impact of competency in the malaysian , marine industry perspective – focus on shipbuilding
TRANSCRIPT
IMPACT OF COMPETENCY IN THE
MALAYSIAN , MARINE INDUSTRY
PERSPECTIVE –
FOCUS ON SHIPBUILDING
By
First Admiral Dato’ Ir Ahmad Murad b Omar (Retired),
FIEM, FIMarEST, MSNAME,
PEng, CEng, ASEAN Eng.
5 October 2016
REMME 2016 1
THE SPEAKER
First Admiral Dato’ Ir Ahmad Murad B Omar (Rtd)
BE (Mech) UTM. MSc EBM (Warwick), P Eng, C Eng, CMar Eng, FIEM, FIMarEST, MSNAME
(US), ASEAN Engineer
Vice President Institute or Marine Engineering Science & Technology
REMME 2016 2
…discuss the impact of competency in the Malaysian Marine
Industry perspective focusing on shipbuilding
Purpose
The purpose of this presentation is to…
REMME 2016 3
► Introduction - Shipbuilding
► Related Competencies vs Work
Breakdown Structure (WBS)
► Impact
► Recommendation
Content
This proposal is structured as follows:
REMME 2016 4
► Introduction
► Related Competencies vs Work
Breakdown Structure (WBS)
► Impact
► Recommendation
REMME 2016 5
RFQ Issuance of
LOA Design/detail
design Fabrication
Installation - outfitting
Commissioning Test/trials Physical handing
Over (PHO)
• Building Strategy
Introduction
REMME 2016 6
Phase 1 (RFQ & LOA)
Collboration agreement
Ident working framework
Submission RFQ
Technical clarification
TPS development
Final deliberation on technical & commercial
Identify & confirm final work packages . Issuance oc contract
Phase 2 (Design)
Aveva marine capability
Basic design - DCNS
Determination of final design protocol
Prelim Design
Detail Design
Develop production drawings
Phase 3 (Fabrication)
Confirm Production Engineering protocol (material
management)
Engage OEM for fabrication transfer of
technology
Supply material
Participitative engagement
production begins with prototyping & prelim
certification
In process monitoring
Final production & Certification
Phase 4 (install)
Master & understand build sequence
Project planning, coordination &
monitoring
Material & accessories & ILS element verified
Outfitting by Zone (Korean Best Practice)
Verification & Insp
Maintenance & Protection
Phase 5 (Test & Trials)
Compliance to drawings approved
Insp dry survey
Insp final & punch list clearance
Compartment closure Insp
Compartment handing over ensuring conformity & compliance
Verification ILS requirements
Make Ready for Physical Handing Over
(PHO)
Phase 6
(PHO)
Preparation of final handing over.
Insp certificate and verification of punch
list clearance
Insp protocol sign off agreement including
screening of ILS elements
ILS elements - documents, training, onboard spares, base
spares, STTE etc
Certificate sign-off and hand over
Determination of Warranty framework
• Breakdown Work packages Build Strategy
Introduction
REMME 2016 7
RFQ Issuance of
LOA Design/detail
design Fabrication Installation -
outfitting Commissioning Test/trials
Physical handing Over
(PHO)
• Overview of Complete Shipbuilding Activity &
Competencies Required
• Estimators • Engineers • Naval Arch • Financial
experts
• Design engineers
• Draughtsman • Naval Arch • Material
engineers • Skilled labor
• Project engineers
• QA/QC Engineers
• Project Engineers
• Naval Arch • Material
Supply chain controller
• Skilled labor force
• QA/QC Engineers
• Project Engineers
• Naval Arch • Commissioning
engineers • OEM
representative • Skilled labor
force
Introduction
REMME 2016 9
► Introduction
► Related Competencies vs Work
Breakdown Structure (WBS)
► Impact
► Recommendation
REMME 2016 10
Competencies vs Work Breakdown Structure
Through the phases of Build Strategy it is obvious that
there are different stages of construction that requires
sometimes similar skill sets and some other time differing
skill sets.
► Weak points identified:
Production Planning & Production Engineering processes
Supervisory, work coordination & work execution (Project
Management)
Subcontractors’ organizational capabilities
skill sets and experience.
REMME 2016 11
Competencies vs Work Breakdown Structure
Ship Building module scope of work mainly cover
implementation of Shipyard production planning system on
all ship building projects
► Job Design - work breakdown & work packaging system
► Job Method - Detailed Work Procedure (DWP)
► Reality-based Planning - Interactive system between planning &
production (Zone Manager - Discipline Integrator)
► Job Instruction - Work Execution Program (WEP)
► Production Method - Integrated Hull, Outfitting & Painting (IHOP)
► Project Management - effective practical methodology / Task Force
meetings
REMME 2016 12
Competencies vs Work Breakdown Structure
- Skills sets required in Shipbuilding
Managers
Administrators
Designers/Engineers
Production Work force
Heavy Equipment Operators
REMME 2016 13
Competencies vs Work Breakdown Structure
- Skills sets required in Shipbuilding
Managers
Project Related
Project Managers
Project Planning
Financial
Cost & Estimation
REMME 2016 14
Competencies vs Work Breakdown Structure
- Skills sets required in Shipbuilding
Administrators
Human Resource
Personnel
Procurement
Purchasing Supply Chain
Material Control
Facilities
REMME 2016 15
Competencies vs Work Breakdown Structure
- Skills sets required in Shipbuilding
Designer/Engineers
Planning
Work Breakdown
Zone Outfitting
Ship Design
Structural Construction
Detail Design
Drafting Production
Drawing
REMME 2016 16
Competencies vs Work Breakdown Structure
- Skills sets required in Shipbuilding
Production
Production Design*
Work Breakdown
Zone Outfitting
Production
Welding Piping Electrical HVAC Outfitting
QA & QC
Inspeectors NDT
REMME 2016 17
Competencies vs Work Breakdown Structure
- Skill sets required in Shipbuilding
Heavy Equipment
Operators
Machine MHEs
Cranage/Rigging
Goliath Crane
Gantry
Mechanical Handling Equip
Fork Lift Transporter Side Loader
REMME 2016 18
Competencies vs Work Breakdown Structure
- Flow Diagram of Ship Construction in a Typical Yard
SHIP 1 SHIP 2
SHIP 3
REMME 2016 19
Competencies vs Work Breakdown Structure
One of the better approach in completing a building
project on schedule would be to apply Korean best
practice. IHOP (Integrated Hull Outfitting & Painting)
REMME 2016 20
Competencies vs Work Breakdown Structure
- Adopting the Korean best practice produces tremendous results
- Achievement of jobs and work packages
- Lesser punch list
REMME 2016 21
► Introduction
► Related Competencies vs Work
Breakdown Structure (WBS)
► Impact
► Recommendation
REMME 2016 22
Impact
- Impact of skill sets on overall shipbuilding
process
Management
•Project mgt failure
•HR planning failure
•Financial fail
Administrators
•Supply chain fail
•Material handling fail
•Facilities ineffective
Design
•Drawings late
•Drawings error
•Design production fail
Production
•Welding failure rework
•HVAC delay
•Electrical cable pulling delay
•Piping delay
•Outfitting delay
Mechanical handling Equipment
•ME not available on time
•Defective
•Lifting delays
REMME 2016 23
Negative Impacts Skill Set Negative Impact Final Result
Project Management Project delays Late delivery charges
Cost estimation Cost projection/estimation run-out
Rectification & re-work cost
Human resource management Manpower utilization poor Manpower cost run-out
Procurement management Material delivery delay Impact on Gantt chart scheduling. Project delay.
Facilities mgt Facilities defective Replacement cost and outsourcing cost
Production design PMT fail to meet schedule Project delay. Cost increase
Drawing delays Impact on schedule Project delay
QA & QC failure Re-work and rectification cost Impact on schedule . liqudated delay.
Non availability of heavy machinery equipment
Cost increase for outsourcing Project cost increase.
REMME 2016 26
► Introduction
► Related Competencies vs Work
Breakdown Structure (WBS)
► Impact
► Recommendation
REMME 2016 27
Recommendation
► Improve shipbuilding line production system:
Indoor - steel fab / panel & block assy / block outfitting - ensuring optimal building method, max use of yard facilities & smooth production flow
On-platform - module outfitting / block painting, erection & joining / platform outfitting - ensuring block/module completion, pallet management, erection-fit up technic & use of IHOP schedule
On-board - on-board painting / HAT / SAT - through zone completion
Project Management Teams – PMT competency to be improved. Be mindful of ten Project Management Knowledge areas.
REMME 2016 28
Recommendation
► Improve shipbuilding line production system:
QA & QC – inspectors undertaking inspections such as welding, electrical. Piping, HVAC and outfitting must be qualified and trained.
Human Resource Development – Interpersonal and skill based training must be equally emphasized.
Disciplinary – all work force must be aware of good disciplinary abiding practice.
Supply Chain & Material Handling – is essential to be developed in order to circumvent delays and issuance of wrong itms.
REMME 2016 29
Recommendation
► Improve shipbuilding line production system:
Workshop Layout & Facilities Management - ensuring max use of yard facilities & smooth production flow
Streamline outfit parts manufacturing production system –
Steel Outfit Manufacture
Pipe Spool Manufacture
REMME 2016 30