Kul-24.
4130
Shipyard engineering
Lecture 6-1: Outfitting
Applied Mechanics
Marine Technology
Lecture in course contents
Production
planning
Introduction
This image cannot currently be displayed.
Shipbuilding process and
ship yard productivity
Outfitting
Design process
and materials
management
Hull production
Objectives, contents and literature
Learning objective:
Understand the main factors that affect the outfitting production
Can create a product hierarchy of outfitting
Can determine the appropriate sub-assemblies for outfitting
production
Contents:
Product hierarchy for outfitting
Construction method Productization - Work breakdown
structure - product hierarchy
Stages of outfitting production
Workshops - block outfitting - area outfitting
Literature
Laivatekniikka. Risnen toim., 2000
Ship production, Storch et al., SNAME
Starting point for Productization
What factors have an effect?
System-based Work Breakdown Structure
System-based construction method
The ship is seen to composed of
systems
E.g. hull, propulsion, air conditioning,
cabins
The hull is constructed first
almost completed
Number of professional groups
make their own sub-system on
broad at same time
challenges:
All unfinished until the end
(Readiness %?)
Fighting between professional
groups and labor leaders
Drawings based on systems
Area-based Work Breakdown Structure
Area-based construction method
The ship is constructed area
by area
Area supervisor is a key
Multi-professional skills are
required
System aspects are suffered
Construction is fragmented
Responsible for commissioning
and operation is not clear
Training and exact definition
for responsibilities are
necessary
Area and system interaction
The ship may include
System, which serves only one area
System, which serves one or a few areas. Part of system can
be located outside the area (for example, air conditioning
aggregate)
System that runs through the area without serving it
System, which is located on the border of area
Alternative solutions for design
Avoid system, which runs through the area without serving it
Minimizing the disturbing effects (routing, space reservations)
Utilization of product hierarchy (Installation box")
Product, what is it?
A part of the ship
Any work package (working place)
The product has a content and definition
It is always associated with the input and output
(interfaces)
Examples:
Hull production
- Ship
- Aft ship
- Block
Outfitting production
- Area or space
- Cabin
- Separator module
Productization
Target of productization
Dividing of the ship into the sub parts, which can be
manufactured by the yard or someone else as cheaply as
possible
Criteria for productization
It should be appropriate for the yard's activities; steel
construction in most cases the common factor
Manufacturing constraints (recourse and time)
Productization
Technical aspects on the basis of ship project
System-area matrix
Passing through system
Suppliers and sub-contractors
Supply, competition
Design process
Agreement in the various design stages
Production control
Transport technology
Ship product hierarchy
GA
Ship
Zones
Hull
System
Ship product hierarchy
Ship General arrangement
Ship product hierarchy
Ship Zone, Hull, Systems
Product hierarchy for the restaurant roof
Ravintola NN
Shkjrjestelmt
Kansi xx
IV jrjestelmt
LV jrjestelmt
Product hierarchy for the restaurant roof
Product hierarchy for the restaurant roof
Product hierarchy for outfitting
Basic elements
Prefabricated
Device such as a pump or electric central
Equipment such as suction filter, sensor or
switch
The raw material such as pipe or steel rod
(6m)
The lowest level of assembly manufactured
from raw materials based on the ship-related
drawings
Rectangular channel, platform, pipe support
Assembly
Modules, which are installed into blocks or
areas of the ship
Consist of devices, equipment, raw materials,
prefabrications, and sub-assemblies
Pipe package, container, aggregate, machine
module
Sofa, bar desk, wall or roof element, cabin,
deckhouse of cargo ship
Product hierarchy for outfitting
Basic elements
Pre fabrication
Prefabricated
Device such as a pump or electric central
Equipment such as suction filter, sensor or
switch
The raw material such as pipe or steel rod
(6m)
The lowest level of assembly manufactured
from raw materials based on the ship-related
drawings
Rectangular channel, platform, pipe support
Assembly
Modules, which are installed into blocks or
areas of the ship
Consist of devices, equipment, raw materials,
prefabrications, and sub-assemblies
Pipe package, tank, aggregate, machine
module
Sofa, bar desk, wall or roof element, cabin,
deckhouse of cargo ship
Assembly
Machine unit (aggregate) - Example
Product hierarchy for outfitting
Prefabrication
Product hierarchy for outfitting
Block
In perfect case, the internally fully equipped assembly
unit
Block-boundary outfitting connects the fully outfitted
blocks to each other using raw materials and fitting
part
Area
In practice the assemblies, prefabrications,
equipment, devices, and raw materials are installed
on board
Class room assignment
Crew cabin area
1. Identify the factors
affecting the
productization
Area versus system
Etc...
2. Specify the product
hierarchy
Basic elements
Prefabrications
Assemblies
Stages of outfitting production
Workshops
Basic elements
Prefabrications
Block outfitting
Basic elements
Prefabrications
Assemblies
Ship and area
outfitting
Basic elements
Prefabrications
Assemblies
Workshops
Traditional workshops
at the shipyard
Machine workshop
Pipe workshop
Module workshop
Heavy plate workshop
Sheet metal workshop
Wood workshop
Electrical workshop
Rigging workshop
Workshops today
in co-operation with suppliers
Subcontractor for contract products
Subcontractor has specialized
workshops for their products
Shipyard has had only basic
equipment and workers
Co-operation is based on annual
contracts
Shipyard workshops support the
installation work
Installers operates
Close to the working place
Fitting pars (e.g. special pipe parts)
Extension of equipment delivery
Deliveries includes workshop work
Block outfitting - motivation and savings
In shipbuilding, the amount of
installation work is decreased
when the work is transferred
to an earlier production stage.
This decrease can be roughly
estimated as follows:
Production stage
Machine unit construction
Module construction
Panel block outfitting
Block outfitting
Area outfitting
Coefficient
1.0
1.2
1.5
2.0
4.0
Advantage of block outfitting
Good working environment
Opportunity to maximize the
downhand installation
Workshop conditions: warm,
lighting, ventilation
Easier transportation of the
material and tools to the work
site (closeness and openness)
Other benefits
Lesser need for repair painting
Reduction of the scaffold and
other supporting work
Better balancing of outfitting
work
Small disturbances due to other
workers
Disadvantages of block outfitting
Production of block is started earlier
Design for outfitting is started earlier (increase)
Block size restrict the outfitting design
Block division and block size is affected by outfitting
aspect
Increased block weight affects the transport
Accuracy requirements for the block installation is higher
than that of the onboard installation
Risk for the broken equipment is increase
Labor and material costs are committed earlier
Stage of block outfitting
Parts manufacturing (OVA)
Before the painting to sub-block (EMO)
Installations into the pre-painted blocks (A separate production step)
Before the painting (EM)
During the manufacturing of panel block (Block is located top to down)
After the painting to sub-block (JMO)
During the manufacturing of sub-assembly, e.g. windows installation
During the manufacturing of grand block (Block is located right side up)
After the painting (JM)
Installations into the painted grand block (A separate production step)
Production step between the block production and hull erection
(Abbreviation used in Helsinki shipyard)
