge fees for their services. The various accreditation bodies have mutual agreementswith each other to ensure that certificates issued by one of the Accredited CertificationBodies (CB) are accepted worldwide.

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Level I: Quality System Manual:

1. The Quality System Manual is a first level document outlining the Quality Policy,Quality Objectives and Structure & general principles of operation of QualitySystem.

2. The Quality System Manual shows how KS&EW intends to meet therequirements of ISO 9001:2000 and now the ISO 9001:2008 standards.

3. The Quality System Manual is a controlled document and is issued throughQuality Assurance (QA) department to relevant departments/sections.

Level II: Quality System Procedures (system Element Procedures):

1. KS&EW has developed more detailed second level document i-e System ElementProcedures.

2. The Quality Management System Procedures specify what has to be done, bywhom, how and when will it be done with-in the scope of the QualityManagement System.

3. All Quality Management System Procedures have a common format whichincludes purpose of the procedure, scope and the detailed step by step instructionin accordance with the ISO 9001:2008 standard. A list of all forms andappendices are included at the end of these procedures.

Level III: Work Instructions/ Process and Inspection Procedures:

1. KS&EW has developed more detailed third level documents.2. The work instructions are detailed instructions, which are easily understandable

and only address the task/work to be performed.3. The work instructions are written for a specific task/inspection and testing

methods/procedures, any special jobs, in order to simplify the operation of thatparticular task/work.

Level IV: Applicable Standards, Products Drawings, TechnicalSpecifications, Forms, Check Sheets and Quality Records:

KS&EW has forth level documents to support Quality System Procedures and the WorkInstruction.

Due to the high effectiveness of the ISO 9000, and ISO 9001:2000 QualityManagement System, KS&EW Management has now achieved certificationagainst ISO 9001:2008 version. This new version of KS&EW ‘QualityManagement System Manual’ has been prepared which outlined the QualityManagement System in KS&EW based on ‘Process Approach’.

***** *****

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Ship Building Hall:Ship-Building Hall (SBH) is the 1st important part of theship building process. It is the place where construction ofShip-Building starts. Ship-Building is also known asFeeding Shop.This hall is divided into four sections, namely;

1. CC-521 (Short Blast Section)2. CC-522 (Forging Shop)3. CC-523 (Marking Section)4. CC-524 (Cutting and Bending Section)

1. CC-521 (Short Blast Section):

This is also known as short blast plant. Drawings are issued from the design officethrough planning department. According to the drawings material is taken from the mainstore. The materials (i-e steel plates) are brought from the steel-yard situated at the cornerof the SBH. Electromagnets or mobile cranes move the materials directly from one end toother, or materials are moved through conveyer belts. The materials are first moved to theshort blast plant where steel plates (materials) are forcefully hit through mild steel balls,this remove and cleans all the contaminants (usually rust) from the metal plates. Aftershort blasting worker coat the sheets with primer to protect it from decay.

1. Short Blast Plant Plate Breath 1 m – 3 mPlate Thickness 4 mm – 50 mm

2. 13 Roller Straightening Machine Up to 15 mm Straight3. Johns Mobile Crane (02) Cranes 25 Ton Each4. Over Head Crane (02) Cranes 10 Ton Each

Machinery list of CC-521

2. CC-522 (Forging Shop):

This portion is also known as forging shop. After sheets have been cleaned they aremoved to the forging shop. In SBH both types of forging (i-e cold and hot forging) aredone. According to the design the sheets are shaped.

1. Profile Bending Machine Capacity 500 Ton2. Light Profile Bending Machine - - - - -3. Face Plate - - - - -

Machinery list of CC-522

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3. CC-523 (Marking Section):

After all the work is done on metal sheets as required, then it is marked with number, sizeand other vital information, now the sheet part is ready and sent to the cutting andbending where the cutting and bending of these sheet are carried out as required.

4. CC-524 (Cutting and Bending Section):

This portion is also called cutting and bending shop. Here the sheets are cut and bentaccording to the issued drawings, and marking done in Marking Section in this sectioncutting usually done by gas cutting process known as oxy-cutting for which a mixture ofoxygen, methane and acetylene is used.

1. Water Plasma Cutting Machine (See Picture)*****2. CNC Cutting Machine

(Oxy & Plasma)Sicomat Cutting Machine Scale # 1:10Omnimat Cutting Machine Scale # 1:10

3. Pieorex Oxy Cutting Machine Optical Cutting Machine Scale # 1:1(See Picture)*****4. French Oxy Cutting Machine

5. Edge Planner Machine To make the Bevel

6. Hydraulic Press Machine Capacity 850 TonCapacity 300 Ton

7. Shearing Machine Cutting Capacity Up-to 10 mm

Water Plasma Cutting Machine

Optical Cutting Machine CNC Cutting Machine

***** *****

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Conclusion:

We have completed our Internship in the Karachi Shipyard and EngineeringWorks Limited.

During this short time we interned in the mention departments at KS&EW.Despite the short stay in each department, we learned a lot from each one ofthem.

In our short time, we observed that KS&EW is a well organized Industry,Each of its department is connected with each other by formally andworking in very good coordination. Each kind of facility forproduction/Sheet body fabrication is available in KS&EW.

As for trainees, we don’t think that any organization is better than KS&EWbecause each person from worker to management is too much trained andcooperative. We gain a lot of technical knowledge from KS&EW which wewill never forget and also this will help us a lot in our professional life.

We are too much thankful to KS&EW employees, for great cooperationwith us during our internship…………………………………..

***** *****