Stages of the Production in Fabrication Shop

Job requests comes from various avenues of the business namely: Dredging International (with Mr. Robin), Damen –Shull buster (Mr. Anish), Damen Modular Dock(Mr.Sajan and Mr.Hari),Company project-Ship Lift(Mr. Igor) and first and foremost the workshop also services six Ship Repair Managers, two Project Engineers and a Junior Engineer.

Stage 1: Communication - A job is given to the Coordinator / Supervisor by a Repair Manager, Projects Engineer or one of the above by means of a hard copy document or email (which is not the preferred option).This document is vitally important, because it describes most aspects of the job. Information appearing on this document should be as follows, Job no. , Scope of work, Managers Name, Material Grades, Date of delivery and very critically a certified drawing , hand sketch or a as per sample item. Depending on the project size a job ,job briefs should be conducted. The job information is then captured and added to the workshop progress list for monitoring and updating. This list is also circulated to monitor job progress. The scope of work is then discussed between the Coordinator and the Supervisor.

Question: How does the workshop ensure job success?

Answer: Ensure an open channel of communication is maintained with all relevant parties involved along with communication methods and be satisfied sufficient information is given to perform the necessary task.

Stage 2: Pasting down of Instruction -Supervisor then orders material in accordance to the scope of work. The Supervisor then instructs and explains to the fabricator as to which duties are to be performed and provides him with a drawing or a sketch of the job. It’s very important that the fabricator is satisfied with the information given to him, because it’s the very information that’s going to equip him on the job. The fabricator when accumulates all the necessary tools and equipment for the job. He also collects the material that was ordered by the Supervisor from the stores. In the case whereby the job performed is not carbon steel and could be stainless steel , alluminum or any other metal type for that matter the Supervisor should advice accordingly. If welding of an intricate piece or the fusion of two individual metals, a Welding Procedure is required. This is done by the Q.C. Department. In the case of a floor development the Welding Procedure assists both welder and fabricator. Once the layout and jig is completed on the floor an Inspector or Supervisor is called out to do an inspection.

Question: How does the workshop enforce quality in this stage?

Answer: Instructions given are clear and well understood. Material grades and quantities to be double checked. If the job requires special skills, then competent skilled labour should be requested accordingly. Involve the Q.C. Department in all areas of the job for both advice and constructive criticism.

Stage 3: The fit up -The third stage is when the material is cut to the size of the layout or the as per sample item. These pieces are carefully assembled and tacked into position. It’s the Supervisors responsibility to check if the fit up is as the drawing requests. Once the Supervisor is satisfied with the fit up the fabricator reinforces the tacked up piece with angle or pipe pieces. This is to minimize or reduce the chances of distortion. In this stage it is vitally important to check beveling with root penetration gaps.

Stage 4:Rootpass - In most situations the frame or structures root run is done position, this ensures that dimensions are maintained. Once root run is completed the Inspector should be called out to witness this stage, however it is difficult in the fast turnaround demand of the marine industry. The Fabrication Shop strives to meet the three critical stages of the fabrication process for Inspection namely: Layout or Jig preparation, fit up or tacked into position and final weld along with dimensional and distortion checks, the in between checks are always preferred but not always possible.

Stage 5 : Interpass - In this stage random checks are conducted by Supervisor or Inspector. Checks on weld runs, tolerance and distortion are carried out.

Stage 6 : Final Inspection – At the final stage it is vital that an Inspector conducts a full inspection of both fabricated and welded item.