NAME : LINGGESWA L INGGESWARAN RAN A/L JAGANATHAN
ID NO : 56280113134
SUBJECT : SHIPYARD SHIPYARD MANAGEMENT AND PROJECT PLANNING
TOPIC : INDI!IDUAL ASSIGNMENT
SUBJECT CODE : LGB 20303
LECTURER NAME : EN A"I" ABDULLAH
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An ideal layout of modern shipyard is based on a production flow basis, with the yard extending back from the river or shore at which the berths or building docks are located. The farthest area from the berths is reserved for the material stockyard and between the two is arranged in sequence the consecutive work and shop processes. Too often existing shipyards follow the river bank and are constrained by their location in a built up area or the physical river bank slope from extending back from the river. Therefore, modified production flow lines are required. Plan for the shipyard will involve decisions to be made from the following: • • • • • • • •
i!e and type of the ship to be built "aterial production per year to be achieved "aterial handling equipment to be supplied "achining processes to be installed #nit si!e and weight to be fabricated and erected Amount of outfits and engine installation to be undertaken $ontrol services to be supplied Administration facilities required
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%. The space for arranging the building blocks of ship which is under construction. The ma&or problem that affects the safety and smooth workflow on shipyard is because of paucity of space for arranging the building blocks of ship under construction. Therefore, a standardi!ed erection sequence diagram is generally available to provide the prioriti!ed erection sequence and it serves as the frame work. 'n order to make a timely erection of the blocks a post plan has to be developed, so that the blocks lie in the nearest possible vicinity of the material handling devices while keeping the priority of erection and the blocks are arranged in the pre(erection area. This kind of readiness of blocks leads to a very complex problem of space. This arises due to the least available space leading to an urgent need for intelligent spatial schedule without compromising the rate of production. There exists two critical problems ahead namely, the spatial occupation layout of pre(erection area and the evacuating pattern in the spatial vicinity. The block shape is assumed be rectangular. The related input data)s are the dates of erection *earliest as well as the latest+, geometrical parameters of block available on pre(erection area, slack time and the like. orld over industrial engineers and decision makers are brainstorming hard to find an ideal solution for their unique problems. -very scheduling and decisional problems end up in complicated iterative loop system.
. orking $ondition hipyard workers working locations are categori!ed as one of the most risky working surroundings. This not only adds the problems to their &ob but actually makes it a work profile full of need for constant caution. hipyards are not one of the most
comfortable places to work in because there is a constant danger in everything they does and also ha!ardous to their health. There are several precautions that need to be taking in count. ometimes it is extremely dangerous to work in cramped space while at other times. As an example, due to fewer places to stand and work one misstep from the high place can cause serious in&ury or even death. The cramped spaces *enclosed spaces+ are one of the riskiest places to be working in. A shipyard worker, while working in such tiny spaces is often at risk of physical in&uries to limbs, head or other body parts along with more serious troubles like suffocation, asphyxiation etc. -xtreme nature of working conditions of shipyard workers is the first problem they face. Also, the high pressure in such tiny spaces can often cause much more grave and permanent damage like eardrum rupture. hipyard workers often complain of problems to their hearing abilities due to working constantly under high pressure conditions. /esides that, working in shipyards are not as the same as one working in office where they can go back on time. There are no fixed timings. The extreme nature of their &ob means the workers have to be available at all times. The unpredictable time schedules make this &ob harder than it already is, and definitely adds to the woes of workers. ometimes they even have to work for several hours together without much rest.
0. "achinery and "aterial 1a!ard hipyards are the places where work happens at a big scale. The machinery used is huge, often requiring immense skill and strength to be handled. A minor divergence while working at such machinery can corroborate to be extremely fatal for any shipyard worker. The seriousness of in&ury can be as loss of life. 'n some cases, records of workers having been gravely in&ured date back to as early as %2345s, where ship construction
really took off all over the world. $onstant danger posed by the heavy machinery is what is third problem faced by shipyard workers. Asbestos is used as one of the construction materials for most ships even till today. hipyard workers involved in work of manufacturing of ships and even those not specifically into that particular aspect of shipyard &obs often receive extremely high exposure to asbestos, making them quite vulnerable to diseases caused by it. Asbestosis, along with mesothelioma which can cause cancer caused exclusively by asbestos exposure are very serious diseases found mostly in workers working in close proximity to this substance. 't is one of the biggest problems faced by workers working in the ship industry especially so since there is still no perfect solution to this problem. 6ne of the bigger problems with this particular aspect of &ob is that the symptoms caused due to exposure to asbestos can surface even after many years. 7eports of these symptoms showing up in a person up to 84 years after exposure to it have been found. This adds a whole new dimension to this problem making it much more serious.
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A perfect layout of this shipyard is indicated in 9igure.% which might be appropriate for a small yard speciali!ing in one or two standard type of ships with a fairy high throughput so that one covered building dock or berth was sufficient. At this point, it may be convenient to mention the advantages and disadvantages of building docks as opposed to building berths. /uilding docks can be advantage in the building large vessels where launching costs are high and there is a possibility of structural damage owing to the large stresses imposed by a conventional launch.
The yard also gives good crane clearance for positioning units. The greatest disadvantage of the building dock is its high initial cost. "any yard reconstructions and upgraded have incorporated undercover construction facilities in the form of docks or slipways within the building halls. 6thers have building halls at the head of the slipway with advanced transfer systems installed so that the hull can be extruded out of the hall onto the slipway for launching. uch facilities permit ship construction in a factory type environment providing protection from the worst effects of weather and darkness. The shipyard in this case is located on the area of %0. hectares and in addition encompasses .8 hectares of water surface area with the depth of 3 meters. This allows the access of river(sea vessels of no more than %4,444 T with empty ballast. "a&or shipyard equipment includes: •
;8% m of mooring lines equipped with compressed air lines, water supply, power
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supply as well as berth cranes with capacities of % 4, 4 and 8 tones 9loating dock allowing to perform the repair of vessel underwater parts with docking
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weight ,444 t, length %%8 m, width %< m and draft 8 m= The slipway allowing repairs of vessels with weight up to %,444 tones and length up to ;4 m.
The current arrangement of the shipyard allows simultaneous repair works for 3(8 vessels of above %44 m length, on the shipyard5s land territory and a float.
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The shipyard should have the effective layout to ensure a smooth flow of work, material, and information through the system. The requirements for effective layout such as: • • • •
"inimi!e material handling costs #tili!e space efficiently #tili!e labor efficiently -liminate bottlenecks
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9acilitate communication and interaction between workers, between workers and their supervisors, or between workers and customers 7educe manufacturing cycle time and customer service time -liminate wasted or redundant movement 9acilitate the entry, exit, and placement of material, products, and people 'ncorporate safety and security measures Promote product and service quality -ncourage proper maintenance activities Provide a visual control of operations or ac tivities Provide flexibility to adapt to changing conditions
This type of shipyard is known as the process layout where it is a group of similar activities together in departments of work centers according to this process or function is that they perform characteristic of operations that serve different customers different needs. This is the most common layout for a small or medium si!e of manufactures. This typical process layout would group lathes in one area, drills in one area, milling machines in one area and so on which shown in 9igure %.
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'n order to stay competitive in the increasingly demanding commercial, military, leisure markets, and shipyard must continuously improve their overall performance and productivity. Their approach to shipyard design and development to ensure that the facilities, processes and
practices will allow the yard to achieve the level of performance required for market success. They use the same tools to analy!e the existing yards and to assist them develop effective performance improvement programs. This shipyard is internationally acclaimed the shipyard benchmarking system that are allows the processes and practices employed in shipbuilding, ship repair and naval vessel support to be quickly analy!ed, compared to international best practice and the performance improvement priorities identified. /ut still, the efficient analysis is &ust the beginning for this shipyard is improved. -ventually, the experts will assist their customers develop every aspect of the performance improvement program and then, it will transfer the necessary technology and, if required, to provide the training and operational assistance to this shipyard. They can also help to find experienced people to &oin their team for full time. They place the particular emphasis on optimi!ing the strategy and approach prior to recommending expenditure on expensive facilities and equipment. The shipyard service includes: • • • • • •
$ost structure review, financial analysis and business strategy develop ment 'ndustry benchmarking and technology profiling 6perational benchmarking and identification of technology gaps evelopment and implementation of performance improvement programs 'mplementation of modern shipbuilding and repair technology "anagement and staff retraining program
"oreover, the shipyard5s location is the important reasons why this shipyard is more competitive than the others shipyard in term of delivering the long term economic viability of the shipyard business. 't also make shipyard layout is the best layout which can access to markets, accessibility for shipping, and depth of surrounding waters, suitability of land surface and the marine environment are all factors to be considered and are crucial to the success of your shipyard development pro&ect. hen they are in the process of explore and choose the location for the shipyard, they were follow some selection criteria such as shipping traffic pattern analysis, topographic, bathymetric and ground studies, the environment impact as well as the ancillary industry and the labor availability. Therefore, the competitiveness that has been study by this shipyard has established the correlation between the use of best practice, output performance and profitability. To achieve the
desired performance, a shipyard must be correctly configured and employ appropriate processes and practices for its product mix and cost base. "ost importantly the shipyard5s benchmarking system, the best layout and the cost structures as well as the capacity models determine the overall characteristics of new and redeveloped shipyards. >ikes this shipyard which they used to specify the processes and practices required achieving market success through optimi!ing the facilities, the production technology and in p articular the pre(production technologies employed.
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/erthing arrangement refer to a place where a ship needs to tie up at alongside a wharf or a pier structure. ith regards to a shipyard, a berth is a place where a ship is moored within a shipyard5s perimeter before or after down(slipping and usually the ship is meant to undergo pre or post slipping works that cannot be done in the docks or on the slipway or further outfitting works after launching while afloat. hile berthed in the shipyard, works that require lifting operations are usually provided for shipside cranes and ship may be pulled conveniently to other nearby outfitting berths if required. >arge ships are usually launched down a slipway or flooded up in a dock where they are built. 'n the case of a shipyard with a building dock the large hull blocks that comprise the ship are assembled on a level line of building blocks which are similar to docking blocks. /uilding docks tend to be shallower than graving docks as the ship is flooded up considerably lighter than the lightship condition. #sually, the building dock has concrete ramps built into the head end of the dock to allow for the construction of more than one vessel at the same time. A docking plan must be made by the ship owner to a dock master to enable him to plan the necessary docking arrangement with regards to correct placement of keel blocks and bilge blocks to avoid placing them at the wrong places. •
"ooring lines ( is a thick rope or cable which is used to tie a watercraft in place. #sually multiple mooring lines are used on the same vessel to distribute the stress, and to act as redundant systems in case a mooring line snaps. "ooring lines may also be known as hawsers. A number of materials can be used to make a mooring line, and most marine supply companies carry an assortment of options which can be customi!ed as needed. "ooring a vessel requires some coordination.
9igure : "ooring >ines The mooring lines need to be thrown to shore, but they are sometimes too heavy and awkward to be thrown easily, especially in the case of lines used on large ships. As a result, sailors use an attachment called a heaving line, a lightweight cord which can be tossed to shore. People on shore can use the heaving line to pull the mooring line over so that the boat can be moored in place. ith a very large ship, a large crew on land may be involved to coordinate the mooring process. 9or smaller craft, a single sailor can handle mooring independently. •
lipway ? will consists a ground way and a sliding way that support the cradle on which the ship is to be launched. The slipway is constructed with concrete, wood, steel or the combination of these all materials. @round ways area is from the building space into the water. They may be permanently left in place or removed and stored between launchings.
9igure 0: lipway
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@round ways ? width is restricted by the width of the sliding ways where they are slightly wider than sliding ways. 9requently, there are only two ground ways are used for endways launches but it is possible to used more than two.
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liding ways( is a structure on which the ship travels into the water. 't is traditionally made of timber where nowadays, the ways are made from steel. The bottom edge of the sliding way and the top edge of the ground ways are usually lad in a slippery surface. A slipway provides for an inclined building berth which it is inclined at an angle and the launch way will facilitate either end launching or side launching operations.
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-nd launching( takes space and occupies areas outside of the yard during the operation of launching. The past thought that end launching was the only method of getting a ship into the water has now given way to advantages of the level building dock and the flood up method. There is the approximate number of inclination of the building berth that is 4.438(4.4<8 to %.444. The vessel is initially constructed on curved body blocks and center line blocks to hold the structure in place. As the structure grew, the keel block, bilge and
cribbing blocks were built around the vessel. Then, the vessel weight is transferred from the center line blocks to the launching cradle. The cradle sides are designed to slide down the launching ways into the water stern first and on the time of launching, the vessel slides backwards down the slipway on the frame until it floats by itself.
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9loating docks( are have the capability of being moved to many locations and are considered by some to be greater value for money than graving docks. 9loating docks are really ships themselves. The structure that was usually made up by the steel is mainly a set of floating tanks serviced by ballast lines to pump rooms. The floating docks is moored and submerged in the water to permit ships to enter. 't is also has the capability to be brought to a vessel that is badly damaged and unseaworthy.
The dock can be maneuvered underneath ships and has the ability to change its own trim to coincide with that of the ship to be docked. "ost floating docks have workshop, facilities and accommodation to allow full support for refit activities at the docks. The dock has its own electric power system, making it entirely independent from shore supply for all docking operations.
9igure 3: 9loating ock
9igure 8: 9loating ock
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9abrication workshop ( is a dedicated area with an assortment of equipment to make possible the creation of sheet metal and structural fabrications. 't is the place where the material will be cut, rolled, bend, pressed and others.
9igure <: 9abrication orkshop
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tockyard( is the place where the materials received from external sources such as plates, structural bars and other construction materials are kept before being conveyed or passed on to the various working bays.
9igure ;: tockyard
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$onstruction 1all ( situated ad&acent to the ship(repair facilities and features direct river access via a conventional slipway launch, or vehicular access for large modules to the dry docks. The hall offers an un(rivaled under(cover building environment allowing large steelwork units such as complete hulls or pro&ect specific modules to be constructed without environmental interference as well as the various front and side loading fork lift trucks.
9igure : $onstruction 1all •
elding orkshop ? is the place where cut parts are fabricated into sub(assemblies, all types of welding such as ""A *"anual "etal Arc elding+, @"A *@as "etal Arc elding+ and @TA *@as Tungsten Arc elding+ are carried out automatically or manually, sub(assemblies being formed into larger assemblies with compartments, piping systems and conduits for cabling and larger assemblies being formed into block assemblies or modules.
9igure 2: elding •
arehouse( is a commercial building for storage of goods. arehouses are used by manufacturers, importers, exporters, wholesalers, transport businesses, customs, etc. They are usually large plain buildings in industrial areas of cities and towns and villages. They usually have loading docks to load and unload goods from trucks. ometimes warehouses are designed for the loading and unloading of goods directly from railways, airports, or seaports. They often have cranes and forklifts for moving goods, which are usually placed on '6 standard pallets loaded into pallet racks. tored goods can include any raw materials, packing materials, spare parts, components, or finished goods associated with agriculture, manufacturing and production.
9igure %4: arehouse
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"ain 6ffice( is place that serves as the administrative center of an enterprise. This is where the management and administration staff carries out their duties.
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ecurity ? is to make sure that the shipyard materials and equipment are protected as well as to ensure the safety of the staff and monitoring of people entering or leaving the shipyard premises.
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Bard ervices ? is to ensure that the shipyard is operated smoothly such as the provision of tug boat services, transportation of materials within the shipyard, all internal technical needs such as electrical and mechanical services as well as the landscaping and cleaning services.
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Technical and -lectrical ervices ? is one of the support team on the technical matters for example engineering, drawing office, planning and control. These people don5t actually build the ships but without them the ship can5t be built.
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'n shipbuilding, the ship is built to order and is usually one(off product. This requires implementation of the unique procurement process for all the materials required and work flow requirements in the shipyard during ship construction. The procurement materials or services for the construction of ships may include the following: • • •
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raw materials such as ferrous and non(ferrous plates, bars, timbers and fiber glass paints for underwater hull, superstructure and interior sub(contract works such as installation of navigation equipment, tiling and cabling spares for ship equipment and ancillaries special tools, equipment and related spares
"aterial flowing from the warehouse to the shops and ultimately the ship is shown in 9igure %% below. 'n shipyards, there are holding places *usually open spaces+ for material to be used for work in progress *'P+. These places should be located to minimi!e travel distance and time for delivery flow by locating them closest to the point of use locations. /ut this is not always the case. ometimes the holding places are located according the available space in the shipyard. Production $ontrol *P$+ which also shown in 9igure %%, prepares work packages and orders the appropriate material required to complete the &ob and maintain even workloads throughout the various workstations within the construction process.
They are help to determine where the material will go, whether immediately to the work station, or to the holding places if craft is not ready to use it immediately. "any times the material may sit in the holding places for long extended periods because the material was not actually needed. And when it is needed, work must stop until that material is located, loaded up and then brought to the workstation. The time it takes to perform this task is dependent on the location of the holding place and its distance from the workstation or the ship. This of course
$auses a slip in the schedule for the work to be performed and time is money. Also if the material is not taken straight to the workstations or ship, then the transportation *usually trucks, possibly cranes+ will have to make multiple trips and cost the shipyard additional money.
9igure %%: /asic hipyard "aterial 9low "odel
CONCLUSION
The range of services offered by the shipyard includes repairs as well as the construction and moderni!ation of vessels. 7epair works for ships weighing up to %,444 tones comprise of: • • •
Arrangement of the defect finding and ship repair process, hip5s hull defects detection, 7eplacement of shell plating areas with deck plating framing,
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efect finding and repair of shaft lines and propellers, ship systems piping, valves and
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other fixtures, auxiliary machinery and ship electrical equipment, /uilding(up welding and mechanical treatment, "ounting and alignment of shaft lines on a vessel.
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The shipyard5s capabilities allow the various types of vessels including sea(river and sea going vessels *up to %%8 m length+, fishing vessels= dry cargo carriers and tankers used the services offered in shipyard. There is also the benefit of a good layout which may include: • • • • • •
smooth material flow reduced inventories better scheduling effective space utili!ation fewer production bottlenecks reduced material handling costs
RECOMMENDATIONS
The success of shipyard depends on the decisions that are made at the design stage. Their capability includes the process design and the others necessary such as civil, structural, mechanical and electrical systems design. /esides that, they also should have great infrastructure facilities that may include dry docks including dock gates, ship lifts, floating docks, ship launch systems, piers, quays, breakwaters, dredging, fabrication halls, and the offices.
The ultimate shipyard is design from a few people from different expertise which are later combined. This will provide all detailed shipyard infrastructure design requirements, improving performance and on how to reduce construction and maintenance costs. Prior than that, their initial concept designs will help the customers to make informed decisions before committing to the cost of final detailed facility design. The design concepts components in the best shipyard are often interchangeable, which means that the customers can combine attributes from two or more concepts to arrive at the concept of the customer5s choice.
RE;ERENCES
%. . 0. 3. 8. <.
http:CCwww.iieom.org( http:CCwww.maritime(rh.comCareas(of(expertiseCbenchmarking.html( http:CCwww.ingentaconnect.comCcontentCsnameC&spdC4%4C444444
