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Introduction
Week 1
A.Y.Odaba 2009
The main aim of this module is to equip students with methods and tools for
production of marine vessels. The objectives of the class are as follows:
Students will:
A.Y.Odaba 2009
Course Outline
Subjects
Introduction to class. Building methods, ship
structures, Product Work Breakdown
Structure (PWBS), Group Technology
Planning and scheduling Costing and value
engineering
Lecturers
Week 1
3 February
Week 2
10 February
Week 3
17 February
Week 4
24 February
Sedef Tersanesi
Fahri Arsoy
Sedef Gemi naat A..
Tuzla/stanbul
Tel.0216 395 4741
Fax. 0216 395 4740
Tanju Kse
Week 6
10 March
Welding procedures,
Inspection of hull welding, destructive and
non-destructive testing etc.
Activities of classification societies
Week 7
17 March
Marine Equipments
(Site Visit)
Week 5
3 March
A.Y.Odaba 2009
Title
AYO
AYO
IHH
Trk Loydu
Hasan Habibolu
Trk Loydu Vakf
Tuzla/stanbul
Tel.0216 446 22 40
Fax.0216 446 22 46
Grdesan, Gebze
Mustafa Grsoy,
Tel.0262 724 8546
Fax.0262 724 8554
Week 8
A.Y.Odaba 2009
Week 9
31 March
Week 10
7 April
EXAM
Mid-Term examination
(Multiple choice / Books open)
Week 11
14 April
Week 12
21 April
Week 13
28 April
General outfitting,
Subcontractors work,
Installation priorities, shafting, propellers,
piping, electrical installations
Week 14
5 May
Review
D311
EXAM
Oerlikon
Hac Doluta
Oerlikon Kaynak
Elektrotlar ve
San.A..,Sefaky/stanbul
Tel.0212 411 1400
Fax.0212 411 1114
Hempel
Seyit Ali Dikerkol
Esra Erbagi
Marketing Department
YONTECH
Ekber Onuk
Yonca Teknik Tersanesi
Tuzla/stanbul
Tel.0216 392 9970
Fax. 0216 392 9969
Yldz Tersanesi
Baki Gkbayrak
Tel. 0216 395 4075
Fax. 0216 395 1290
IHH, AYO
IHH
Other Conditions
TERM-TIME ASSESSMENTS
Mid-Term Examination
Quiz
Assignment
Attendance
Contribution of term work on achievemet scores
Contribution of final exam scores on achievement scores
Quantity
1
4
2
:
:
A.Y.Odaba 2009
Weight (@ points)
%20
%20
%20
Compulsory
% 60
% 40
A.Y.Odaba 2009
Glossary
Cycle time
Effectiveness
Efficiency
Process
Reliability
Rework
Waste
Work
Work efficiency
A.Y.Odaba 2009
Work Efficiency
WORK
WORK + WASTE
A.Y.Odaba 2009
x 100 %
Utilization
Relation between the time when the equipment actually is used for productive time
(machine time) and the total time available
What is AVAILABLE time ?
Utilization 40 %
A.Y.Odaba 2009
15 %
15 %
Personal allowances
15 %
Technical allowances
15 %
Manual time
40 %
Machine time
Definitions
Machine UTILIZATION =
Personnel PRODUCTIVITY
Project PERFORMANCE
A.Y.Odaba 2009
MACHINE TIME
TOTAL AVAILABLE TIME
USED MANHOURS
TOTAL QUANTITY
ALLOCATED MANHOURS
USED MANHOURS
Process Re-enginering
The goal: is to decrease the the amount of waste in any work process
Before
Work
A
Waste
Work
After
Waste
Work
Work
B
Waste
A.Y.Odaba 2009
Waste
More work
in the same
amount of time
Same amount
of work
in much
less time
Efficiency
Reliability
zzzz
z z
Cost
A.Y.Odaba 2009
3h 25 min.
1h 15 min.
$ 55 per output
$ 36 per output
Plate
Cutting
Plate
Forming
Curved Panel
Line
Profile
Forming
Steel
Stockyard
Shotblasting &
Priming
Web & Comp.
Line
Profile
Cutting
Block
Construction
Miscellaneous
Assemblies
Large Panel &
Double Bottom
Line
Small Panel
Line
A.Y.Odaba 2009
Ship
Hull
Structure
Hull Form
Shell
Plating
Bulkheads
Machinery
Decks
Outfit
------
Main
Machinery
Auxiliary
Machiney
------
Piping
Frame
Body Plan
A.Y.Odaba 2009
Profile &
Buttocks
------
------
HVAC
Mechanical
Electrical
------
A.Y.Odaba 2009
A.Y.Odaba 2009
What 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 Strategy
An agreed design, engineering, materials management,
production, planning and testing plan
prepared before the work starts
so as to identify and integrate
all the necessary processes [T.Lamb, 1996]
A.Y.Odaba 2009
Type of work
Hull construction
Outfitting
Painting
Resources
Material
Manpower
Facilities
Control of
Production
Process
A.Y.Odaba 2009
Product Work
Breakdown Structure
(PWBS)
Hull Block
Construction Method
(HBCM)
A.Y.Odaba 2009
HMCM
ZOFM
Blocks:
simple & logical boundaries
min. number of blocks
provide min. scaffolding
provide max. accessibility
On-unit
On-block
On-board
ZPTM
PPFM
Classifies pipe-pieces
Organized independently of the hull structural block
A fabrication process rather than the assembly work of HBCM/ZOFM/ZPTM
A.Y.Odaba 2009
HMCM
ZOFM
ZPTM
PPFM
A.Y.Odaba 2009
Hull
Erection
Grand-block
Joining
Block
Assembly
Semi-block
Assembly
Sub-block
Assembly
Part
Assembly
Part
Fabrication
Part
Assembly
Part
Fabrication
A.Y.Odaba 2009
Part
Fabrication
Sub-block
Assembly
Part
Assembly
Part
Fabrication
Part
Fabrication
Part
Assembly
Part
Fabrication
Part
Fabrication
Produce non-subdividable
Part
Fabrication components&piece parts;
work stages: marking,
cuting & bending
A.Y.Odaba 2009
Parts Fabrication
Marking
Line Heating
A.Y.Odaba 2009
Press Bending
(courtesy NSNet Shipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo)
Sub-Block Assembly
Welding a sub-block
Palletized sub-assemblies
awaiting block assembly
A.Y.Odaba 2009
(courtesy NSNet Shipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo)
Block Assembly
Hull Erection
A.Y.Odaba 2009
(courtesy NSNet Shipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo)
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Operation
& Test
On-board
Outfitting
On-block
Outfitting
Semi-block
Assembly
Grand-Unit
Assembly
Unit
Assembly
Component
Procurement
Unit
Assembly
Component
Procurement
A.Y.Odaba 2009
Component
Procurement
Grand-Unit
Joining
Unit
Assembly
Component
Procurement
Component
Procurement
Unit
Assembly
Component
Procurement
Component
Procurement
Component
Procurement
Outfit Components
Ventilation ducts
A.Y.Odaba 2009
(courtesy NSNet Shipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo)
On-Unit Outfitting
A.Y.Odaba 2009
(courtesy NSNet Shipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo)
On-Block Outfitting
Fitting out of
ventilation-duct pieces
(courtesy NSNet Shipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo)
On-Board Outfitting
On-board outfitting
On-board outfitting
A.Y.Odaba 2009
(courtesy NSNet Shipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo)
A.Y.Odaba 2009
(courtesy NSNet Shipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo)
30 pipe pieces
5 walkway sections +
handrail
8 supports
A.Y.Odaba 2009
(courtesy NSNet Shipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo)
Finish
Paint
Finish
Under-coat
Paint
Primer
A.Y.Odaba 2009
Primer
Primer
Shop
Primer
Shop
Primer
Finish
Under-coat
Paint
Primer
Unit
Assembly
Shop
Primer
Application of
anti-corrosive paints
Surface preparation
and primer coating
for plates and sections
Zone Painting
(courtesy NSNet Shipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo)
Palletizing
Coating
Testing
Pipe Piece
Assembly
Pipe
Fabrication
Pipe
Fabrication
Pipe
Receiving
Pipe
Receiving
A.Y.Odaba 2009
Testing
Pipe Piece
Joining
Pipe Piece
Assembly
Pipe
Fabrication
Pipe
Receiving
Pipe
Receiving
Pipe
Receiving
Different arriving
materials are grouped
according to the
type of material
PPFM Classification :
Straight
PPFM Classification:
Unit assembled
Palletizing areas
(courtesy NSNet Shipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo)
Principle Event
Schedule
Block Erection
Master Schedule
Block Assembly
Master Schedule
On-board Outfitting
Master Schedule
On-unit Outfitting
Master Schedule
On-block Outfitting
Master Schedule
Monthly Schedule
Monthly Schedule
Monthly Schedule
Weekly Schedule
Weekly Schedule
Weekly Schedule
A.Y.Odaba 2009
A.Y.Odaba 2009
Producibility
A.Y.Odaba 2009
A.Y.Odaba 2009
(courtesy NSNet Shipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo)
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11
(courtesy NSNet Shipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo)
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13
(courtesy NSNet Shipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo)
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15
(courtesy NSNet Shipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo)
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19
(courtesy NSNet Shipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo)
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22
(courtesy NSNet Shipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo)
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22
(courtesy NSNet Shipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo)
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24
(courtesy NSNet Shipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo)
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24
(courtesy NSNet Shipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo)
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27
(courtesy NSNet Shipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo)
28
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(courtesy NSNet Shipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo)
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(courtesy NSNet Shipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo)
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(courtesy NSNet Shipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo)
A.Y.Odaba 2009
(courtesy NSNet Shipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo)
Launching
43
Start
Fabrication
A.Y.Odaba 2009
Keel Laying
workdays in
building dock !!!
Delivery
End of Week 1
Questions ?
A.Y.Odaba 2009