Development of an Interim Product Structurefor Shipbuilding

First Marine International LimitedDesign for production

Development methodology and application of an interim product structure

Evolution of ship production technologyConstruction methodProduction technologyOperations effectPiece part construction on building ways Multiple building positions Limited production equipment Long construction cycle time Sequential production operations Highly labor intensiveBlock assembly and erectionon building ways or in a building dock Reduced building positions Increased fabrication equipment Some automated panel assembly Reduced construction cycle time Parallel assembly of blocks Excessive block assembly time Narrow product range Long learning curve on 1st of class Hierarchical interim productassembly throughout definedstages of construction Single building position High levels of automation Maximized use of robotics Minimum construction cycle time Totally integrated ship assembly Maximized labor / facility utilization Broad product range No learning curve on 1st of classSTICK BUILDINGBLOCK BUILDINGPRODUCT ORIENTED

PRODUCT ORIENTEDImprove performanceIncrease outputReduce priceExpand marketIncrease profitConstruction evolution

PRODUCT ORIENTEDConstruction evolutionDesign Methodology: Top down - progressively developing levels of detail. Outside inwards - starting with hull form and filling it with necessary systems. Unique design - limited repeatability across ship types.Design Methodology: Bottom up - progressively reducing the level of detail of lean designed interim products to match the level of ship definition. Inside outwards - optimizing the internal arrangement of interim products then wrapping the hull form. Unique vessel - through the aggregation of standard interim products with maximum repeatability across ship types

PRODUCT ORIENTEDTotal change in ship design methodology driving significantcultural changes throughout all traditional shipbuilding operations, management and organization.Construction evolutionThe design methodology has remained unchanged since the times of wooden vessels. It has been enhanced with computerization and adapted to suit the changes in materials and production equipment.

EVOLUTIONREVOLUTION INTERIM PRODUCT STRUCTURE The means for change Design methodology

PotentialOwnerBasic DesignVendorsTechnologyEquipmentProductionEngineeringTechnologyEquipmentFacilitiesProjectManagementPlanningPRODUCTIONPurchasingCost ControlVendorsClassificationOWNERVessel Design andEngineeringUnique Design Culture

Unique Design CultureVessel Design andEngineeringVessel Design andEngineeringThe process starts againLong lead timeExcessive production engineering effortRebuild planning information databaseIncreased capital investment in facilities Long and expensive learning curve on first of classSuccess relies on:Series build contractsRepeat orders for similar vesselsBeing highly competitive with a narrow product mix

Unique Vessel CultureMarketing &Conceptual DesignPreferredVendorsShipbuildingTechnologyEquipmentTechnologyEquipmentFacilitiesProductionEngineeringPlanningDatabaseOWNERVessel Design andEngineeringPotential customersInterimProduct Database

Unique Vessel CulturePRODUCTIONVessel Design andEngineeringPRODUCTIONMETHODOLOGYVessel Design andEngineeringInterimProduct DatabaseMethods and developments remainReduced Lead timeOngoing production engineering improvementsDeveloping planning information databaseStrategic capital investment planningMinimized learning curve on first of classSuccess relies on:The ability of the design and engineering functionsto consistently apply the interim product structureto the design of all new vessels

Product-oriented production is:-The definition of a shipyards product range as a clearlydefined hierarchy of assemblies. Each assembly beingan interim product in the construction of the completevessel. The categorization of those assemblies by production process similarity to establish interim product families. The development of dedicated production process lanes for each product family which maximizes the application of automation and robotics to realize optimum shipyard performance across a wide product range.

Identify Block / Unit FamiliesDevelop FacilitiesDefine interim productsPrepare processengineeringBlock Breakdown / Outfit UnitizationDesign Rules andGuidelinesOverall ApproachSteel DesignOutfit DesignZone Definition

Primary Zone CharacteristicsMajor areas of the vessel which require different approachesfor assembly and constructionUsually with different structural configurations anddifferent concentrations and types of outfitting

Limited levels of outfitting usually consisting of minorequipment, piping and electrical may include some stores.Bow and Stern Primary ZonesComplex 3D structure with minimum opportunity forautomatic assembly. Usually long assembly cycle times.

Low levels of relatively simple outfitting usually confinedto cargo handling and hold access systems.Primarily heavy flat steel structure with double skin andsingle skin block configuration highly suited to automatedassembly. Cargo Hold Primary Zone

High levels of machinery outfitting traditionally involvingthe highest concentration of outfit manhours and trade disciplines. Primarily curved panel and shaped flat panel structurehaving open block configurations suitable for semi-automated assembly.Machinery Space Primary Zone

High levels of hotel outfitting highly suited for modular orcontainerized production.Relatively light flat panel structure highly suitable forautomatic and semi-automatic assembly in dedicatedprocess lanes.Accommodation Primary Zone

If you consider the cargo hold then:Zones are defined in a three tier hierarchy.Primary, secondary and tertiary.

They must be capable of flexible definitionwithin the primary zones to suit the work packaging.

For example, a zone suitable for a painting work package is not necessarily suitable for a pipe installation work packageZone Hierarchy

Cargo Hold - Primary ZoneThe primary zone includes all of the cargo hold areafrom the forward engine room bulkhead to the foreend collision bulkhead. Including the main deckand external hull.

Cargo Hold - Secondary ZonesTypical secondary zones would be: Inner bottom zone Side tank zones Center tank zones Main deck zone

Cargo Hold - Tertiary ZonesTypical secondary zones would be: Inner bottom tank zones Center tank zones Side tank zones Inner side shell zones Center deck zones Side deck zones

Zone DefinitionBlock Breakdown / Outfit UnitizationZone Definition

Establish a natural block breakdown in each primary zone of the vessel.Avoid areas of complexconnection, alignment andwork content.Make block breaks selfstaging from the structureEnsure that erected blocksare self supporting andaligning.For example, in the cargo hold zone:Basic Rules forNatural Block Breakdown

3D Flat Panel BlocksBlocks assembled fromtwo or more flat built-up panels in a 3D configurationwithout a flat working basefor completionDouble Skin Panel BlocksBlocks assembled on a flatdouble skin base and built upwith other panels and subassemblies Flat Panel BlocksBlocks assembled fromtwo or more flat builtup panels on a flat panelbase1. Flat panel blocks2. 3D Flat panel blocks3. Double skin panel blocksCargo Hold ZoneIdentify Block TypesBlocks which can utilize the same production process and have a similar assemblymethodology.

Define functionalspaces in each primary zoneDefine servicesroutes in each primary zoneSuperimpose cross zone services routes. Define Primary zone interfacesSuperimpose services lines in routes. Define secondary zone interfacesSuperimpose services lines in routes. Define tertiary zone interfaces.Refine functionalspaces in each secondary zoneFinalise services routes. Define block & unit interfacesDefine the outfit breakdown for block, unit & zone outfittingDefine shipboard primary zones and principal services routes through zones

Identify Block / Unit FamiliesBlock Breakdown / Unitization

Establish the block types in all primary zones from the block breakdown:Flat single / double skin blocksComplex 3D blocksCurved single skin blocksLight flat panel blocks

Group similar block types across primaryzonesBlock Product FamiliesDefine the principalcharacteristics ofeach group of blocktypes: Scantling range Dimensions Weight Lifting and turningDefine block family characteristics

Identify Block /Unit FamiliesPrepare processengineering

Process engineering is:-The graphic representation of the assembly sequenceof a ship erection block, an outfit unit or a shipboard zone.It is prepared for each item or zone in a format which simulates a flow line production operation and identifiesthe stages of construction. It is used to determine the optimum assembly or installationsequence and to identify lower levels of interim products which are to be the subject of dedicated process lanes.

Block assembly analysisFore end block examplePrimarily steel work content

Using the block assembly analysis asa basis, develop the lower levels ofassembly in a shop floor productionsimulation Join double skin assemblyto flat panel baseUpper fore end blockComplete double skinassembly Complete flat built-uppanel assemblyComplete flat built-uppanel sub assemblyComplete flat built-upPanel minor assembliesJoin curved built-uppanel to flat panel baseComplete curved built-uppanel assemblyComplete curved built-uppanel sub assemblyComplete curved built-uppanel minor assembliesJoin soft nose assemblyto blockComplete soft nosesub assemblyComplete soft noseminor assembliesCompletedBlock- Stages of construction

Engine Room Block- On-block OutfittingUsing the block assembly analysis as a basis, develop the lower levels of assembly in a shop floor production orientationCompletedBlockBlockAssemblySubAssembly

Prepare Process EngineeringIdentify Block / Unit FamiliesDefine interim productsPrepare processengineeringBlock Breakdown / Outfit UnitizationZone Definition

Using the block process engineering look for areas where a fundamental process changeoccurs or there is a change in stage of constructionand identify the interim products STAGE OF CONSTRUCTION CHANGE AREAS

FUNDAMENTAL PROCESS CHANGE AREAS

From the block process engineering, extractthe defined interim products and develop theblock type family tree or process flow-chartSmall minor assemblieshaving a T configurationEXTRACT THE INTERIM PRODUCTSSmall minor assembliesStiffened on one sideMinor assemblies havingA curved T configurationFull block length assembliesstiffened on one or two sidesComplex 3Dsub assembliesFlat stiffenedpanel assembliesFlat built-uppanel assembliesFlat built-up panelunit assembly3D blockAssembly

EXTRACT THE STEEL INTERIM PRODUCTSParallel mid-body hopper side block typesCategory A: Blocks clear of transverse bulkheadsCategory B: Blocks in way of transverse bulkheads - Hopper side block family

Ship ConstructionBlock AssemblySub AssemblyMinor AssemblyPart FabricationGrand Block AssemblyBlock AssemblyUnit AssemblyMajor Sub AssemblyCurved Panel AssemblyFlat Panel AssemblyMinor Sub AssemblyMinor AssemblyPlate Part FabricationFlat 3D Block Family Flat Built-up Unit FamilyFlat Built-up Panel FamilyComplex 3D Sub Assembly FamilyFlat Stiffened Panel FamilyShort Straight T Configuration FamilySmall Stiffened Assembly Family Long Stiffened Assembly FamilyCurved T Configuration FamilyRolled Plate Part FamilyShip ConstructionBlock AssemblyMinor AssemblySub AssemblyPartFabBlockUnitMinorSubPlatePartMajor SubMinor AssemblyGrandBlockFlatPanelCurvePanel3DBlockFlatBuiltFlatBuilt3DCompFlatStiffSmallTsSmallStiffLongStiffCurveTsRldPlate1836543654180901803690Construct the block process flowchart Identify the stages of construction Identify production work areas Identify product families Define interim product quantities Primarily steel work content

Within product rangeacross vesselsFrom current company performance and future throughput targets determine the: annual interim product throughput for each product family level of technology to be applied in production areas manning levels in each production area Address each interim product family in the hierarchy and engineer thestructural arrangements to match thedesired level of production technology Summarizethe interimproduct families

Ship ConstructionBlock AssemblySub AssemblyMinor AssemblyPartsBlock AssyOutfit Sub AssyOutfit Minor AssyOutfit PartsEquipment Sub AssyPipe Sub AssyPipe Minor AssyFoundation Minor AssyEquipment PartsPipes PartsStructural PartsIdentify product families - On-block Outfitting Block AssemblyPanel AssemblyPanel AssemblyPanel Assy

Within product rangeacross vesselsFrom current company performance and future throughput targets determine the: annual interim product throughput for each product family level of technology to be applied in production areas manning levels in each production area Address each interim product family in the hierarchy and engineer theoutfitting arrangements to match thedesired level of production technology Summarizethe interimproduct families

Within product rangeacross vesselsFrom current company performance and future throughput targets determine the: annual interim product throughput for each product family level of technology to be applied in production areas manning levels in each production area Address each interim product family in the hierarchy and engineer theoutfitting arrangements to match thedesired level of production technology Summarizethe interimproduct families

Engineer the interim product arrangements - For example the steel hopper side blockLimited automated assemblyopportunitiesLarge web assembly, uniqueto block type, difficult handlingDifficult fitting and weldingof large curved face plateShell longitudinals fitted intoweb slots and shell plates fittedIndividually Limited automation largelymanual assembly and welding

Steel hopper side block structural arrangement Web plating arranged to enable theassembly of built-up flat panel unitson automated assembly linesReduced workcontent at blockassemblyParallel assembly of units, reducedcycle timeWeb assemblysimilar to otherareas of vesselDifficultfitting andwelding oflarge curvedface platesDifficult fitting and welding ofbilge plate and longitudinalTraditional block assembly structural configurationLargely manual assembly processes with high manhourslong assembly cycle time and difficult work orientations

Unitized assembly structural configurationReduced work content at block assembly with increasedautomated unit assembly opportunities and reduced cycle time,difficult sub-assembly configurations with high manhours. For example, hopper side block structural arrangement Face flat toeliminateplate seamBilge assemblyfor specialized jigStandard Tbeam assemblySmall curved face flat brackets for specializedrobotic weldingTraditional block assembly structural configurationLargely manual assembly processes with high manhourslong assembly cycle time and difficult work orientations

Define level of assembly technologyReview process engineering and revise as necessaryReview process flowcharts and revise as necessaryProduct-oriented structural configurationMaximized use of automated process lines with increased opportunities for robotics Standard configurations of interim products and the separation of complex assemblies for specialized jig and manipulator assembly Unitized assembly structural configurationReduced work content at block assembly with increasedautomated unit assembly opportunities and reduced cycle time,difficult sub-assembly configurations with high manhours. For example, hopper side block structural arrangement Traditional block assembly structural configurationLargely manual assembly processes with high manhourslong assembly cycle time and difficult work orientations

Panel Plates thickness range dimensions weight range side shape range edge preparations steel quality range number per panelDefine the interim product family characteristics Flat Stiffened PanelsFlat Built-up PanelsComplex Sub-assembliesPanel Stiffeners section range scantling range weight range fitting angle range edge preparations steel quality range spacing range number per panelStiffened Panels dimension range weight range plate butt joint length range stiffener fillet joint length range throughput requirementTransverse Webs dimension range weight range connection fitting variations fitting angle range edge preparations steel quality range number per panelLongitudinal Girders dimension range weight range connection fitting variations fitting angle range edge preparations steel quality range number per panelBuilt-up Flat Panels dimension range weight range plate butt joint length range fillet joint length range throughput requirement component configuration variations component weight variations component fitting angle variations dimension range weight range plate butt joint length range fillet joint length range throughput requirementReduce variationand define acceptable rangeCompile product familydatabase from characteristics

Define Interim ProductsDevelop Facilities

Define the high volume steel interim product process lane requirementsFor example flat built-up panel unitsProduct CharacteristicsSub-assembly CharacteristicsUnit assembly CharacteristicsPerformance CharacteristicsSub Assembly - Flat stiffened PanelsUnit Assembly - Flat built-up unitsPerformance - Cycle time and manhoursProduct FamilyStiffener CharacteristicsScantlingsSpacingPlate CharacteristicsThickness rangeEdge preparationsSteel QualityProduct FamilyFamily CharacteristicsMaximum dimensionsMinimum dimensionsMaximum unit weightOptimum Unit SizeNumber of platesNumber of stiffenersNumber of websSub Assembly PerformanceCycle time requirementsManhour requirementsUnit Assembly PerformanceCycle time requirementsManhour requirementsDesign the process lane layout and specify equipmentFlat stiffened panel outputFlat built-up unit output

Identify complex assembly products - Bilge sub assembliesBilge sub assembly product family characteristics(from preferred structural configurations) Closed bilge assemblyOpen bilge assemblyStructure variationLongitudinals on margin plateTwo or more bilge platesShell longitudinalsaround bilge Stiffening onOutboard side of girderGeometric variationDefine acceptable variation range

Complex assembly products - Bilge sub assembly product family Product assembly sequence Closed bilge assemblyBilge floors to margin plateBilge girder to floors andmargin plateBilge plate to floors, girderand margin plateBilge floors to bilge girderBilge plate to floors and girderOpen bilge assembly

Bilge sub assembly product family - Fitting jig design Product assembly baseTank top margin plate orBilge girderDesign jig baseFixed and leveled ground beams Adjustable floor beams(forward and aft adjustment)Adjustable height supports

Set bilge floorsDesign floor setting toolBilge sub assembly product family - Fitting jig design Adjustable floor clampPivot forward and aft toset floor angleMagnet clamps tomargin plate / girderand floors

Set bilge girderClosed bilge assembly onlyDesign girder setting jigBilge sub assembly product family - Fitting jig design Adjustable girder setting armForward and aft pivot forfloor angle alignment

Bilge sub assembly product family - Fitting jig design Adjustable bilge platelower clampBilge plate fairing chainUpper chain guideHydraulic chain tensioning jackHydraulic pin type bilgeplate fairing jacksSet bilge shell platesDesign shell plate setting jigDefine jig variation constraints

Develop Facilities

Summarize the product analysis and facility developmentFor each ship type in the product rangeDescribe the zone definition methodology Typical examples of zone subdivision for each vessel type in the companys current product rangeRules and guide lines for the identification and application of a shipboard zoning system must include: The methodology for identification of shipboard zones and at what stage in the design and engineering process each level of zoning is defined The application of the zoning hierarchy in the development of the vessel cost and manpower estimate, design and development of production information The application of the zoning hierarchy in the production of the vessel for production and material control, manpower control, production work packaging, system traceability and vessel completion.Secondary ZoningRule set and guidelines for the identificationand application of secondary shipboard zones during the development and execution of a double hull tanker contractTertiary ZoningRule set and guidelines for the identificationand application of tertiary shipboard zones during the development and execution of a double hull tanker contractPrimary ZoningRule set and guidelines for the identificationand application of primary shipboard zones during the development and execution of a double hull tanker contract

For each ship type in the product rangeDescribe the zone definition methodologyDevelop generic rulesand guidelines for zonedefinition

Define the rules for the development of a natural block breakdownDevelop the optimum structural arrangement at each blockerection jointDevelop the optimum block breakdown in each primary zoneof each vessel in the current product rangeDefine the block erection sequence and the range ofblock weightsCalculate the average joint length by weld type for each blockFor each ship type in the product rangeDevelop the block breakdown methodology12345678910

Define the rules for the development of a natural block breakdownDevelop the optimum structural arrangement at each blockerection jointDevelop the optimum block breakdown in each primary zoneof each vessel in the current product rangeDefine the block erection sequence and the range ofblock weightsCalculate the average joint length by weld type for each blockFor each ship type in the product rangeDevelop the block breakdown methodologyBlock BreakdownRules and guidelines for the development ofThe block breakdown: Positioning of block breaks Block erection sequence Range of block weights Optimum structural arrangements at each block erection joint

Define the rules for the development of a natural block breakdownDevelop the optimum structural arrangement at each blockerection jointDevelop the optimum block breakdown in each primary zoneof each vessel in the current product rangeDefine the block erection sequence and the range ofblock weightsDefine the facility constraints for block erectionDock/building way constraintsMaximum and minimum vessel sizesCalculate the average joint length by weld type for each blockCranage constraints and capacitiesTandem lift capabilitiesBlock erection and setting timesErection joint cycle timesFor each ship type in the product rangeDevelop the block breakdown methodology

Define the rules for the development of a natural block breakdownDevelop the optimum structural arrangement at each blockerection jointDevelop the optimum block breakdown in each primary zoneof each vessel in the current product rangeDefine the block erection sequence and the range ofblock weightsDefine the facility constraints for block erectionDock/building way constraintsMaximum and minimum vessel sizesCalculate the average joint length by weld type for each blockCranage constraints and capacitiesTandem lift capabilitiesBlock erection and setting timesErection joint cycle timesFor each ship type in the product rangeDevelop the block breakdown methodologyBlock BreakdownRules and guidelines for the development ofThe block breakdown: Positioning of block breaks Block erection sequence Range of block weights Optimum structural arrangements at each block erection jointShip Erection ConstraintsRules and guidelines for shipconstruction Vessel sizes Cranage constraints Block erection times Erection joint cycle times

For each ship type in the product rangeDevelop the block breakdown methodologyBlock BreakdownRules and guidelines for the development ofThe block breakdown: Positioning of block breaks Block erection sequence Range of block weights Optimum structural arrangements at each block erection jointShip Erection ConstraintsRules and guidelines for shipconstruction Vessel sizes Cranage constraints Block erection times Erection joint cycle timesDevelop generic rulesand guidelines for thedevelopment of vesselblock breakdowns

Develop the optimum process engineering for each blockfamily in the current product rangeDefine the format and content of process engineering informationDescribe the methodology for developing process engineering and at what stage in the design and engineering process each level of process engineering is preparedDescribe the application of process engineering in the development of the vessel design and production informationDescribe the application of process engineering in the production of the vessel for production and material control, production work packaging and vessel completion.For each block familyDevelop process engineering and flowchartsAgree the assembly sequence and methodology for each block family

Develop the optimum process engineering for each blockfamily in the current product rangeAgree the assembly sequence and methodology for each block family Define the format and content of process engineering informationDescribe the methodology for developing process engineering and at what stage in the design and engineering process each level of process engineering is preparedDescribe the application of process engineering in the development of the vessel design and production informationDescribe the application of process engineering in the production of the vessel for production and material control, production work packaging and vessel completion.Process engineering Rules for the development of process engineering. Application of process engineering in pre-production and production operations Process engineering of each block familyFor each block familyDevelop process engineering and flowcharts

Process engineering Rules for the development of process engineering. Application of process engineering in pre-production and production operations Process engineering of each block familyDevelop the process flowchart for each block familyIn the current product rangeAgree the stage of construction, work area and product families for each of the interim products in the block familiesDefine the format and content of process flowchartinformationDescribe the methodology for developing process flowchartsand at what stage in the design and engineering processeach level of process flowchart is preparedDescribe the application of the process flowcharts in the development of production information and production planning of a contractDescribe the application of the process flowcharts for productioncontrol and workstation loading and schedulingFor each block familyDevelop process engineering and flowcharts

Describe the application of the process flowcharts for productioncontrol and workstation loading and schedulingDevelop the process flowchart for each block familyIn the current product rangeAgree the stage of construction, work area and product families for each of the interim products in the block familiesDefine the format and content of process flowchartinformationDescribe the methodology for developing process flowchartsand at what stage in the design and engineering processeach level of process flowchart is preparedDescribe the application of the process flowcharts in the development of production information and production planning of a contractProcess engineering Rules for the development of process engineering. Application of process engineering in pre-production and production operations Process engineering of each block familyProcess flowcharts Rules for the development of process flowcharts Application of process flowcharts in pre-production and production operations Process flowcharts for each block familyFor each block familyDevelop process engineering and flowcharts

For each block familyDevelop process engineering and flowchartsDevelop generic rulesand guidelines for thedevelopment of blockprocess engineering

For each steel interim product familyDevelop interim product data sheetsDefine the interim product family characteristicsDefine size, weight and work content rangeDefine the range of acceptable structural variationsDefine the range of acceptable geometric variationsProduct Family Characteristics Range of acceptable dimensions Range of product weights Range of work content Structural & geometric variation

Product Family Characteristics Range of acceptable dimensions Range of product weights Range of work content Structural & geometric variationMaximum weight of productFor each steel interim product familyDevelop interim product data sheetsDefine the interim product family characteristicsDefine size, weight and work content rangeDefine the range of acceptable structural variationsDefine the range of acceptable geometric variationsDefine production process characteristicsDescribe the product assembly sequenceDescribe the process capabilityDefine the product production cycle timeDefine the process lane throughput

For each steel interim product familyDevelop interim product data sheetsDefine the interim product family characteristicsDefine size, weight and work content rangeDefine the range of acceptable structural variationsDefine the range of acceptable geometric variationsProduct Family Characteristics Range of acceptable dimensions Range of product weights Range of work content Structural & geometric variationDefine production process characteristicsDescribe the product assembly sequenceDescribe the process capabilityProduction process characteristics Product assembly sequence Process line/workstation capability Product cycle time Process lane throughputDefine the product production cycle timeDefine the process lane throughput

Format and content of drawings necessary to complete thework at the specified workstationFor each steel interim product familyDevelop interim product data sheetsDefine the interim product family characteristicsDefine size, weight and work content rangeDefine the range of acceptable structural variationsDefine the range of acceptable geometric variationsDefine production process characteristicsDescribe the product assembly sequenceDescribe the process capabilityDefine the product production cycle timeDefine the process lane throughputDefine format and content of production informationDefine format and content of product assembly informationDefine accuracy control proceduresDefine quality control procedures

For each steel interim product familyDevelop interim product data sheetsDefine the interim product family characteristicsDefine size, weight and work content rangeDefine the range of acceptable structural variationsDefine the range of acceptable geometric variationsProduct Family Characteristics Range of acceptable dimensions Range of product weights Range of work content Structural & geometric variationDefine production process characteristicsDescribe the product assembly sequenceDescribe the process capabilityProduction process characteristics Product assembly sequence Process line/workstation capability Product cycle time Process lane throughputDefine the product production cycle timeDefine the process lane throughputDefine format and content of production informationDefine format and content of product assembly informationDefine accuracy control proceduresDefine quality control proceduresFormat & content of PI Drawing format and content Accuracy control procedures Quality control procedures

For each outfit interim product familyDevelop interim product data sheetsDefine the interim product family characteristicsDefine size, weight and work content rangeDefine the range of acceptable product variationsDefine the range of acceptable geometric variationsProduct Family CharacteristicsProduct Family Characteristics Range of acceptable dimensions Range of product weights Range of work content Structural & geometric variation

For each outfit interim product familyDefine format and content of production informationDefine format and content of product assembly informationDefine accuracy control proceduresDefine quality control proceduresFormat and content of production informationFormat & content of PI Drawing format and content Accuracy control procedures Quality control procedures

Database contents and controlAuthorized by senior company officialsAll department managers ACCOUNTABLE for implementationPoliced by production engineering departmentFormalized process for changeChange implementation only after formal authorization

Database contents and controlShipboard ZoningZone definition for each vessel in the current product rangeRules and guidelines for developing shipboard zonesDefinition of stage of design identification of zonesRules and guidelines for the implementation of zoning methodology in pre-production and production operationsZoning MethodologyDatabase

Block breakdown for each vessel in the current product rangeShip Block BreakdownRules and guidelines for the development of a block breakdownDatabase contents and controlZoning MethodologyPreferred configurations of erection jointsErection facility constraints and attributesBlock Breakdown MethodologyDatabase

Process engineering for each block type in current product rangeRules and guidelines for developing process engineeringDefinition of stage of design development of process engineeringRules and guidelines for the application of process engineeringmethodology in pre-production and production operationsBlock Process EngineeringDatabase contents and controlZoning MethodologyBlock Breakdown MethodologyProcess Engineering MethodologyDatabase

Preferred interim products and characteristics for the construction of all types of vesselsDefined production processes, constraints and attributes for allproduction process lanes and workstationsDefined format and content of production information requiredto efficiently construct a vessel through all stages of productionInterim Product StructureDatabase contents and controlZoning MethodologyBlock Breakdown MethodologyProcess Engineering MethodologyDatabaseCompanyInterim ProductStructure

Zoning MethodologyBlock Breakdown MethodologyProcess Engineering MethodologyCompanyInterim ProductStructureDatabase ApplicationAnalytical base for all operationsdevelopment and controlApply to the designof a new vesselAssessment of the producibility of a new vessel designProduction impact assessmentof a new vessel designApply to the designof new facilitiesIdentify facility developmentrequirementsMonitor efficient operationof facilityMonitor development of designand production informationSpecify performanceApply to performanceimprovementIdentify areas for performanceimprovementDevelop process change andassess performance impactImplement and monitor changein pre-production and productionoperations Interim ProductDatabase

Interim Product DatabaseDesign Rules andGuidelinesSteel DesignOutfit Design

The design rules and guidelines must:Interpret the interim product structure in a waydirectly applicable to the design and engineering process.Provide rules and guidelines for each stage of the design and engineering process. Provide decision making criteria which define the impact of alternative design/engineering solutionson the performance of the production processes.

For example: The development of a midship sectionStructural ConfigurationsPreferredstructuralconfigurations

For example: The development of a midship sectionStructural ConfigurationsDouble skin process line attributes and constraints Base panel identification Secondary panel identification Preferred cut-out and connection configurations Panel size and acceptable scantling variation Double skin depth constraints Preferredstructuralconfigurations Plate edge preparation orientationsProcess lane attributes and constraintsProduction process laneAttributes and constraints

For example: The development of a midship sectionStructural ConfigurationsPreferredstructuralconfigurationsProcess lane attributes and constraintsProduction process laneAttributes and constraintsBlock Breakdown Options Identification of optimum block break locations Definition of optimum block break arrangements Block dimension and weight constraintsBlock breakdown optionsBlock Breakdown Options

Develop the design rule database - Steelwork Design

For example: The development of a Lower Machinery SpaceSpatial arrangement of main and auxiliary equipment throughout each primary zoneSpatial arrangement of service routes throughout each primary zonePrimary Zone Definition

Development of a Lower Machinery SpaceDefine secondary zones and continue design develop[ment.Allocation of the local functional spaces in the secondary zonesDefine initial integrated block breakdownDefine final integrated block breakdown and erection sequence.

Development of a Lower Machinery SpacePreferred unitized assembly configurations

Development of a Lower Machinery SpaceEquipment & pipe assembly process lane attributes and constraints

UnderstandingCommitmentDevelopmentImplementationUnderstandingCommitmentDevelopmentImplementationPRODUCT ORIENTED OPERATIONS

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