Content
1. General Overview
2. Quality and HSE Management System
3. DMHI’s ERP System
4. Facilities and Capacities
5. Performance Record
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History
EARLY STAGE
INTEGRATION
MODERNIZATION INNOVATION
1974
1997
2 Mai Mangalia Shipyard
Daewoo Brand
DMHI - Most Competitive Heavy Industry in Europe
2008 Present Joint Venture
1974-1978 – Construction of shipyard’s site, Dry Dock No. 1 & 2 1976-1997 – Construction of various newbuilding projects such as Bulkcarrier 65,000 TDW / 100,000 TDW, Crude Oil Tankers of 89,000 TDW, as well as Offshore Jackets and the hull of the Frigate “Marasesti”
1985 – Start operating the 3rd and largest dry dock used for shiprepair business
Jan. 22 1997 – Daewoo-Mangalia Heavy Industries S.A. is founded as a joint venture company between Daewoo Shipbuilding & Marine Engineering Co.,Ltd.(Korea) and 2 Mai Mangalia Shipyard S.A.(Romania) 2004 – DMHI shifts its newbuilding strategy on the construction of complete big size commercial vessels only (Panamax / Post- Panamax Containerships, Panamax Tankers, Capesize BC) End 2007 – DMHI stops its ship repair business activity in order to construct only large-size new buildings
2008~2009 – Expansion of the shipyard site for new assembly and painting facilities and conversion of Dry Dock No.3 for newbuilding activity 2009 – Delivery of the biggest vessels ever built in Black Sea and Mediterranean Sea area : > 5,905 TEU for Hamburg Sud/Germany > 180K Capesize B/C for Tsakos / Greece 2011 – Setting a record in number of vessels delivered: 11 vessels, of which 5 Containerships, 3 Bulk Carriers, 2 AHTs and 1 submersible drilling barge 2015 – Delivery of 2 unit of 9,100 TEU Containership for Capital Ship Management, which is the biggest vessel ever built in the Black Sea and Mediterranean Sea area
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DSME (Korea) Daewoo Shipbuilding & Marine Engineering
51%
ROMANIAN GOVERNMENT
2 Mai Mangalia Shipyard
49%
Shareholder Structure
6
Organization Chart of DMHI
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HULL OUTDOOR DIVISION
OUTFITTING DIVISION
PAINTING DIVISION
PRODUCTION MANAGEMENT DIVISION
` MANAGEMENT UNIT PRODUCTION UNIT
VICE PRESIDENT
PRESIDENT & CEO
BOARD OF DIRECTORS
QUALITY / HSE MANAGEMENT DIVISION
INOVATION OFFFICE
ADMINISTRATION MANAGEMENT DIVISION
TECHNICAL SUPPORT DIVISION INDOOR DIVISION
Organization & People
DMHI 2,512 employees
Subsidiaries 1,083 employees
Subcontractors 4,746 employees
TOTAL 8,341 employees
As of December 2015
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INTERNAL SUBCONTRACTORS 4,746 employees
PRODUCTION (WORKERS AND FOREMEN)
1,694 employees
Business Concept
An industry leader in the global shipbuilding and offshore market. Most advanced competitive edge shipbuilding and offshore.
Vessel with high quality & technology
DESIGN
DSME Initial & Basic Design
(R&D, Model Test)
DSME / DSEC(*) Detail Engineering
(Class Approved Drawing)
DMHI Production
Design
SUPPLY CHAIN
DSME / DSEC Supply for Main Equipment
(Mainly Korea & Far East)
DMHI Purchase Bulk Material
(Plate / Profile / Paint)
DMHI Storage and Inventory Management (through ERP System)
PRODUCTION
DSME Know-How
Method / Machine
DMHI Production Planning
(through ERP System)
DMHI Production
DMHI Quality Control at DSME
Standard
Continuous know how transfer Client satisfaction
DSME Marketing Engineering Tendering &
Concept Design
DMHI Production Engineering Support
DMHI HSE Strong Policy
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(*) DSEC: DSME subsidiary for engineering and procurement
Integrated Management System (IMS) - Since December 2010
Implementing the Integrated Management System for Quality, Environmental and
Occupational Health & Safety, designed and documented in accordance with requirements of
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SănătateHealth
SiguranţăSafety
MediuEnvironment
CalitateQuality
HSE Statistics
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Lost Time Incident Rate (LTIR) = (no of Lost Time Incidents) x 200,000 Total Working Hours Total Recordable Incident Rate (TRIR) = (no of Total Recordable Cases x 200,000) Total Working Hours Fatalities = total no. of fatalities cases, recorded during one year; Pollutions = no. of pollutions (oil spills, etc.) recorded during one year; * Formulas source : Occupational Safety & Health Administration, United States
Department of Labor (www.osha.gov)
HSE Indicators 2012 2013 2014
LTIR 0,20 0,45 0,33
TRIR 0,39 0,50 0,56
Fatalities 0 0 1
Pollutions 0 0 0
DMHI’s ERP System - MAGICS
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Production Management System
Basic Information
Hull BOM
MAGICS
Production Planning System
Quality Management System Design Management System
Material Management System
Outfitting BOM
Basic Information
PO Request
Purchase Order
PML
Material Delivery
Material Arrival
Inventory/Closing
Owner Supply Item
Basic Information
Production Design
Production Plan
Logistics
Production Analysis
Work Order Basic Information
Long Term Schedule 1 Month Schedule
3 Months Schedule
Inspection Plan
Inspection Request Inspection Schedule
Inspection Results Quality Problem
Quality Analysis
Basic Information Drawing Plan
Drawing Results Drawing Analysis
Document Control
Subcontractor Work Control
Block Control
[ MAGICS Log-in Screen ]
Human Resource Management
Basic Human Mgmt Salary Calculation
Job Evaluation Training & Education
Facility Management System
Basic Information Preventive Maintenance
Break Down Maint. Analysis
Docks Length Width Depth Cranes
Dry Docks
No. 1 302M 48M 9M G 2 x 480T
J 2 x 120T
J 1 x 50T
J 2 x 16T No. 2 320M 48M 9M
No. 3 360M 60M 13M
G 1 x 1,000T
J 2 x 50T
J 2 x 16T
YARD ENVIRONMENTAL DATA Water Depth : 8 ~ 11 m Wave Height : 0.2 m Tide : Null Current : Null Ground Elevation : 3 m above MSL (quay) Median annual temperature : 12.4°C Thermal amplitude : 23…25°C Climatic type : Moderate Dry
ANNUAL PRODUCTION CAPACITY Production capacity : 12 Vessels / year, in equivalent of 12 vessels/year of 180,000 DWT bulk carriers and / or 11,000 TEU containerships. Site Area : 980,000 m2 Outfitting Quay : 1,590 m Covered Shop : 95,960 m2 Storage Area : 6,500 m2 (Covered) Steel Stock : 13,800 m2
35,000 Ton Steel Cutting : 15,000 Ton/month Pre-Erection Platform : 20,000 m2
DMHI’s Production Facilities
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Shipyard Layout & Natural Environments
1. SSY - Steel Stock Yard 2. TLS - Treatment Line Shop 3. CAS – Cutting & Assembly Shop 4. CSS – Component & Sub-ass’y Shop 5. OHS – Outfitting & Hull Shop 6. EAS – Engine Ass’y Shop 7. CMS – Comp. Fabr. & Maintenance shop 8. BTC – Blasting Cells (Old) 9. PTC – Painting Cells (Old) 10. BPC – New Blasting & Painting Cells 11. SBC – Steel Outfitting Blasting Cells 12. UGS – Unit Module & Galanization Shop 13. APS – Accommodation Preoutfitting Shop 14. HCS – Hatch Cover Grand Ass'y Shop 15. MES – M/E Storage Shop 16. PBS – New Panel Block Shop 17. NGA – New Grand Ass’y Platform 18. QAP – Quay “A” Platform 19. QBP - Quay “B” Platform 20. QCP - Quay “C” Platform 21. PEP – Pre-erection Platform 22. 1DK – No.1 Dry Dock 23. 2DK – No.2 Dry Dock 24. 3DK – No.3 Dry Dock
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Facilities for Hull Fabrication
Activity/Layout Code Facilities Concept / Remarks
Steel Stock Yard (SSY)
Capacity (Area, Bays): Cranes:
~35,000 ton (~16,100 m2, 6 ) 8 x 20 ton mag. O/H
Treatment Line Shop (TLS)
Capacity (Lane): Max. Breadth & Length:
~30,000 ton / month, (2 Lanes) 4.2 m, 15 m
Modern facilities with blasting system, dry oven and marking
Cutting (CAS/CSS/PBS)
Plasma (Dry & Wet) : Oxy-Gas: Oxy-Gas Parallel Cutting:
~15,000 ton / month 4.2 m 15 m
− Marshalling systematization (DSME know-how);
− Automatic beveling
Bending (CAS)
Equipments: − 2,000 ton roll bending − 1,000 ton press − Profile bending
Maximum length of plate in case of 2,000 ton roll bending: 13 m
T-Bar Fabrication (CMS)
Area: Automatic T-Bar Line:
1,836 m2 − Edge preparation − Automatic Weld, Straightening
The facility has two N/C Oxy-Gas cutting machines. Feeding Roller conveyor
Hatch Cover Fabrication (OHS / HCS)
Indoor: Outdoor: Cranes:
3,504 m2 , 3 bays
2,880 m2, 2 bays
2 x 50 ton, 2 x 5 ton, 1 x 3.2 ton
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Facilities for Outfitting Fabrication
Activity/Layout Code Facilities Concept / Remarks
Pipe Fabrication (OHS)
Bays: Bending M/C: Pipe Rotators:
3 5 10
Facilities based on JIS Standard TIG 300, Semi-auto Arc CO2
Steel Outfitting Fabrication (OHS)
Bays: Blasting & Painting:
2 Separate shops inside shipyard
Galvanizing (UGS)
Area (bays): Treatment Baths: Galvanizing Baths:
1,000 m2, (1) 9 7.5 m x 1.5 m x 1.7 m (435~450°C)
Automatic control of temperature and environmental friendly
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Facilities for Indoor Assembly
Activity/Layout Code Facilities Concept / Remarks
Minor Assembly (CAS/CSS/PBS)
Cutting & Assembly (CAS): Components & Sub-Ass’y (CSS): Panel and Block (PBS) :
2 (296 m x 36 m x 25 m) 1 (296 m x 36 m x 14 m) 6 (60 m x 24 m x 10 m)
Largest 167 m x 45 m x 39.8 m
Panel Lines (CAS/PBS)
Cutting & Assembly (CAS): Panel and Block Shop (PBS):
2 (296 m x 36 m x 25 m) 1 (296 m x 36 m x 14 m) 1 (300 m x 32 m x 36.3 m)
PBS –Semi-automatic line
Curved Assembly (CAS/NGA)
Cutting & Assembly (CAS): New Grand Assembly (NGA): Gantry Cranes:
1 (296 m x 36 m x 25 m) 1 (296 m x 36 m x 14 m) 1 x 250 ton / 4 x 30 ton
Largest 270 m x 22.5 m Submerged Arc Welding with metallic powder (FGB)
Grand Assembly (NGA/PBS)
NGA Platform and Cranes: PBS – Panel Line Output:
1 x 250 ton / 4 x 30 ton 600 ton Block Transfer Car O/H Crane: 250 ton
PBS: Automated panel line Max. block size: 30 m x 30 m
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Facilities for Indoor Pre-outfitting
Activity/Layout Code Facilities Concept / Remarks
Unit Module Fabrication
(UGS)
Area: Cranes:
1,000 m2, 1 bay 2 x 10 ton O/H
Maximize the productivity of pre-outfitting through pre-assembly of: supports, pipes, equipment, electrical etc.
General Pre-outfitting Shop
North Platform Bays: Cranes: NGA Bays: Welding: Tools:
4 (largest: 22m x 20m x 12m) 4 x 2.0 ton (1 for each bay) 3 (largest: 25m x 25m x 16.5m) Semiautomatic CO2 Specialized related Pipe, Steel Outfitting, Electrical – Pneumatic impact wrench, etc.
Pre-outfitting ratio: 85 - 90% Similar with Top Korean Shipyard
Accommodation Pre-Outfitting (APS)
Dimensions: Cranes:
34 m x 18 m x 10 m, 2 bays 1 x 3.2 ton O/H
Pre-outfitting ratio: 80 – 85%
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Facilities for Indoor Blasting and Painting
Activity/Layout Code Facilities Concept / Remarks
Block Blasting Cells (BTC)
No. of Cells: Blasting Nozzles:
2 (30m x 22m x 15m) 16 sets
Steel shot blasting
Block Painting Cells / Shelters (PTC)
No. of Cells: Painting Shop: Shelter:
1 (36m x 22m x 15m) 1 (97m x 22m x 13.5m) 1 (40m x 22m x 10m)
Steel shot blasting
New Block Blasting Cells (BPC)
No. of Cells: Blasting Nozzles:
2 (32.5mx31mx18.5m) 12 sets
Steel shot blasting Environmentally friendly
New Block Painting Cells (BPC)
No. of Cells: 2 (32.5mx31mx18.5m ) Environmentally friendly
Steel Outfitting Blasting Cells (SBC)
No. of Cells:
2 (18.4m x 17.6m x 9m) Steel shot blasting Environmentally friendly
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Facilities for Pre-erection & Outfitting
Activity/Layout Code Facilities Concept / Remarks
Pre-erection Platform For Dock no. 1 & 2
(PEP/1DK/2DK)
Area: Cranes (Working in Tandem): Jib Cranes:
20,000 m2 2 x 480 ton (850 ton) 2 x 120 ton, 2 x 50 ton, 2 x 15 ton
Pre-erection welding joint paint remedy is performed before erection in Dry Dock
Pre-erection Platform For Dock no.3
(3DK)
Total Area: Goliath Crane: Jib Cranes:
16,800 m2 1 x 1,000 ton 2 x 50 ton, 2 x 15 ton
Pre-erection welding joint paint remedy is performed before erection in Dry Dock
Transportation
Heavy Transporters: 1 x 500 ton 2 x 450 ton 1 x 330 ton 1 x 138 ton
450 ton units - possibility to work in tandem: −Maximum capacity 800 ton −Maximum load dimension:
52m x 22m x 15m
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Facilities for Erection in Dock Stage
Activity/Layout Code Facilities Concept / Remarks
Dry Dock no.1 (1DK)
Dimensions (Water Draft): Gantry Cranes (Tandem): Jib Cranes: Utilities:
302m x 48m x 9m (7.35m) 2 x 480 ton (850 ton) 2 x 120 ton, 2 x 50 ton, 2 x 15 ton Electric power, CO2, O2, LPG, Compressed Air
Above Sea level with 9 m, in line with Dry Dock no. 2 Launching of Dock no. 1 shall be related with Dock no. 2 launching/partial launching
Dry Dock no.2 (2DK)
Dimensions (Water Draft): Gantry Cranes (Tandem): Jib Cranes: Utilities:
318m x 48m x 18m (7.35m) 2 x 480 ton (850 ton) 2 x 120 ton, 2 x 50 ton, 2 x 15 ton Electric Power, CO2, O2, LPG, Compressed Air
Sea Level, aligned with Dry Dock no.1
Dry Dock no.3 (3DK)
Dimensions (Water Draft): Gantry Cranes: Jib Cranes: Utilities:
360m x 60m x 13m (8.5m) 1 x 1,000 ton 2 x 50 ton, 2 x 15 ton Electric Power, CO2, O2, LPG, Compressed Air
Sea Level
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Facilities for Outdoor Outfitting in Quay Stage
Activity/Layout Code Facilities Concept / Remarks
Quay A (QAP)
Length (Platform Area): Jib Cranes: Bearing Capacity: Utilities:
620m (620m x 20m) 1 x 50 ton, 1 x 15 ton 100 ton / m2 Electric Power, CO2, O2, LPG, Compressed Air
Quay B (QBP)
Length (Platform Area): Jib Cranes: Bearing Capacity: Utilities:
430m (430m x 20m) 1 x 120 ton, 1 x 15 ton 200 ton / m2 Electric Power, CO2, O2, LPG, Compressed Air
Quay C (QCP)
Length (Platform Area): Jib Cranes: Bearing Capacity: Utilities:
540m (540m x 10m) 2 x 50 ton 200 ton / m2 Electric Power, CO2, O2, LPG, Compressed Air
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Barges: 5 Pontoon Barges: 46
Performance Record (After Joint Venture)
AHT: 2
Drilling Rig Barge: 1
PSV: 3 OSV: 3
Bulk Carriers
Capesize: 7 Kamsarmax: 6 Handysize: 13 Coaster: 30 Coaster Combi Freighter: 6
Tankers
Crude Oil Tanker: 4 Product Carrier: 3 Chemical: 5 Handymax Juice Carrier: 2
Containerships
Post Panamax: 18 Panamax: 10 Feeder: 43
Pure Car Truck Carriers
6,500 CEU PCTC: 2
Total: 148
Commercial Vessels
Total: 3 Floating Docks
Total: 9
Offshore and Offshore Support Vessels
Total: 51 Barges
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L x B x D x d 228.0 x 32.2 x 19.8 x 12.2 (m) Class American Bureau of Shipping Units built 3 (HNs. 5003 / 04 / 05) Buyer / Actual Owner LMZ – Greece / ELETSON Corporation - Greece
DMHI’s New Building Performance Record 69,000 TDW Crude Oil Tanker
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L x B x D x d 275.0 x 32.2 x 21.5 x 12.0 (m) Class Germanischer Lloyd Units built 4 (HNs. 4052 / 53 / 54 / 55) 4 (HNs. 4062 / 63 / 64 / 65) 2 (HNs. 4073 / 75) Buyer NSB – GEBAB – CONTI / Germany
DMHI’s New Building Performance Record 4,860 TEU Containership
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L x B x D x d 272.0 x 40.0 x 24.2 x 12.5 (m) Class Germanischer Lloyd Units built 3 (HNs. 4066 / 67 / 68) Buyer Hamburg Süd / Germany
DMHI’s New Building Performance Record 5,560 TEU Containership “Monte Class”
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L x B x D x d 286.45 x 40.0 x 24.2 x 12.5 (m) Class Germanischer Lloyd Units built 3 (HNs. 4069 / 70 / 71) Buyer Hamburg Süd / Germany
DMHI’s New Building Performance Record 5,905 TEU Containership “Rio Class”
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L x B x D x d 292.0 x 45.0 x 24.7 x 16.5 (m) Class BV (3 units) / DNV (1 unit) / LRS (1 unit) / GL (2 unit) Units built 7 (HNs. 1045 / 46 / 47 / 48 / 50 / 51 / 52) Buyer Tsakos (2 units) / Greece Anangel Maritime Services (3 units) / Greece Claus Peter Offen (2 units) / Germany
DMHI’s New Building Performance Record 180,000 TDW Bulkcarrier
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L x B x D x d 270.4 x 40.0 x 21.7 x 12 (m) Class Germanischer Lloyd Units built 6 (HNs. 4082 / 83 / 84 / 85 / 86 / 87) Buyer Claus Peter Offen / Germany
DMHI’s New Building Performance Record 5,550 TEU Containership
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L x B x D x d 48.87 x 13.8 x 7 x 5.2 (m) Class Lloyd’s Register Units built 2 (HNs. 6003 / 6004) Buyer AHT Commander / Germany
DMHI’s New Building Performance Record 100 TBP Anchor Handling Tugboat
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L x B x D x d 229.0 x 32.26 x 20.2 x 12.2 (m) Class 3 Bureau Veritas / 1 NKK / 2 LR Units built 6 (HNs. 1053 / 54 / 55 / 56 / 57 / 58) Buyer Larus (2 units) / Greece Dalnave (2 units) / Greece KC Maritime (2 units) / Hong Kong
DMHI’s New Building Performance Record 82,000 TDW Bulkcarrier
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DMHI’s New Building Performance Record 8,600 TEU Containership
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L x B x D x d 299.9 x 48.4 x 24.8 x 14.5 (m) Class Lloyd’s Register Units built 4 (HNs. 4091 / 92 / 93 / 94) Buyer Zodiac Maritime Agencies Ltd. / U.K
DMHI’s New Building Performance Record 6,500 CEU Pure Car Truck Carrier
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L x B x D x d 199.90 x 32.26 x 32.59 x 10 (m) Class Det Norske Veritas Units built 2 (HNs. 4401 / 4402) Buyer Ocean Yield AS / Norway
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DMHI’s New Building Performance Record 9,100 TEU Containership
L x B x D x d 299.9 x 48.4 x 24.8 x 14.5 (m) Class Lloyd’s Register Units built 2 (HNs. 4095/4096) Buyer Capital Ship Management Corp. / Greece
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DMHI’s New Building Performance Record 112,000 TDW Product Carrier
L x B x D x d 249.9 x 44.0 x 21.2 x 15 (m) Class American Bureau of Shipping Units built 3 (HNs. 5006/5007/5008) Buyer Eastern Mediterranean Maritime Ltd. / Greece
DMHI’s Orderbook
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TYPE CAPACITY NUMBER OWNER COUNTRY
Product Carrier 112,000 TDW 1 Eastern Mediterranean
Maritime Greece
Containership 9,100 TEU 2 Capital Ship Management Greece
Crude Oil Tanker 112,700 TDW 9 Tsakos Energy Navigation Greece
Bulk Carrier
180,000 TDW
3 Anangel Maritime Greece
Crude Oil Tanker 112,000 TDW 2 Minerva Marine Greece
Crude Oil Tanker 156,000 TDW 4 Maran Tankers Management
Greece