Feature of Shipbuilding Industry

8/11/2019 Feature of Shipbuilding Industry

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1. Capital IntensiveFacility Optimization

2. Labor IntensiveSkilled labor

Trained engineer/technician

3. Technology IntensiveHull form development

High-tech application

4. Long-Term ROI

5. Global CompetitionPrice

Quality Requires Q/C & Q/A

Delivery time - Requires

productivity improvement

Financing Export credit

6. Spillover EffectsEmployment

Technology

Ancillary industry

Economic impact

7. Cycle-Boom-and-Recession Industry

CHARACTERISTICS OF SHIPBUILDING INDUSTRY


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Quality

Price

Delivery

Financing

Good DesignProduction TechnologyQuality Control

Engineering CostMaterial CostOver HeadOther Management Cost

Production PlanningSchedulingCredibility

Export Credit

Technology Enhancementby continued training andR&D

StandardizationHigh ProductivityLocalizationPackage Purchase

Computer IntegratedProduction ManagementSystem

Long Term / Low InterestExport Credit Facility

GLOBAL COMPETITION


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Shipbuilding is an assembly process, involving hundreds of thousands of individually

prefabricated parts and items of machinery, equipment and outfit. The secret of

efficient shipbuilding lies in how efficiently we can put them all together.

Technological change has transformed shipbuilding from a project-oriented

construction process to a mass-production manufacturing process. Ships are now

built in factories

THE SHIPBUILDING PROCESS

CONSTRUCTION ACTIVITY

Preparation for production

Prefabrication and

block assembly

Hull erection

Completion and testing

MILESTONE EVENT

1. Execute Contract

2. Cut Steel

3. Lay Keel

4. Float Out

5. Delivery


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- m o d u

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a i n

t i n g

D i m e n s i o n

c o n

t r o l

& i n

s p e c

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( i n c l u

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)

T r a n s p o r

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)

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EXAMPLE OF A TYPICAL SHIPBUILDING PROCESS

Material receiving& preparation

Marking, cutting &conditioning of steel

Assembly of 2Dblocks

Assembly of 3Dblocks

Assembly ofgrand blocks

Erection

Launching

Commissioning& trials

Delivery

B l o c k o u

t f i t t i n g


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PROGRESS OF SHIPBUILDING TECHNONOLOGY (Cont.)

Computers allow detailed definition of every part, integrated purchasing, detailed

planning and scheduling of every construction activity, resource leveling

Precision Steel Cutting results in better fit, robotic welding, reduction in rework,

improved quality

Pre-Outfitting prefabricating outfit material in a shop and fitting it on a hull block inanother shop is more than 3x more efficient than fitting it piece by piece on board

ship and more than 9x more efficient than fitting it on a ship that is afloat

Goliath Cranes building a ship in 900-ton blocks is a lot more efficient than building

it in 60-ton blocks

Mega Docks building five ships at a time in one dock is a lot more efficient than

building one ship in each of five docks


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PREPARATION FOR PRODUCTION (Cont.)

Design and engineering two steps:

Functional design is the detailed specification of all structure, material and

equipment, meeting all the relevant regulatory requirements

Production engineering is the development of all the detailed drawings, sketches,

instructions and other documentation needed by the shipyard to build the ship.

Production planning three steps:

Build strategy: how are we going to build this ship?

Scheduling: when are we going to build it?

Resource allocation: what manpower/facilities do we need?

Procurement three main areas:

Major and long-lead-time machinery and equipment

Commodity materials, such as steel, pipe, cable and paint

Subcontractors


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PREFABRICATION

Hull Steel:

JIT delivery of plates and structural shapes to a storage area

Blasting and painting with a primer

Cutting, marking, shaping, labeling

Manufacture of two-dimensional subassemblies (panels)

Outfit:

JIT delivery of pipe and other material to warehouses

Cutting, marking, shaping, labeling, palletizationJIT delivery to the appropriate work stations for attachment to or installation on

hull structure


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PREFABRICATION OF PLATES


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PREFABRICATION OF FLAT PANELS


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PREFABRICATION OF OUTFIT


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8. BLOCK ASSEMBLY

Flat-Panel Blocks:

Three-dimensional assemblies of flat panelsPre-outfitted: everything that goes into them piping, vent ducting, cable trays

is installed in the shop

Fully painted except at the butts

Curved-Panel Blocks:

Three-dimensional assemblies of both flat and curved panels involvingthe complex shape of the hull structure fore and aft and requiring

computer-set jigs

The processes are the same as for flat-panel blocks but are much more complex

Equipment Modules:

Three-dimensional, self-supporting, self-erecting assemblies of equipment,mounted on foundations or temporary skids

Everything in a module is tested and operational:

only the external connections remain


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FLAT-PANEL BLOCKS


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CURVED-PANEL BLOCKS


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CURVED-PANEL BLOCKS (Cont.)


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10. GRAND BLOCKS

Blocks may be combined into mega blocks, giga blocks and even tera blocks" that weighas much as 3,000 tons or more, especially if they are to be assembled in a floating dock.


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GRAND BLOCKS


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11. HULL ERECTION

The big three "Koreans each have at least one mega dock in which five or six ships

can be erected simultaneously: goliath cranes span the dock and the area alongside it.

As the blocks are set in place and aligned, the butts between them are welded up and

the tanks and other internal spaces are inspected and tested.

The dock is flooded about once every five or six weeks. Two or three of the ships in the

dock are then floated for the first time and their hull integrity is checked. The other two

or three, which were floated the last time the dock was flooded, are towed out and

moored at a pier. The dock is then pumped dry and erection of two or three more ships

is started.

In this way, one mega dock can produce 20 to 25 ships a year.

Single ships are also erected in smaller graving docks, in floating docks, and on

land-level facilities.


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HULL ERECTION IN A DOCK


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HULL ERECTION IN A DOCK (Cont.)


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HULL ERECTION IN A FLOATER


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HULL ERECTION ON A SLAB


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12. COMPLETION AND TESTING

Most big ships tankers, bulkers and containerships are 90% to 95% complete

when floated out of the dock.

Final outfitting and system testing is conducted once the ship is afloat and at a pier.

Trials are then carried out to confirm each ships performance characteristics: a

naming ceremony usually precedes delivery.

LNG carriers are different: they are only 60% to 65% complete when floated out of

the dock, because the cargo containment system cannot be installed until the hull

is complete.

Final outfitting and system testing of LNG carriers is conducted in parallel with theinstallation of the cargo containment system.

Trials of LNG carriers include rigorous testing of the cargo system with actual LNG,

in addition to all the standard procedures.


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13. NEW SHIPYARD PLANNING PROCESS

The main areas to be focused for the new shipyard planning are

OPTIMIZE

ECONOMIZE

MAXIMIZE

MINIMIZE

the facilities and layout

the capital expenditure

the production efficiency

the building cost (yard and ships)


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NEW SHIPYARD DEVELOPMENT PROCESS

STEP I

1. Worldwide and Domestic

Shipbuilding Market Study

2. Government Policy Review

3. Ancillary Industries Review

4. Infrastructure Review

5. Labor Availability Study

STEP II

6. Site Selection(Data Analysis & Evaluation)

7. Shipyard Design Criteria

8. Shipyard Capacity Planning

9. Production Flow &Methodology

10. Shipyard Layout

STEP III

11. Workshop & ProductionFacilities Planning

12. Selection of Machinery& Equipment

13. Engineering & ConstructionPlanning

14. Manpower Planning

15. Organization &Management Plan

16. Construction Schedule

17. Project Cost Estimation

18. Financial Feasibility Study


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14. SHIPYARD PLANNING STAGE I

AREA 1Shipyard Facility

1. Review of Clients Requirement

2. Preliminary Site Survey

3. Shipyard Capacity

4. Shipyard Layout

5. Machinery & EquipmentSelection

6. Production Plan

7. Preliminary Cost Estimate& Scheduling

Conceptual Design & Preliminary Feasibility Study

AREA 2Civil & Building Work

1. Review ofBasic Site Information

2. Preliminary Study of Civil,Building and Other Structures

3. Preliminary Cost Estimation& Scheduling

AREA 3Shipyard Management

1. Manpower Requirement

2. Management & Organization

3. Training

4. Financial Feasibility Study


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SHIPYARD PLANNING STAGE III AND IV

STAGE III - Tender

SELECTION OF CONTRACTOR

Detail Design Detail Scheduling

Detail Cost Estimation

ConstructionManagement

STAGE IV - Contract

SHIPYARD CONSTRUCTIONProcurement &

LogisticManagement

ConstructionManagement &

Supervision


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16. SHIPYARD CONSTRUCTION COST BREAK DOWN

Above figure is based on shipyard having 2 dry-dockscapable of buildings up to VLCC

Civil work(excl. harbor &

land cost)Machinery &

Crane

Equipment

Building WorkConsultancy &

Contingency


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17. SHIP PRICE BREAK DOWN


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18. HHI (Hyundai Heavy Industries)


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18. DSME (Daewoo Shipbuilding & Marine Engineering)


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Feature of Shipbuilding Industry

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