SUBJECT: PRODUCTION & PROJECT MANAGEMENT (GE)

SUBJECT CODE: 15ETN152

ANSWER KEY

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 UNIT-I

2 MARKS-ANSWER KEY
1. Write a short note on production design?
Production design is the process of breaking down the initial stage of design of a product into the
design by which the product can be fabricated by the fabricator it will the translation of initial stage
design into a detailed form with all details of the product through which the fabricator of the product
will fabricate the product with ease.
2. Give an example for pre-panel fabrication?
Pre-Panel fabrication is Process of fabricating a Structural member which will be a part of a
panel. Example: assemble of shell side stringer to the shell assembly of a block in which the shell side
stringer will be a primary structural member which will be fabricated separately and then welded to
the shell unit assembly here shell is a panel and shell side stringer is the pre panel.
3. Discus about welding of two non-similar grade material?
There are many places where two non-similar grade materials welding is possible on a ship
especially where foundation of any machinery on deck has to be placed designer instead of going for
higher thickness plate of same material will opt to higher grade material of optimum thickness so such
scenario leads to welding of non-similar grade materials where few points to be taken care in such
welding are
 Edge preparation of two plates which are getting welded (as per WPQ)
 Welder qualification
 Welding process and consumables
 Pre-Process requirements like Preheating etc.
 Welding sequence
4. Define riveting?
Riveting is an operation whereby two plates are joined with the help of a rivet. Adequate
mechanical force is applied to make the joint strong and leak proof. Smooth holes are drilled (or
punched and reamed) in two plates to be joined and the rivet is inserted. Holding, then, the head by
means of a backing up bar as shown in figure, necessary force is applied at the tail end with a die until
the tail deforms plastically to the required shape. Depending upon whether the rivet is initially heated
or not, the riveting operation can be of two types: (a) cold riveting riveting is done at ambient
temperature and (b) hot riveting rivets are initially heated before applying force. After riveting is
done, the joint is heat-treated by quenching and tempering. In order to ensure leak-proneness of the
joints, when it is required, additional operation like caulking is done.
5. Discus in short about WPQ?
A Welder Performance Qualification (WPQ) is a test certificate that shows whether a welder
possesses the necessary experience and knowledge to perform the specifications of a particular weld
procedure. MES conducts destructive and non-destructive tests on a weld coupon provided by the
welder to determine whether the welder is capable of producing a good weld quality using the
welding processes, materials and prescribed procedures. Upon passing the procedure requirements, a
welder is given a qualification record (WPQR) specific to the procedure weld variables.
6. What parameters of welding does WPS gives?
The Welding Procedure Specification is a required document for all code welding. Your
customer either directly or indirectly specifies to what code your company must qualify. The WPS

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outlines all of the parameters required to perform your welding operation. In short, the WPS is the
recipe for your welding operation. It describes the following
 Welding process or processes used,
 Base materials used,
 Joint design and geometry,
 Gases and flow rates,
 Welding position and includes all of the process conditions and variables.
7. Give a sketch for nomenclature of a fillet weld?
Fillet welding refers to the process of joining two pieces of metal together whether they be
perpendicular or at an angle. These welds are commonly referred to as Tee joints which are two
pieces of metal perpendicular to each other or Lap joints which are two pieces of metal that overlap
and are welded at the edges.

8. How Panel fabrication is done give an example?

Panel is a Primary strength member which may be combination of plates stiffeners and pre-panel
or plates & stiffeners the panel is a unit assembly in block construction stage Example: Bulkhead
panel fabrication in ships block where plates are assembled first & welded then stiffeners are
assembled and welded if bulkhead has pre-panel the pre-panel is also assembled and welded then as a
whole unit the bulkhead is assembled on block.
9. In block fabrication how members levelled after assembly with deck plate?
After assembly of all stiffeners, Girders, Bulkhead and shell plate on block deck plate they are to
be levelled on the deck to maintain the evenness of the deck on top so each coroner which has to be
welded has to be marked a minimum height from deck and the same level from floor has to be marked
as a reference datum in a pillar or flor near by the block and a tube filled with water is to be held
against the level marked in the corner of structural members to be welded and other end held at the
datum or reference level gives the difference in the deck evenness which can be adjusted by the
fabricator to maintain the deck evenness.
10. Discuss about the purpose of stiffener in a panel?
The panel which is assembled on the deck acts as primary strength member which has to transfer
certain load and further transmit the load to adjacent member so when a panel like bulk head or girder
are to be placed in ship for this reason when a load is imposed on it may deform so to keep these
panel stiff and resist the deformation the stiffeners are to be welded on the panel which acts as
secondary strength member. For example, in bulkheads stiffeners like Bulb bars, L angle, T bar can be
used as stiffening members & in Girders to stiffen the web flange is provided.

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16 MARKS-ANSWER KEY
1. Briefly discus principles of design for production in ship building.
Production Design;
The detailed specification of manufactured items parts and their relationship to the whole
procedure design needs to take into account how the item will perform intended function in an
efficient safe and reliable manner.
Principle of design for Production Ship building;
Design to reduce production cost to a minimum compatible to the requirements of the vessel to
fulfil its operational functions with acceptable reliability and efficiency.
Primary objectives;
To produce a design which represents acceptable compromise between demands of performance
and production and where appropriate take into account the needs of overall repair and maintenance
To ensure that all design feature is comfortable with known characteristic of the shipyard facilities
To apply the individual design for production principle and procedures in so far as they are relevant
to particular vessel and the particulars shipyard where the vessel is to be built
Co-ordinates the inter relationship between the making electrical outfitting works with
the structure work in order to create fully integrated design.

Implementing Design for Production Procedures:

 All departments within the shipyard exist to support the production effort. Design and
drawings offices are of particular importance because so many of the early decisions they
take, irrevocably affect production activities.
 Traditionally, drafts people have been used to produce drawings, which, in effect, are
technical pictures, rather than being used to produce sets of working instructions.
 The need to provide specific workstation information to the shop floor will be achieved only
by a change of procedures within the technical office. For some time leading shipyards in
many parts of the world have subdivided contract cycle times in such a way as to allow an
extended period prior to production for detailed design, planning, and production
engineering activities.
 This has facilitated the development of design for production techniques and procedures. The
short production cycle time characteristic of those shipyards requires a longer design lead
time to carry out the necessary technical work; as a result, overall contract cycle times have
not, until relatively recently, been significantly shorter.
 The extensive application of design of production has, however, now realized shorter lead
times while still improving productivity. Design for production is primarily concerned with
designing work content out of the vessel and with improving the efficiency of production.
 The achievement of these objectives will in turn lead to higher labour and facility utilization
and to shorter cycle times. High labour utilization and better use of the working day will come
from improved work flew as interim products related directly to work stations are
incorporated in the design in increasing numbers.
 Reduced cycle times will come from a reduction in work content and a ship breakdown
geared to the yard’s facilities.

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 Many designs for production applications, particularly relating to geometry and block
breakdown, do not of themselves affect lead time significantly, and a start may be made on
their implementation even in cases of very short lead time.

 Other applications, for example outfit assembly techniques, do require an investment both in
time and money to realize the potential benefits. In these cases, it will be necessary for each
individual shipyard to review its own position and to define an implementation program. In
both cases, however, the implementation will in fact consist of two parallel yet interrelated
processes.  Generalized experience and practice gained by systematically attempting to
apply design for production principles by the ship designer on designs.

 which are produced at the inquiry stage and may or may not. be built. Experience can also be
gained by looking at the published designs of production facilities in overseas yards. Visits by
ship designers to overseas yards should incorporate a study of the extent to which the
principles and procedures put forward in this manual have already been implemented.

 Specific experience from ships actually built by the yard. This is gained by examining
achievements and setbacks resulting from the application of new design for production ideas.

 Experience gained on specific contracts can be added to the general body of experience if
shipyards consciously decide to implement design for production in this way and if they
involve all appropriate members of the technical and management team. Thus, design
decisions may routinely combine the requirements of design for performance with those of
production.

 Lead time requirement is a product of the level of technology employed in the engineering
office (for example, the extent of the use of computers) and the balance chosen within total
contract cycle time between lead time and production time.

 In making the transition to longer lead times, the order book will be a dominant factor as
continuity of ship production must be assured. This implies that the implementation of design
for production procedures must be phased to suit each individual yard.

 For the design/production integration to be carried out effectively requires properly educated,
trained, shop-floor-experienced people.

 Too many designers are in the position of having to make major design decisions having
barely seen, let alone worked in a shipyard.

 And in many cases where shipyard-based technical people move to ship or production
management, they do so at too high a level. In Japan and Scandinavia, the approach is from
the bottom UP, with well qualified young people getting direct shop floor experience.

 An interim solution might be for individual shipyards to give young graduate naval architects
and engineers early shop floor experience by using them in the role of field or staff engineers.
Typically, a Staff engineer would work within a production area or workshop or on board and
would be the interface between production and technical functions.

 A network of engineers communicating and providing feedback to ail stages of design would
make a significant contribution to design/production integration. Finally, another major
feature of the successful implementation of design for production is discipline.

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  Before work starts, the whole manufacturing and construction process must be thought
through and laid out in detail on paper.

 This preproduction effort will be largely wasted unless production has the discipline to follow
the determined program, methods and procedures. Apart from the need for discipline, it is
also clear that if production is to follow the "plan," then it must be fully involved in the
thinking stages.

2. Explain in brief about welding, types of welding, edge preparation?

Welding;
Welding is the process joining two similar or dissimilar metals with input of heat and
function three of welding joints which are extensuring in shipyards are
1)Butt welding joint
2)Edge welding joint
3) T-joint
4)Lap joint

Normally in all shipyards the welding of bulkheads plates and deck plates
other similar panels done with temporary ceramic packing that is because to avoid the
welding from both sides.
In the bow area were the bulbous floors are their the closing of shell plate
particularly difficult from onside so they normally shipyards will go for slot welding.
Normally ships major machinery foundation and sea chest boundaries and
their plates where leakage of water is possible shipyards for full penetration welding
with de penetration testing the weld strength of fillet weld.

Example;
Welding of plates or welding of bulkhead or deck plate or the welding its measured by its throat
thickness and leg length of the corresponding welding
Designers do the production for a ship will provide document which is called welding table

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 The documents will have details of welding for different or same thickness with frame of plate at
different grades of frame the throat thickness of the considering the fact ring called weld factor
The welding of two dissimilar grade metals has to be done with ultimate care where one has to be
done with ultimate care where one has to concentrate on the materials fusion temperature of two
different grades of metals one has to choose perfect type of electrode and process of welding to get a
stronger weld.

Edge preparation;
Edge preparation is very important for welding (joining) thicker sheets and plates heavy pipes and
solid material.
Size and shape of edge preparation or groove depends on what material is used and joint design.
Edge preparation is dependants on strength required or load bearing of the joint single square groove
will not penetrate full thickness of the joint but double v groove will get full thickness
Edge preparation consists of removing material along edges of metal surfaces. You must prepare
edges for welding when parts and assemblies require certain strength. To achieve
full welding penetration, you must cut the edges of the metal.

a. Effect of Edge Bevel or Groove:

The effect of edge bevelling or grooving is to control the amount of weld reinforcement, the
amount of weld penetration is also affected by changes in bevel depth and volume. For butt, fillet and
multipass welds, the maximum weld width should be at least somewhat wider than the weld depth. A
ratio of1.25 to 1.5 weld width/weld depth is preferred to reduce the possibility of centre weld
cracking. Proper joint bevels and proper welding parameter selection assist in obtaining this
relationship

When to Bevel or Groove:

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 Bevelling or grooving is especially desirable for butt joints thicker than 5/8 in. bevelling is
sometimes used for material as thin as 1/4 in. where it can assist in tracking the weld seam with knife
edged wheel followers. In positioned tee joint or comer joint fillet welding where complete root
penetration is desired, the abutting member is generally bevelled if the depth of fusion desired for
each weld exceeds 3/8-in.

Effect of Root Face Dimension:

The unbevelled root face should be thick enough for the weld to fuse down into but not through the
butte root faces, or “nose” of the joint. If the thickness of the nose is inadequate, there will not be
enough metal mass to absorb the heat of the molten metal and it may spill out of the bottom of the
joint.

d)Methods of Edge Preparation;

Flame or Plasm arc Cutting - may be done manually or with flame planers or
cutting machines Refer to your ESAB Representative for a description of plate
edge preparation techniques and equipment supplied by ESAB. All loose scale and
slag resulting from cutting must be removed before assembly and welding. Itis not
necessary to remove the oxide film formed on cooling; in fact, it is good practice to
allow this oxide film to remain on the edges if the plates are to be stored for some
time before welding since it will assist inpreventing rusting.

3. Explain in brief about structural design & prefabrication with examples?

structural design
 The design of ship structure is the process of applying rules and experience to integrate
individual structural components into efficient and easily constructed assemblies, modules,
and hull.

 The design of a ship's structure has a major influence on the construction cost of the ship
through the work content and the quantity of material.

 Many ship structural designers use "standard structural details" which they may have
"borrowed" from other designers in another shipyard.

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 For naval ship, they may simply copy the old BUSHIP standards, which are over 20 years
old. Chances are that the decision to use a particular detail will be made without any regard
to producibility requirements for the shipyard involved.

 The smaller the number of standard details considered, the easier it will be to use them.

 It should also be remembered that as there are a great number of connections between the
structural components of a ship, the "best" design for one shipyard may not be the "best" for
another.

 The "best" structural design detail depends on:

 Module definition and erection methods.

 Manual versus computer-aided lofting.
 Manual versus NIC burning.
 Extent of automatic welding.
 Whether or not the shipyard has a panel line.
 Facility and equipment.

 The basic goal of design for ship production is to reduce work content, and the development
of structural details should accomplish this goal.

 When deciding between alternative structural details, it is necessary to utilize the cost trade-
off technique

 The minimum considerations must include:

 Number of parts
 Joint weld length, type, and position
 Completion of spaces/tanks within modules

 A number of typical structural connections will be discussed, with alternatives showing

better design for ship production details.

 Before getting into the details, it is necessary to consider the selection of module boundaries.

 Pre-fabrication

 Small pre-fabrication involves the assembly, where necessary by welding, of sheet metal and
pipe work to form small-sized pieces such as walkways etc.

 The welding is either done electrically or using gas in inert atmospheres.

 The main aim of large-scale pre-fabrication, which can be done both in parallel and in series
with small pre-fabrication, is the construction of semi-worked items which make up elements
in the base structure and plating.

 When assembled with the appropriate walls of insulation and sound-proofing this type of pre-
fabrication can produce almost complete “blocks” which are then used to construct the ship.

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  Interiors are made of wood which comes from the ship-yard carpenters and from other
materials which are previously worked in the appropriate department.

 The materials used must retain their characteristics in a marine environment.

 Different blocks of the ship are then constructed contemporaneously in different “islands”,
thus providing for better work organisation and most importantly reducing the overall
construction time.

 Work from the ground is carried out using safety platforms, parapets, scaffolding, elevator
platforms and cranes, all of which are essential for working at high level on the blocks.

 As work progresses it becomes necessary to work in restricted spaces, particularly when

carrying out interior work on small cabins carved out of the block.

 Example:
 A Bulkhead may have Girder or stringer which will be grouped and pre-fabricated
 A shell may have Girder or stringer which will be grouped and pre-fabricated

4. Write a brief note design for welding in shipbuilding?

 There is still a need for designers to be more aware of whether the Design for Build concept
is being actively followed.

 This has been highlighted when building vessels with a significant proportion of thin plate in
the structure.

 A basic principle in building these structures is to minimise the heat going into the structure,
as this tends to induce the phenomenon of thin plate distortion.

 Consequently, the effects are seen as rework and possibly build schedule impacts.

 One issue was the use of intermittent welding on non-structural bulkheads

 The application of intermittent welding will reduce the amount of heat going into the
structure by about 50%.

 However, there appeared to have been non-structural areas where this had not been applied,
and also wet spaces where double continuous welding had been carried out to remove the
possibility of corrosion occurring in the unwelded spaces.

 The wet spaces were subsequently produced using intermittent welding and a silicone sealant
in the area between the welds.

 Swedged bulkheads were also a low heat input option for non-structural areas.

 The welding of very thick plate to very thin plate caused significant distortion problems due
to the differences in heat transfer between the two thicknesses setting up thermal stress,
which manifested itself as distortion.

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 These issues and others need to be highlighted at a much earlier stage as rework creates
additional cost and, if not carried out correctly, could create undesirable metallurgical
structures in the plate.

 This need has been identified by some shipyards as being the domain of a Production
Engineering Group.

 In the case of an outsourced design strategy then this will become a much more critical
interface to be managed.

 The outsourcing of design has been highlighted as an increasing trend, but a number of
drawbacks have also been raised. Such issues as language barriers, time differences and lack
of knowledge of build yard capabilities have been cited.

 It is highly unlikely that ships are designed with potential distortion effects as a major
consideration.

 Structural distortion is traditionally regarded as a problem generated by welding.

 However, this is not always the case. It is very pertinent to look into the influence that
‘design’ has no distortion.

 This is to be noted that distortion has to be addressed at the concept design stage followed by
detail design.

 The following are the key factors related to design which influence extent of distortion.

 Distortion increases with decrease in plate thickness

 With decrease in panel width (frame spacing), buckling strength increases for same
plate thickness.
 The heat input at which buckling is likely, decreases as plate thickness decreases and
the free span increases.
 The critical buckling strength decreases with decrease in Young’ modulus and
increase in Poisson’s ratio.
 The critical buckling strength reduces as the size of panel increases for the same
thickness of panel.
 Increase in stiffener scantlings increases critical buckling strength for same plate
thickness.

 The role of designers in adopting a “design to reduce distortion” philosophy is also

significant in the overall scheme of this problem.

 In the places like double bottom margin plate and shell plate in bilge strake region the
connection is very typical where access will be a big problem and has to be taken into
consideration while designing the block

 In skeg region the access for welding will be a problem which the designer has to consider
and give a suitable design for construction of skeg of a ship

 In forward region of ship where we have the bulbus bow of the and the flare region will have
lot of structural members internally to take heavy loads in the forward due to forces like
panting, pounding, etc. So construction of the forward block will be not similar to all other

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 blocks due to its structural complexity where welding of all member and shell plate and
structural integrity to be considered by the designer while designing.

5. Discuss in detail about quality control in shipyard?

 Quality control is a process by which entities review the quality of all factors involved in
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 to
management who make the decision to allow or deny the release, whereas quality assurance
attempts to improve and stabilize production, and associated processes, to avoid, or at least
minimize, issues that led to the defects in the first place
 For contract work, particularly work awarded by government agencies, quality control issues
are among the top reasons for not renewing a contract.

Total Quality Control

 "Total quality control" is a measure used in cases where, despite statistical quality control
techniques or quality improvements implemented, sales decrease.
 If the original specification does not reflect the correct quality requirements, quality cannot
be inspected or manufactured into the product.
 For instance, the parameters for a pressure vessel should include not only the material and
dimensions, but also operating, environmental, safety, reliability and maintainability
requirements.
 Quality Control department of a shipyard has 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, and
work instructions and customer’s requirements.
 Handles non-conforming products.
 Maintain inspection records.
 Maintains and controls the measuring and test equipment’s 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 (arrange
highly efficient and sophisticated equipment’s and also fulfil the training
requirements of the personnel’s as well by providing training whenever required).

Shipbuilding Quality Control (SQC):

 The main aim of Shipbuilding Quality Control (SQC) is to check and control the different
processes or procedures carry out in the manufacturing of a ship, as shipbuilding demand an

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 accurate, precise and accident free work, so that to minimize the wastages of materials,
instruments and tools
 QC put efforts to make possible efficient working by proper inspection of equipment’s, tools,
and various tests for materials, so that to use high quality of materials during manufacturing.

Ship Repair Quality Control (SRQC):

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

Engineering Quality Control (EQC):

 The quality check for the all the steel works carried out in Shipyards are properly checked and
controlled in EQC.
 The different manufacturing works carried out consist of developing/manufacturing high
pressure vessels, rollers for sugarcane and cement industries, etc

In all the production departments, Quality is checked with the help of the following two main
methods:
 Destructive Testing (DT): Destructive Testing, tests are carried out to the specimen's failure,
in order to understand a specimen's structural performance or material behaviour under
different loads. These tests are generally much easier to carry out, yield more information,
and are easier to interpret than non-destructive testing.

 Common DT methods used at Shipyards are:

 Stress tests
 Crash tests
 Hardness tests
 Metallographic tests

 Non-Destructive Testing (NDT): Non-destructive testing or Non-destructive testing (NDT) is

a wide group of analysis techniques used in science and industry to evaluate the properties of
a material, component or system without causing damage

 Common NDT methods used at Shipyards are:

 Visual Inspection
 Magnetic-particle Test (MPT)
 Dye penetrant Test (DPT)
 Radiographic Test (RT)
 Ultrasonic Test (UT)

Quality Assurance:
 Quality assurance, or QA for short, is the systematic monitoring and evaluation of the various
aspects of a project, service or facility to maximize the probability that minimum standards of
quality are being attained by the production process.

 QA cannot absolutely guarantee the production of quality products.

 Two principles included in QA are:

 "Fit for purpose" - the product should be suitable for the intended purpose

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  "Right first time" - mistakes should be eliminated
 QA includes regulation of the quality of raw materials, assemblies, products and components,
services related to production, and management, production and inspection processes.

Works of QA & QC:

 Monitoring the implementation of Quality Management System throughout the organization.
 Planning and scheduling of internal and external audits.
 Initializing NCR IQA (Non Conformity Report of Internal Quality Audit).
 Arranging follow up audit through auditors to verify the implementation and correctiveness of
the corrective actions.
 Planning and scheduling the Quality Council meeting to review.
 Customer’s feedback.
 Follow up of previous management review.
 Changes that could affect the Quality Management System.
 Weak areas and recommendations for improvement.

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 UNIT-II

2 MARKS-ANSWER KEY
1. Define accuracy?
It is defined as the use of statistical techniques to monitor control and continuously improve
shipbuilding design details planning and work methods so as to maximize productivity.
2. Discus about tolerance with an example?
Tolerance limits which reflects normally achieved accuracy when bending plates for curved shell.
3. Write a short note on theodolite?
It is a surveying tools this instrument measures a horizontal angle relative to a fixed reference point
and vertical angle derived by a gravity referenced level vector a computer connected to the theodolite
can use those two to estimation distances and fixed position of objects on the ocean’s surface.
4. Discuss in short about Flow chart with an example?
A diagram of the sequence of moments or outing of peoples or things involved in a complex system
or activity.
(or)
A flow chart is a formalized graphical representation of a logical sequence, work or manufacturing
process organization charts or similar formalized structure
Example;

For example, Ship Building Flowchart.

5. Define a process?
It is a series of actions which are carried out in order to achieve a particular result.
6. Why green metal is provided in hull construction?
Aluminium is called as green metal, because it is a very environmentally friendly metal. Recycling
this material saves 95% of the energy required to produce aluminium from raw materials. The main
reason of the green metal which provided in hull construction are the properties, they are Low weight
Highly malleable Resistance from corrosion Durable strength on flammable Recyclable Long-life
Affordability

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7. Write about laser-measuring technique?
Laser measurement technology is widely used in flexible docking system of aircraft and missile
cabin. Such systems generally contain digital measurement system, position and attitude adjustment
mechanism, control system and data processing system the digital measuring system is used to
measure the position and orientation of the components quickly and accurately. The data processing
system is used to analyse and calculate the theoretical position. The control system is used to adjust
the position and attitude of the components. The digital measurement system has just been introduced
into section connection of shipbuilding processes, there is still much room for future research and
application in ship industry.
8. How a process is analysed while planning for construction?

9. Discuss about Production design done for ship Design?

Production design include preparing the ship models such as construction and fitting as 3d in
computer environmental and required for production of documents and projects for smooth and
predictable process for manufacturing.
10. How a process selected while planning?
 Appraisal
 Planning
 Execution
 Monitoring

16MARKS-ANSWER KEY
1. Briefly explain any two measuring techniques used in shipbuilding industry?
A typical ship is made up of many structural elements and consists of more than a hundred
different components. The seamless installation and assembly of all components is critical. In order to
achieve this, it is necessary for the shipbuilders to keep the measurements, shapes, and positions of
each component to exact specification in accordance with the ship’s design. Any deviation in
dimensions can cause problems during the assembly process, impacting the overall quality and
performance of the ship, and compromising on its sea worthiness. In cases of minor misalignment,
reworks and repairs are usually possible, although this will require manufacturers to invest additional
resources into correcting the problem. This, in turn, leads to increased labour cost, time, production
downtime, and even loss of business.
Apart from the potential loss of productivity due to problems with misaligned components, deviations
in measurements during shipbuilding can lead to more serious consequences. A major component of a
ship’s structure is in its hull, which is the main contributing factor in maintaining buoyancy. If the
misalignment is not detected in time, before a ship is allowed to set sail, issues with stability, hull
stress, and other possible damages may occur. In serious instances, flooding may occur during the
voyage, which could lead to disrupted journeys, damaged goods (in the case of cargo ships), or a
maritime disaster with casualties.

Modern metrology solutions A common challenge shipbuilders face in the course of their work lies
in having to take measurements of the ship components. The sizes of these components are usually
large and that makes it hard to measure them properly with traditional instruments and hand tools (e.g.

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gauges, micrometres, and callipers).With these tools, there are concerns with the consistency and
reliability of the measurements, as the readings are obtained manually and are largely dependent on
the technician’s experience and skill. The subsequent report generation also requires a tremendous
amount of time and effort to prepare, given that measurements still need to be analysed and processed
manually before the reports can be drafted.

Measurement is a term which talks about precision, calculations and predictions for future
initiatives; important aspects of ship-building and many other maritime operations ranging from
vessel surveys of all types to designs of new builds altogether. Measurement, like vessel builds
undergo regular updates and investigation which leads to new practices and technological innovations
done to change the landscape of gathering relevant data about the measured entity.

The 21st century saw many innovations within the measuring field with new technological
advancements/ new means to obtain data and new data to obtain altogether. Examples of such
innovations include the different implementations of CAD technologies and optical measurement
which add to the precision and cost-efficiency factor in shipbuilding.

Tape measuring is the leading method in the various production stages from parts fabrication to
subassemblies, including plates, curved plates and profiles, panels and curved panels for nearly 2/3 of
the yards. For measuring sections, blocks and hull assembly less than half of the yards use 3-D co-
ordinate measurement techniques, whereas the others use theodolite systems. Some use both systems
parallel. Roughly 1/6 of the yards use these systems also for checking panel, curved panel and
subassembly tolerance control. Two yards use stationary photogrammetric measuring both for
checking parts (plates) and panel accuracy. For measuring the flatness, the rotation laser is used on
very few yards for subassemblies and higher production stages. The measuring frequency is handled
quite differently, spot check or 100% - check seem to be real alternatives, only very few yards have
established a systematic approach for the frequency of checks.
2. Explain problems of accuracy with block construction process?
• Assembly accuracy detection in the process of building ships, it has long been known that in
manufacturing components in accordance with design drawings, the dimensions of these
components may vary to an extent that adjustments have to be made during the construction
process to arrive at the vessel depicted in the design.

 These adjustments can include a significant amount of re-work,

including trimming of excess material, inserting additional material, pulling, straightening and
bending structure to suit alignment, and in some cases discarding components which are too
distorted to be reasonably utilized, The setting of accuracy goals and the understanding of the
actual accuracy attainable in various manufacturing processes in the shipyard has been identified
as a means of pre-determining some of the aforementioned problems and to avoid them by
adjustments during the manufacturing process.
 Although this matter has always been of importance in shipbuilding, it is probably more critical
modern shipbuilding techniques utilizing Product Work Breakdown Structure (PWBS)as units,
blocks and complex modules are erected and a multitude of systems need to fit together.
 This is opposed to the older systems approach to ship construction where simultaneous
interconnection at one time of many systems or components of the same system did not occur. In
order to address accuracy control, the NSRP has compared accuracy levels measurement such as
those contained in. This reference provides data on the cutting of individual pieces for fabrication
and on the fabricated components themselves.
 It is interesting to note from this data that the U.S. shows some superiority over Japan in the
cutting of components, whereas the reverse is true for fabricated components. This may be due to
the fact that most shipyard cutting is accomplished by numerically controlled equipment which is

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 available worldwide, whereas fabrication requires control of many other processes. This suggests
that the Japanese have a better control of accuracy on fabricated components.
 This also suggests followed the Pareto principle for prioritizing them methods development. They
recognized that for hull construction typically about 5 % of workhours are required for parts
cutting, 50% for sub-assembly and block-assembly, and 45% for hull erection.
 Thus, they first focused on statistical accuracy control and line heating as means to reduce the
work hours associated with the large percentages. This ultimately led to the need provide
shrinkage compensation both for flame cutting and for subsequent welding operations. In contrast,
shipyard managers elsewhere focused on the least amount of work hours with N/Cutting and
ultimately direct computer control of cutting machines,
 They continued to look for devices to force fits without significant drop in sub-assembly, block
assembly, and hull-electioneer-hours, without improvement in safety, and with the continuance of
locked-in stresses. The most modern approach which has been taken to achieve accuracy control
in shipbuilding is termed “Statistical Accuracy Control.
• In this procedure, the manufacturing processes throughout the shipyard are closely monitored,
dimensional data of components is collected and a data base established.
• This data is then statistically analysed and based on theme an dimensions and standard deviations
exhibited by any repetitive production process, adjustments are made to the “designed”
dimensions of components so that “adjusted” dimensions can be used in the production process to
enable components to be produced having dimensional characteristics that are within anticipated
mean values and variance.
• The process, when applied to all the various components throughout the vessel, can result in a
pre-determined knowledge of the ultimate dimensions of the entire vessel within the combined
mean dimensions and standard deviation of its parts. Further adjustments can then be made such
that the dimensional characteristics of each of the components can be defined for the construction
process and fabrication can proceed to these specific dimensions with the confidence that the
results will be within an acceptable tolerance level. This will result in all components fitting
together to form the complete vessel without the need for expensive and time-consuming rework.
• The practice of incorporating additional material into components, to be trimmed later as
necessary, can be virtually abolished, since all material can be cut to a predetermined tolerance.
Accuracy control is not considered as a separate structural alternative herein, but the amount of
rework assumed for alternatives is identified in Section 7.0. Reduction of this rework by greater
accuracy control will be self-evident in the results presented in that Section.
• The traditional method of hull block assembly is completed with the use of crane lifter lifting
block segments one by one. The adjustment and positioning of the segments are carried out
by using a plurality of elastic screws or oil tops. The main disadvantage of this technique is
that the crane utilization rate is relatively low, the cycle is long, labour intensity of workers is
high and the positioning accuracy for assembly is poor. Information sensing technology and
data acquisition methods are the premise of the integration of industrial automation and
information technology in intelligent manufacturing. MAA (Measurement Assisted
Assembly) is one of the integrated intelligent manufacturing technology, and it is also the
inevitable trend of digital intelligent docking technology for ships and other large-scale
products Right now, hull and folding butt joint tracking and measurement technology is still
in the preliminary stage, which is mostly learning from the aircraft and spacecraft cabin
docking measurement technology. We can predict the development direction of the ship block
jointing tracking technology based on the summary of relative measurement technology.
Measurement of component position is more commonly used by laser tracker, indoor GPS,
camera system etc. Indoor GPS can only be used in a fixed space, and it is vulnerable to
interference from the signal which may cause the error. Comparatively speaking, laser

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 measurement technology has the characteristics of non-contact, no guide rail, fast detection
speed, good portability and so on. It is widely used and studied. the function, principle and
measurement method of the laser tracking measurement technology. A flexible assembly
technology system was proposed on this basis, and it was integrated with a number of
advanced digital technologies the problem of aircraft components assembly positioning. The
research of technology and principle of digital flexible assembly for aircraft components
docking based on laser tracking and positioning was carried out. The laser tracking
measurement system was developed based on the laser tracker software package.

• A number of experts conducted in-depth research on flexible assembly of large parts, they all
emphasized that the application of laser measurement technology in flexible assembly of
large parts was a growing trend. The laser tracking and positioning measurement system is
connected through the Ethernet.

• The measurement data obtained by the laser tracking and positioning system are directly fed
back to the system computer after processing the measured data through the processing unit.

• The computer is then compared with the position of the exact mathematical model to obtain
the correct value of the assembly position, which can guide the assembly process.

3. Briefly explain process planning in shipbuilding?

Process planning systematic determination methods by with product is to be manufacture
economically and on schedule function which established process on parameter to be used convert a
raw material finding between defect intermediate stages between designing manufacture.
Main Information of process planning;
 Product specification and quantity of work
 Quantity of work to be completed
 Available of raw, material tools equipment’s personnel
 Sequence production
 Standard time
 Machine on which process will be for performed will be for performed
 Schedule of the process
Process planning procedure;
 Preparation of working drawing so geometrical shape dimension tolerance surface tension
surface finish surface coating information or inspection identification material
specification
 Make or buy decision
 Process selection based on automation kind of work flow quality level, delivery agencies
etc
 Machine capacity and machine selection
 Selection of material fixtures auxiliary equipment’s

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  Prepare document like operation and roots sheets

Process planning procedure control;

Shipbuilding process is
 Complex.
 Long cycle operation.
 The most important objective in shipbuilding is maintained delivery schedule
in few of above point proper planning essential determine very sequencely
and inter related operations and activities or derived construction.
Planning Activities;
 Long-time term 2 to 3 years
 Medium term monthly or half yearly
 Short term day to day.

4. Briefly explain interconnection between production design and process planning is

shipbuilding?

Production Design;
 Design information reinforce made internal for production process
 Design is made according material available limitation is suitability
 Structure design is given important
 Optimize initial of crane in short facilities
 Minimize material usage
 Good acceability is use of transport storage
 Component easy to assemble and act
 Modification structure components design difficulty
 Bulbous made mini pies
 Hull design is optimizing
Planning Planning;
 Product specification and quantity of work
 Available of raw material tools equipment’s personnel sequence production
 Standard time
 Machine on which process will be performed

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  Process selection based on automatic kind of work flow quality level delivery
agencies etc
 Make or busy decision
 Prepare document like operation and root sheets
 Machine capacity and machine selection
 Schedule of the process.

5. Explain the following with sketch:

a) Production process analysis
b) Assembly charts
c) Operation process chart
d) Flow process chart
a) Production process analysis
Process planning can be defined as the act of preparing processing documentation for
the manufacturing of a full vessel (or) an assembly

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b) Assembly charts
• It’s is defined as the schematic chart of assemblies’ sub-assemblies part assemblies’
units and block assemblies
• This chart gives a clear bird eye view of assembling of blocks and is components
sub-assembly operations assembly operations etc

c) Operation process chart

• The operation chart is graphical and symbols representation of the manufacturing
operations used to produce a vessel
d) Flow process chart
• A Flow process chart is a chart of all the activities involved in a process it is similar
to the operation process chart except that more details is been shown by including
transportation delays as well as operation, inspections and storages.
• Thus, this chart is been made (or) mapping is been done for the identification of
delays during production of a vessel and for improvement of it by minimising time
delays.

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23 | P a g e
 UNIT –III

2MARKS-ANSWER KEY
1. How a process is planned?
Process is planned as the act of preparing processing documentation for the manufacturing of fall
vessel or an assembly Design-material procurement-fabrication-subassembly-fabrication units-
surface-preparation-painting-outfitting-test/trials-delivery.
2. Write short note on scheduling in Planning with an example?
The Planning and scheduling process are presented in stage related to the design cycle
These stages include basis planning major detail planning working detail planning and work
instruction planning.
3. How manpower estimated for a process?
The industry must estimate the structure of the organisation at a given point in time
For this estimation the number and type of employees needed have to be determined
4. Write short notes on Labour organisation?
The International Labour Organization (ILO) is a United Nations agency whose mandate is to
advance social justice and promote decent work by setting international labour standards. the ILO
employs some 2,700 officials from over 150 nations at its headquarters in Geneva, and in around 40
field offices around the world.

 A path to full and productive employment and decent work for all: The 2030 goals.
 An international legal framework for fair and stable globalization.
 A level playing field.
 A means of improving economic performance.
 A safety net in times of economic crisis.
 A strategy for reducing poverty.

5. Discuss about material control in a yard?

Shipyard planning and material control have three fundamental objectives: □ Ensure that all
required resources (drawings, material, labour, subcontractors and. facilities) are all available when
the work is scheduled. Organize the work to be the most productive possible.
6. Write about industrial relations?
Industrial relation is defined as relation of individual as group of employees and employer’s for
engaging themselves in a way to maximizing the productive activities.
7. What do you mean by plant safety?
Safety deficits in refinery plants can the environment and the hearth of employees and local
residents in the event of damage down time and loss production can inner sustained added cost it can
provided complete safety verification throughout the entire life cycle of plant
It complies with statutory regulation governing industrial safety surface water protection
environment and hazardous goods.
8. Write short notes on Personal management?

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 Personnel management is that part of the management function which is primarily concerned
with human relationship with an organisation
9. Write short notes on training human relations?
Human relation training has greater significance in organisation as employs has to a maintain
human related not only with other employs but also with their customers.
10. What do you mean by production control?
Production control is meant by monitoring of difference between actual and scheduced
performance of a project.

16MARKS-ANSWER KEY
1. Discuss in Detail about models for process planning?
Process planning is a systematic determination of methods by which product is to be
manufacture economically and on schedule formation manufacture economically and an schedule
formation which establish process and process parameter to be used covered the raw materials into
finish product defined like intermediate stages between designing and manufacturing
Main Information of process planning
• Product specification and quantity of to be completed
• Accessibility of raw materials tools equipment and personnel
• Sequence of production
• Standard time
• Machine on which process will be perform
• Schedule of the process.
Process Planning Procedure
Preparation of working drawing showing geometrical shape dimension tolerance type
of surface formation surface coating information for inspection identification code materials
specification
Process selection based on level of automation kind of work flow quality level
delivery agencies etc
Machine capacity and machine selection of materials jig fixture auxiliary equipment
Requires documents like operation and roll sheet
Planning Activities
• Long term ;2-3years or more
• Medium term; Monthly a half yearly
• Short term; day to day
Long Term
Long term planning for ships will be master pan it contains master schedule which is
circulated from the planning department various other department of shipyard

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 The complex nature of the ship building need planning and production control very important
because ship building is capital activity with large capital investment in plan and may there high
equipment ultization with high output essential requirements also techniques for advance outfitting
cannot be successful in termination without high level of plant output good planning production
control also helps and timing completion work and maintenance of delivery schedule

2. Briefly explain the following with sketch

a) Gantt charts
b) CPM
c) PERT
d) Transportation model

a) Gantt charts

• A Gantt chart is a horizontal bar chart developed as a production control tool in 1917 by
Henry L. Gantt, an American engineer and social scientist. Frequently used in project
management, a Gantt chart provides a graphical illustration of a schedule that helps to plan,
coordinate, and track specific tasks in
project. 

• A Gantt chart is constructed with a horizontal axis representing the total time span of the
project, broken down into increments (for example, days, weeks, or months) and a vertical
axis representing the tasks that make up the project (for example, if the project is outfitting

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 your computer with new software, the major tasks involved might be: conduct research,
choose software, install software).

• Horizontal bars of varying lengths represent the sequences, timing, and time span for each
task. Using the same example, you would put "conduct research" at the top of the vertical axis
and draw a bar on the graph that represents the amount of time you expect to spend on the
research, and then enter the other tasks below the first one and representative bars at the
points in time when you expect to undertake them.

• The bar spans may overlap, as, for example, you may conduct research and choose software
during the same time span. As the project progresses, secondary bars, arrowheads, or
darkened bars may be added to indicate completed tasks, or the portions of tasks that have
been completed. A vertical line is used to represent the report date.

b) CPM
• Critical Path Method (CPM) developed in the 1950s is an algorithm needed for planning,
arranging, scheduling, coordinating, and governing of a project. It is presumed that in this
method the activity time is specified and fixed. It is used to calculate the quickest and latest
start time for each task.
• CPM helps to distinguish the critical and non-critical tasks, reduces the time and bypass the
queue formation in the process. It is essential to identify critical activity because if any
activity is hindered, it will clutter the whole process.
• In this process, first, the list of all the activity is prepared, followed by the time required by
each of these activities. Then the dependency connecting the activities is decided. Here, the
series of the activity in a network is defined as ‘path’

Advantages of CPM

 Provides an outline for long term coordination and planning of a project.

 Recognizes critical activities
 Easy to plan, schedule, and control project
 It improves productivity
 Manages the resource needed

Disadvantages of CPM

 For beginners it’s difficult to understand

 Software too expensive
 Sometimes, to structure CPM is too time-consuming
 It cannot control and form the schedule of a person involved in the project
 Allocation of resources cannot be monitored properly

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CPM Example

o
d)PERT
• A PERT chart is a project management tool that provides a graphical representation of a
project's timeline. The Program Evaluation Review Technique (PERT) breaks down the
individual tasks of a project for analysis

Advantages of PERT

 Planning for Large Project- It is used in scheduling large project by the project manager
 Visibility of Critical Path- It is used to show the critical path in a clear way. The critical path
those paths were activities cannot be paused under any conditions.
 Analysis of Activity- This will provide the management with the progress report and the
completion of the project including the budget.
 Coordination Ability-This helps in improving the communication within different
departments of the company.
 The What-if Analysis– This analysis benefits the company to recognize the risk linked with
any projects.

Disadvantages of PERT

 Time Focused Method- PERT is a time-bound method, so finishing project or activities on

time is of high importance. If it does not happen than a problem can arise
 Subjective Analysis- Here, the project activities are recognized according to the available
data. However, it is difficult in PEERT projects as it is applicable for the only new project are
which is not repetitive in nature, therefore, the collection of information to be subjective in
nature.
 Prediction Inaccuracy- PERT does not have any past records for a framework of a project, so
prediction comes into play. The project will be ruined if the prediction is not accurate.
 Expensive- Too expensive in terms of time consumed, research, prediction, and resources
utilized.

PERT Example

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 4)Transportation model
• The Transportation Model Characteristic • A product is to be transported from a number of
sources to a number of destinations at the minimum possible cost. • Each source is able to
supply a fixed number of units of the product, and each destination has a fixed demand for the
product
Aim of Transportation Model
• To find out optimum transportation schedule keeping in mind cost of transportation to be
minimized.
Transportation Problem
• The transportation problem is a special type of LPP where the objective is to minimize the
cost of distributing a product from a number of sources or origins to a number of destinations.
• Because of its special structure the usual simplex method is not suitable for solving
transportation problems. These problems require special method of solution.
• The problem of finding the minimum-cost distribution of a given commodity from a group of
supply canters (sources) i=l, ..., m to a group of receiving canters (destinations)j=l, ..., n
• Each source has a certain supply (si)
• Each destination has a certain demand (dj)
• The cost of shipping from a source to a destination is directly proportional to the number of
units shipped

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 Simple Network Representation

Sources, Supply s1, Supply s2, Supply Sm,

Costs c. IJ, Demand d0, Demand d2, Demand d 1, Destinations
The Transportation Model Characteristic
• A product is to be transported from a number of sources to a number of
destinations at the minimum possible cost.
• Each source is able to supply a fixed number of units of the product, and each
destination has a fixed demand for the product.
• The linear programming model has constraints for supply at each source and
demand at each destination.
• All constraints are equalities in a balanced transportation model where supply
equals demand.
• Constraints contain inequalities in unbalanced models where supply is not equal
to demand.
Application of Transportation Model
• Minimize shipping costs
• Determine low cost location
• Find minimum cost production schedule

3. Briefly explain Procedure control and system control of production?

Production control is responsible for monitoring cost and schedule the while leak in progress
the production control origination is generally responsible for issuing man hour budget to be used to
control the ship building process relates actual work completed and actual mon hours spent there data
are covered by control group in order to monitor expended man hour production progress and
productivity and to feedback system oriented data for estimation for ship building projects thus
particular indene for moniting expended man hour progress and productivity are sufficient.
Man, hour Expensive
The character of man power index (man hours per unit time) is the same for the various control group
of work packages which apply to all work categories.

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Production progress
Production progress use different measures (weight, welding parameter, laid cable length etc)
per time factor it is sometime necessary to apply more than one index for each group of work
packages.
When compared to period schedules they are the basis for short term adjustment such as
shifting workers or using overtime when the shipyard organisation it is practical to delegate such
control to the part of delegates such control to the managers gets of parts fabrication shop and
assembly section.
Productivity indices
productivity indices utile both man hours expended and the measures used for monitoring
production process (Weight, Welding, parameters, cable length etc).Each of the latter is usually an
average based on the performance with the specific control group of work packages any curve which
appears above this efficiency indicates man hours expensive an above average rate Productivity
evaluation can be simplified by a productivity control group (PCG) concept it eliminates
consideration of specification man power control group and the same indices to man power expensive
progress and productivity apply within each manufacturing level.
Zone to System Transportation
The productivity indices use full to transporting manpower expended for zone-oriented work
to the system by stem data needed for estimation in man hour expensive can be collected but different
method for grouping work package depending on the degree of control required. Attritionary its
usefully to separately address each material item to for which there is no between its weight and
required fixing man hours main engine, boilers, hatch, covers etcThis permits collection of man hour
expensive by component which is immediately identification with a system thus consideration of two
saved of zone-oriented data parametric and nan parametric man hours total man hours appertained to a
system can be exposed by formula
HT=HP+PC
HC=total man hour
HP=total parametric man hour
HC=total non-parametric man hour.

4. Briefly, explain the following:

a) Time and motion study
Ship motion simulation in reliability of ship endurance into port
Due to economic reasons port Manu veering of large vessel are commonly performed in
condition closed to the limits related to ship dimension under keel clearance weather condition and
towing distance this is mainly caused by the ultra large contain ship or either single certain propeller
vessel they can perform man veering in very tight propeller vessel they can perform Manu veering in
very tight access and strong weather condition up to port operation limits using their thruster and
Propeller to increase efficiency of Manu veering by tug boats
The bottle necks of ship cancelability in most parts are the narrow port entrance and small
turning basins there are several phenomena which should be considered in the risk assessment of ever
during Manu veering in restricted water
Operational safety is related to both potential and real hazards of manoeuvring
operation and performed by a ship during ship approach and entry into a harbour the related to

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manoeuvring operation can be compare operational risk the risk of case due to incorrect and main
function internal power personnel technical system and external events.
The operational relation of ship entering a harbour is the probability of free ship
performance during saving along the approach channel the port entrance inner port canal and dock
ship turning and both Manu veering

EXAMPLE
The study of ULAS based of ship motion simulation carried out in the environmental of
interactive for irisin simulator simplex navigator confirmed the port accessibility for the ultra large
container ship under particular condition
Full mission simulation creates the environment of real navigation and work condition
including collaboration between ship master, pilot, tug master, vessel traffic services and it’s the best
tool for the operational safety and reliability studies of ship Manu veering in restricted water
The reliability assessment of ship entry into the port has been performed taking into account 3
stage of ship entry
A, B, C, related to particular areas and necessary case charge
A-Navigation along the approach channel
B-passing with main entrance
c-passing the inner entrance

b) Management cycle of a shipyard

Project definition-visualization the complete project a true structure
Vender pre-Qualification -define and track process store result for future projects
Design approval-Make visible approval comments in the building phase to assure vessel is
built to connect design
Building-important hull paint and outfitting
Delivery-documentation and structure immediately
Operation-Expensive feedback to new project hull maintenance conversion.
Apply Chain Management Cycle;
System and zone oriented in management cycle indicates primary focus system or zone of
each phase in the cycle during planning okay transformation from system orientation to zone
orientation through execution and some testing to manner in which the work is performed

1. Estimation
2. Planning
3. scheduling
4. Execution
5. Evaluation

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5. Briefly, explain the following:
a) Dry docking
b) Maintenance of ships

a) Dry Docking
Dry docking is a term used for repairs or when a ship is taken to the service
yard. During dry docking, the whole ship is brought to a dry land so that the submerged portions of
the hull can be cleaned or inspected.
WHY DRY DOCK THE SHIP

The dry dock is not required by SOLAS, MARPOL, TONNAGE OR LOADLINE

conventions. It is actually a CLASS society requirement. This is to conduct the docking survey as per
the classification society. The docking survey is part of the periodical survey conducted by the
classification society in order to maintain the vessel in class. The docking surveys are conducted by
the class societies surveyors.

The durations to conduct dry dock

• For ships of up-to 15 years age (before the 3rd special survey) 2 dry docks in each window of
5 years.

• The duration between above two surveys will be at-least 2 years and maximum 3 years.

• For ships over 15 years of age (beyond the 3rd special survey) dry dock every 2 years.

MAIN AREAS OF INTEREST IN DRY DOCK INSPECTION

• ShelI plating

• Side shell coating

• Stern frame

• Rudder

• Propeller

• Sacrificial anodes/ ICCP arrangement

• Logs and echo sounder transducer

• Anchor and cable

• Chain locker

• Sea suctions and chests

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 • Bilge keel and fittings

Generally following is the sequence followed: -

• Vessel will maintain a running defect list.

• The defects which warrant attendance in the dry dock will be moved to a dry dock file.

• The contents of the dry dock repairs is updated to include all the particulars and plans relevant
to the repair or maintenance.

• Basis of the current contents of the dry docking file , a consolidated initial Dry dock
specification will be generated.

• This copy is considered both by ship's officers as well as the manager's superintendent.

• With due review of the specs, they are finalized and forwarded to various dry docks for
raising quotations.

• Basis of the vessels operating area and availability of dock, also most importantly, the tenders
submitted by the various dry docks ,the vessel is booked for dry dock in a particular period.

• Charterers are informed and the vessel is arranged to go out of employment for the period it is
to be in the dry dock.

• It is common for most ship owners to maintain patronage with a particular group of dry docks
and try to arrange the employment of their vessels in such a fashion that they may disengage
and proceed for dry dock without wasting too much time in transit.

• Ship's plans are forwarded to the dry dock in advance.

• A docking plan is discussed.

• Keel blocks are laid as per the vessel's docking plan.

• Stability calculations are prepared prior arriving at the dry dock.

• In consultation with the dry dock the docking trim is agreed upon.

Common services required when in the dry dock

• Docking assistance

• Access to vessel (as own gangway will be unusable)

• Shore power (as generators will be overhauled)

• Shore crane for heavy items

• Oxygen and gas lines for gas cutting

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 • Welding connections for steel renewals

• Fire main to remain pressurized (own pump unusable)

• Portable educators and pumps for emptying unpumpables

• compressed air for miscellaneous jobs

• communication facilities

• medical and safety facilities

• garbage reception facilities

• Shore water supply

• Sewage connection or reception facilities

• Ballast water prior dock flooding on departure.

Stability during Docking:

• When the ship enters a dry dock, it must have a positive metacentric height; and is usually
trimmed by stern. The floor of the dry dock is lined with keel blocks, which are so arranged
such that they can bear the weight of the ship. When the ship enters the dry dock, her
centreline is first brought in line with the centreline of the keel blocks by using a combination
of plum lines and Leica theodolite.

• The dock gates are then closed and the water is pumped out of the dock in stages. Since the
ship has a trim by stern, the stern of the ship will first sit on the keel blocks. The rate of
pumping out water is reduced as the stern is almost about to touch the keel blocks. The reason
is, it is from this stage of the docking procedure when the stability of the ship starts getting
critical. The interval of time from when the stern takes the blocks to the moment when the
entire ship’s weight is borne by the blocks is called Critical Period. We will understand the
details a little later.

• When the stern of the ship takes the blocks, it is fixed to the shores (sides of the dock). This is
carried out from aft to forward so that by the time the entire ship takes the blocks, it is fixed to
the shores. When the ship is completely borne by the blocks, water is pumped out quickly
from the dock.

what happens during the critical period?

• When the ship’s stern just touches the keel blocks, part of the ship’s weight is being borne by
the keel blocks. The contact between the stern and the keel block creates a normal reaction or
up thrust. The magnitude of this upward normal reaction increases as the water level in the
dry dock reduces. It is this up thrust that creates a virtual reduction in the metacentric height
of the ship. Hence it is very crucial to maintain sufficient positive metacentric height before
docking, lacking which, the ship may heel over to either side, or even slip off the keel blocks
and capsize.

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 • The purpose, hence, is to calculate the metacentric height of the ship at different stages of the
docking process, and ensure that it does not fall below the safe limit. Follow the figure
underneath, which shows a ship that has just touched the keel block by its stern. The location
of the centre of floatation (F) is known from the hydrostatic curves at the given displacement.
Since the location of the stern is a known point, its distance from the centre of floatation can

b) Maintenance of ships;

Maintenance Work is Done Onboard a Ship

• Maintenance is one thing that keeps any mechanical equipment or machinery going. Weather it is
a small machine or a large structure, efficient maintenance can help with prolonged life and
favourable outcome. On a ship, maintenance is one thing that keeps machinery up to date and is
smooth running condition. In this article we will learn as to how maintenance is being carried out
on a ship.
• In a ship’s engine room, where the maximum machines are located, engineers and crew carry out
the maintenance for safe and efficient operation. Each machine on board a ship requires
maintenance which has to be carried out at regular intervals of time.

• In the earlier days, the number of crew members and engineers on a ship were large and so the
maintenance was carried out fast and easily. However, in the present scenario, the number of crew
members and engineers on the ship has reduced drastically.

• Many ships carry only 3-4 engineers on board a ship and even the time required to carry out
maintenance on the ship has reduced.  Maintenance requires manpower and time which may not
be available all the time as the number of crew members is less and the amount of machinery is
more

• It is for this reason important to plan the maintenance of the machinery in advance so that the
machinery can be overhauled and maintained properly. Generally, second engineer is required to
plan the schedule of maintenance on a ship.

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• Efficient planning and adequate usage of equipment’s is the key to productive maintenance.

• Types of maintenance procedures followed on a ship.

1) Preventive or Scheduled Maintenance System

• It is famously known as the PMS or Planned Maintenance System. In this type of system, the
maintenance is carried out as per the running hours like 4000 hrs, 8000 hrs etc., or by the calendar
intervals like 6 monthly, yearly etc. of the machinery. The maintenance is carried out irrespective
of the condition of the machinery. The parts have to be replaced if it is written in the schedule,
even if they can be still used.

2) Corrective or Breakdown Maintenance

• In this system the maintenance is carried out when the machinery breaks down. This is the reason
it is known as the breakdown maintenance. This is not a suitable and good method as situations
may occur wherein the machinery is required in emergency. The only advantage of this system is
that the working of machinery parts is used to its full life or until it breaks. This system might get
costly as during breakdown several other parts may also get damaged.

3) Condition Maintenance system

• In this system the machinery parts are checked regularly. With the help of sensors etc. the
condition of the machinery is accessed regularly and the maintenance is done
accordingly. This system requires experience and knowledge as wrong interpretation may
damage the machinery and lead to costly repairs which may not be acceptable by the
company.

UNIT-IV

2MARKS-ANSWER KEY
1. Define capacity?
Capacity of yard in time is calculated on the basis of the maximum completions over the last 15 years.
Capacity calculations are based on data of six ship categories, notably offshore, bulk carrier, dry cargo
passenger, fishing, tanker and miscellaneous. Furthermore, this calculation takes into account the shift
of yards into ship repair and conversion activities under the assumption that no capacity increase has
been undertaken that is devoted to repair operations.
2. Write a short notes capacity planning?

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Capacity planning is the planning required to ensure all the resources are available for the production,
the resources which has to ensure are, labour or employees for the hull production as well as
outfitting, number of spaces required for block assembly, steel stockyard for keeping plates, efficient
machines for cutting and welding, etc.
3. CGT –Abbreviate and give a short note?
Compensated gross tonnage, (CGT), is a unit of measurement intended to provide a common
yardstick to reflect the relative output of merchant shipbuilding activity in large aggregates such as
World, Regions or Groups of many yards.
4. Discuss about Design capacity with example?
Design capacity is the maximum output of a structure, facility, process, machine, tool or component
based on its design. It is the capacity that can be achieved under ideal conditions with unlimited
resources such as labour, power, materials and parts.
5. Define Effective capacity?
Effective capacity is the maximum amount of work that an organization is capable of completing in
a given period due to constraints such as quality problems, delays, material handling, etc. The phrase
is also used in business computing and information technology as a synonym
for capacity management
6. How operational Survey is done?

7. Discuss in short about Utilization in yard?

8. What Strategy is used to improve capacity in shipyard?

9. Write short notes on lead strategy?

Capacity planning is a strategic process whereby a company determines what level of capacity it
will need to satisfy the level of demand for its products or services over a period of time. A lead
strategy is aggressive and involves increasing capacity in mere anticipation of an increase in demand.
10. Give an example for Lag Strategy?
A lag strategy is conservative and involves increasing capacity only when there is an actual increase
in demand. It may result in a loss of potential or current customers who must go elsewhere if demand
suddenly outpaces current capacity, and customers can't or won't wait.
16MARKS-ANSWER KEY
1. Briefly explain methods of estimation of capacities of shipyards?
The method is based on highest shipbuilding output on reward which could base the an estimation
of shipbuilding capacity because the demand is very high almost all shipyard will try produce
maximum capacity because the demand is very high almost all shipyard will try produce maximum
capacity in this method would still be enough measure this methodology considered to be reasonable
demand for building of new ship is very high shipbuilding output is closed to to capacity all shipyard
are expected to response to this high demand.
The Advantage of the Method is it simplifying
This method involves lot of weakness like when the shipyard had reach the full capacity some
shipyard where not working with full capacity this maximum production is not a few reliable measure

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of capacity more over new facilities have been constructed existing facilities have been upgraded after
the period where the shipyard reach their full capacities continue to increase after the period of full
capacity the shipbuilding capacity use to produce other equipment than ships for instance offshore
facilities is not taken into account in this methodology but would be converted back to ship and
should have been included in the calculation and finally dereplication decreasing the values of product
of equal stock is not related in the estimate
Yard-by yard measurement of capacity method
In this method maximum capacity of shipyard is compensated on he both of gross tonnage for
certain period of time in this method on the basis of estimated gross tonnage the shipyard by increase
the gross tonnage by modifying is construction methods and by increasing its building dock capacity
and techniques.
Therefore, full modification capacity method solely depends upon capacity planning it is the
process of determining the production capacity needed by the organisation demand for its products
and the design capacity in accuracy and output.

2. Briefly explain strategies for modifying capacity?

3. Briefly explain models for capacity planning under the special conditions of shipbuilding?

Method for capacity planning used in ship building industry;

Important
• Impact ability to meet future demands
• Affects operating costs
• Involves long term commitments
• Affects completeness
• Affects case of management
Factors involve;
Design capacity; maximum output rate devices capacity an operation process facility it is
designed for.
Effective capacity
Design capacity increase allowance sun as personal time maintenance and scrap
Actual Output
Rate of output actually achieved cannot exceed effective capacity
Objective
• Amount of capacity needed
• Timing of changes
• Need of to maintain balance
• Extend of flexibility of facilities

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Methods
• Estimate future capacity requirements
• Evaluate existing capacity
• Identify alternative
• Implement alternative chosen
• Monitor results.

4. Explain Yard-by-Yard aggregate method with an example?

In this method maximum capacity of shipyard is compensated on he both of gross tonnage for
certain period of time
In this method on the basis of estimated gross tonnage the shipyard by increase the gross tonnage
by modifying is construction methods and by increasing its building dock capacity and techniques.
Therefore, full modification capacity method solely depends upon capacity planning it is the
process of determining the production capacity needed by the organisation demand for its products
and the design capacity in accuracy and output.

5. Explain maximum capacity approach method with an example?

The method is based on highest shipbuilding output on reward which could based the an
estimation of shipbuilding capacity because the demand is very high almost all shipyard will try
produce maximum capacity because the demand is very high almost all shipyard will try produce
maximum capacity in this method would still be enough measure this methodology considered to be
reasonable demand for building of new ship is very high shipbuilding output is closed to capacity all
shipyard are expected to response to this high demand. The Advantage of the Method is it simplifying
This method involves lot of weakness like when the shipyard had reach the full capacity some
shipyard where not working with full capacity this maximum production is not a few reliable measure
of capacity more over new facilities have been constructed existing facilities have been upgraded after
the period where the shipyard reach their full capacities continue to increase after the period of full
capacity the shipbuilding capacity use to produce other equipment than ships for instance offshore
facilities is not taken into account in this methodology but would be converted back to ship and
should have been included in the calculation and finally dereplication decreasing the values of product
of equal stock is not related in the estimate

UNIT-V

2MARKS-ANSWER KEY
1. Write a short note on Production standard with example?
Since much of this production work needs to be done at earlier stages of construction, the
planning, engineering and material control efforts also must be accomplished much earlier in the
construction period. Resources available for these up-front activities typically are limited. Therefore,
shipyards are quickly recognizing that a comprehensive program to develop engineering, planning,
materials and production standards help relieve the strains of excess resource requirements, while
reducing overall costs as well.

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2. How Girth length is measured?

3. Discuss in short about shell expansion?

The arrangement of the shell plating taken from a 3-dimensional model may be represented
on a 2-dimensional drawing referred to as a shell expansion plan. All vertical dimensions in this
drawing are taken around the girth of the vessel rather than they’re being a direct vertical projection
4. How nesting is done?
Normally a ship is built one portion or block at a time, and nesting is done for each block. In
the nesting process, hundreds of members to form a block are allocated in accordance with thickness
and material for several to tens of rectangular steel plates and arranged for efficient cutting-out at a
small scrap ratio.
5. How Block division plan done?
The hull is divided longitudinally into blocks, and each block is again divided into assemblies
and sub-assemblies. This division of blocks is known as block division plan. The size of assemblies is
decided in the designing stages, considering the carnage capacities and special layout of the shipyard.
It is ensured by all shipyards that all joining processes are carried out mostly by downhand welding
.
6. How steel plates tested in yard for defects?
Visual inspection of steel plates for defects, such as out of square, scabs and slivers (peeling
away / pitting), corrosion, laminations, inclusions, etc. Dimension check of steel plates. Especially
thickness of the plates, it shall be clearly mentioned in the inspection. Inspection of bought out items,
such as heavy-duty pipes, SORF flanges, etc. Checking overall dimensions of the main tank as per
specification/ IS code/ drawings/ tolerance given as applicable. Checking the completeness of welding
Visual check / Dimensional check of all the fittings Hydrostatic pressure. Tank should not leak at any
joint.
7. How hardness of steel checked?
The testing of steel’s properties often begins with checking hardness. This is measured by
pressing a diamond pyramid or a hard steel ball into the steel at a specific load. The Vickers
Diamond Pyramid Hardness tester, which measures the DPH mentioned above, uses an indenter
with an included angle of 136° between opposite faces of a pyramid and usually a load of 10, 30,
or 50 kilograms-force. The diagonal of the impression is measured optically, and the hardness
expressed as the load in kilograms-force divided by the impressed area of the pyramid in square
millimetres. 
8. How profile and plate bending checked?

9. Write a short notes quality control in shipyard?

Quality control is a process by which entities review the quality of all factors involved in
production. Carries out inspection and testing related to inspection (during processes and after
developing the finish goods) in accordance with the quality plans, procedures, and work
instructions and customer’s requirements

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10. Give an Example for panel and how it is made?
Panel is a Primary strength member which may be combination of plates stiffeners and pre-panel
or plates & stiffeners the panel is a unit assembly in block construction stage
Example: Bulkhead panel fabrication in ships block where plates are assembled first & welded
then stiffeners are assembled and welded if bulkhead has pre-panel the pre-panel is also
assembled and welded then as a whole unit the bulkhead is assembled on block.

16MARKS-ANSWER KEY
1. Briefly explain production standards in several parts of the ship production?
• Definition of Standards
The standard represents the consensus of the portion of the industry represented by the
organization that issues it. Standards are in accordance with established procedures for
certification, development, approval (ensuring consensus) and review of the standards
organization.
• Purpose of Standards
Conformation of a standard is done to ensure acceptability, compatibility, interchangeability,
identicality, or other aspects of commonality. Frequently the standard contains tests to be used to
determine that the conformation is within the specified tolerances. While there are many reasons
for using standards in many different applications, the ultimate one is to save money.
• The Categorizing Standards
Reference can be made to the type and level of a standard. type is the area of concern or function
of a standard and level can refer either to the portion of the ship being considered or to the breadth of
the organization developing the standard and its intended application. A standard may be of one type
or a combination of types.
TYPES OF STANDARDS
HARDWARE SOFTWARE
Performance Nomenclature
Operating Characteristics Drawing
Size Procurement
Envelope Documentation
Interface
Design Criteria
Construction
Testing

There are advantages in applying different standards to different sized portions of the ship.
SHIP LEVELS
Ship
Module System
Unit Equipment
Panel Components

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 Plate or Shape Parts

Standards are utilized at levels ranging from the individual shipyard to the international organization.
Standards created at one level are often adopted at higher or lower levels.

2. Explain briefly about methods of man-hour estimation?

The estimation of labour man-hours for ship production is considered an important item during the
early stage of negotiation before signing the contract. With few information about the ship during the
preliminary design stage, it is necessary to apply a good prediction method for estimating the ship
production man-hours. In this paper, the previous works for estimating the shipyard labor man-hours,
based on hull steel and outfit weights as shipyard output measure, are presented and their limitation is
discussed. Add to that, the yardstick productivity measure for shipbuilding yards, man-hours per
compensated gross tonnage, is presented. Based on this productivity measure, a method is proposed to
predict the ship production man-hours and its effectiveness is examined. In addition, the influence of
any improvements in ship production activities on the prediction approach is investigated.
A man-hour is the amount of work done by one worker in one hour. Ten people working for eight
hours would do 80 man-hours of work, for example. If you know, from experience or prediction, how
many man hours it takes to complete a certain project, you can estimate how productivity will be
affected by adding or removing workers. This does not always work perfectly; doubling the number
of workers on a construction site might not halve the building time because you only have one
working crane, for example. Still, man-hours are an important concept in managing teams of workers.

Calculating man-hours

Determine how many people are working on the project. For our example, we will say that we have
20 workers. Calculate how many hours each person works, not counting break time, holidays
or vacations. Multiply the number of hours per day by the number of days worked. For our example,
we will assume that all our employees work 8 hours a day, minus a half hour break time, five days a
week. This means that each employee contributes 37.5 man-hours per week. 3. 3 Multiply how much
each person works by the total number of workers. In our example, 20 people working 37.5 hours a
week equals 750 man-hours in one week.
Calculating how long it will take to complete a project.
Determine how many man-hours it takes to finish the project. This will either be known from
experience or will have to be estimated, and is specific to each project. As an example, let's say our 20
employees will be planting corn by hand. We want to plant 30 acres of corn by hand, and we expect
this to require 800 manhours. Divide the number of man-hours required by the number of workers.
800 man-hours divided by 20 workers is 40 hours. Since our workers put in a little under 40 hours
each week due to breaks, they will be able to finish planting in just over five days. Perform the same
calculation with a different number of workers to see the effect of hiring extra help or taking people
off the project. If we cut our workforce by five people, for example, it would take 53.3 hours, or just
over seven days (800/15=53.3). Divide the number of man-hours needed to complete the project by
the amount of time you want it to take. This calculation will tell you how many people must be put on
the job to finish it within a certain deadline. Let's say our corn needs to be planted within three days,
because we want it to be finished by the time it's forecast to rain. Since one worker does 7.5 hours of
work a day, he or she would do 22.5 hours of work in 3 days. Divide 800 by 22.5 to get 35.6. We
would need 36 workers (or 35 full-time workers and 1 part time worker) to finish the job in time.
How to Calculate Man Hour Costs
Labour costs include wages paid to workers for doing a certain amount or hours of work. Often
you may need to make a choice between contractors when one company explicitly quotes an hour rate

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while the other proposes a flat rate to complete the same amount of work. To properly compare such
offers and find out the best deal, you need to calculate costs per man, per hour. As an example,
calculate such costs if three men accomplished a project for a flat rate of $15,120 working
seven business days, eight hours a day.
Things You'll Need:
Multiply the number of days by the number of working hours per day to calculate the total number
of hours. In our example, the number of hours is 7 days x 8 hours/day = 56 hours. Multiply hours by
the number of workers to compute a man-hour value. In our example, man-hours needed to complete
the project is 56 hours x 3 men = 168 man-hours. Divide the total labour cost by the man-hours value
calculate the man-hour rate. In this example, the man-hour costs are $15,120 / 168 man-hours = $90
per man-hour.
3. Briefly discuss the production documents required for ship Block production?
There are various types of documentation
Production documentation; for block construction
• Part list
• Profile list
• Nesting
• Material requirement
• Plate bending bending data
• Weight and centre of gravity
• Assembly sequence
Production Documents;
• Block erection
• Sequence hull construction
• Steel hot work
• Pipe work(piping)
• HVAC work
• Electrical cambering and insulation work
• Living and bulkheads
• Point and deck covering
• Ceiling and doors
• Outfitting and finishing
• Fixturing and breakables

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Piping Documentation
• Material of pipes
• Schedule member
• Pipe standard
• Pipes classification according
• Schematic diagram
As on the basic of schematic diagram the cables laying process is been carried forward
as
• Run of cables /routing of cables
• Segregation
• Instauration arrangements
• Termination
• Marking
• Test after installation
Outfitting Documentation;
 Ship operation outfit documents
 Cargo handling outfit documents
 Safety and environmental control related outfit documents
 Stress control system outfit documents.

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4. Give a known shipyard layout and discuss the each aspect of the layout?

General Yard Layout

The guiding principle is logical material flow. This is facilitated by allowing adequate road ways for
transporters and other vehicles, such as forklifts, mobile cranes, and centerlift carriers. Personnel
traffic should be separated from industrial traffic and provision made for personnel transport from
parking areas located away from the industrial part of the yard. The perimeter of the shipyard should
be reserved for rail, barge, and truck delivery of raw materials and interim products that were built at
other shipyard facilities or by subcontractors. Parking and administration buildings should also be
located on the perimeter to avoid interference with material delivery.

Building positions

The traditional building position for ships are longitudinal sloped building ways or shipways the
vessel is built on blocks and other supports. Just prior to launching, support is shifted to stationary
groundways and sliding ways positioned above the ground ways. Addition temporary supporting
structures, called cradles and poppets, are also installed. At launching, release mechanisms are used,

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permitting the vessel to slide down the ways into the water. Ships are commonly launched stern first
on longitudinal shipways. Detailed arrangements and computations are required to assure launches do
not damage the new vessel. The disadvantages of conventional sloped shipways, primarily in terms of
aligning blocks, were discussed previously. Alternatives include graving docks, side-launch shipways,
or erecting the ship on land-level building ways and moving it to a floating dry dock or ship lift for
launch.

Material handling
The adoption by many yards of heavy-lift surface transporters represents a major change
in material-handling equipment over the past two decades. This followed the introduction and growth
in size of modules.
Warehousing facilities
In many groups technology shipyard’s rehousing, pallet preparation, and all transport equipment are
the responsibility of the material control group

Cutting Edge Preparation

Material to be N/C cut is generally chosen because of its difficulty in burning and layout.
Numerically controlled burning is generally used for processes requiring high precision and for plates
cut repetitively from the same N/Tape or data. of recommended cutting methods for different
categories of steel parts and the reasons for each selection are instructive and should give the reader
insight into available equipment and selection criteria.

BLASTING AND PAINTING

• Block surface preparation and painting
• Parts fabrication shop
• Erection and painting
• Pipe fabrication.

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5. Explain how Block division plan made and what parameters of block construction extracted
from block division plan
Requirements in generation of block division Plan
Requirements in generation of block division it is necessary to optimize both of the seam
position and the combination of the parts the concept of dimension optimization can be applied into
optimization of seam position which has already researched in the field of structure optimization
therefore the main problem to realize the optimization of block division is to develop the method it is
required to optimize not only erection block but also all the hierarchy from parts to ship.
Requirements in evaluation of the division plan
The effectiveness to use the product model information in the evaluation has been proved in the
previous researches therefore it is desirable to achieve the evaluation using the product model by
integrating optimization engine and product model.

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