NAME : LINGGESWARAN A/L JAGANATHAN

ID NO : 56280113134

SUBJECT : SHIPYARD MANAGEMENT AND PROJECT PLANNING.

TOPIC : INDIVIDUAL ASSIGNMENT

SUBJECT CODE : LGB 20303.

LECTURER NAME : EN. AZIZ ABDULLAH

Table of content.

Introduction…………………………………………………………………………………….. 1

The layout and other problems in shipyard………………………………………………….. 2

The shipyard layout……………………………………………………………………………. 5

The improvement plans………………………………………………………………………... 6

Berthing and docking arrangements…………………………………………………………. 9

The material flow within the upgraded shipyard…………………………………………… 19

Conclusion……………………………………………………………………………………... 21

Recommendations……………………………………………………………………………... 22

References……………………………………………………………………………………… 23

Introduction.

An ideal layout of modern shipyard is based on a production flow basis, with the yard

extending back from the river or shore at which the berths or building docks are located. The

farthest area from the berths is reserved for the material stockyard and between the two is

arranged in sequence the consecutive work and shop processes. Too often existing shipyards

follow the river bank and are constrained by their location in a built up area or the physical river

bank slope from extending back from the river. Therefore, modified production flow lines are

required.

Plan for the shipyard will involve decisions to be made from the following:

Size and type of the ship to be built

Material production per year to be achieved

Material handling equipment to be supplied

Machining processes to be installed

Unit size and weight to be fabricated and erected

Amount of outfits and engine installation to be undertaken

Control services to be supplied

Administration facilities required

The Layout and Others Problems in Shipyard

1. The space for arranging the building blocks of ship which is under construction.

The major problem that affects the safety and smooth workflow on shipyard is

because of paucity of space for arranging the building blocks of ship under construction.

Therefore, a standardized erection sequence diagram is generally available to provide the

prioritized erection sequence and it serves as the frame work. In order to make a timely

erection of the blocks a post plan has to be developed, so that the blocks lie in the nearest

possible vicinity of the material handling devices while keeping the priority of erection

and the blocks are arranged in the pre-erection area. This kind of readiness of blocks

leads to a very complex problem of space. This arises due to the least available space

leading to an urgent need for intelligent spatial schedule without compromising the rate

of production.

There exists two critical problems ahead namely, the spatial occupation layout of

pre-erection area and the evacuating pattern in the spatial vicinity. The block shape is

assumed be rectangular. The related input data's are the dates of erection (earliest as well

as the latest), geometrical parameters of block available on pre-erection area, slack time

and the like. World over industrial engineers and decision makers are brainstorming hard

to find an ideal solution for their unique problems. Every scheduling and decisional

problems end up in complicated iterative loop system.

2. Working Condition

Shipyard workers working locations are categorized as one of the most risky

working surroundings. This not only adds the problems to their job but actually makes it

a work profile full of need for constant caution. Shipyards are not one of the most

comfortable places to work in because there is a constant danger in everything they does

and also hazardous to their health. There are several precautions that need to be taking in

count.

Sometimes it is extremely dangerous to work in cramped space while at other

times. As an example, due to fewer places to stand and work one misstep from the high

place can cause serious injury or even death. The cramped spaces (enclosed spaces) are

one of the riskiest places to be working in. A shipyard worker, while working in such tiny

spaces is often at risk of physical injuries to limbs, head or other body parts along with

more serious troubles like suffocation, asphyxiation etc. Extreme nature of working

conditions of shipyard workers is the first problem they face. Also, the high pressure in

such tiny spaces can often cause much more grave and permanent damage like eardrum

rupture. Shipyard workers often complain of problems to their hearing abilities due to

working constantly under high pressure conditions.

Besides that, working in shipyards are not as the same as one working in office

where they can go back on time. There are no fixed timings. The extreme nature of their

job means the workers have to be available at all times. The unpredictable time schedules

make this job harder than it already is, and definitely adds to the woes of workers.

Sometimes they even have to work for several hours together without much rest.

3. Machinery and Material Hazard

Shipyards are the places where work happens at a big scale. The machinery used

is huge, often requiring immense skill and strength to be handled. A minor divergence

while working at such machinery can corroborate to be extremely fatal for any shipyard

worker. The seriousness of injury can be as loss of life. In some cases, records of workers

having been gravely injured date back to as early as 1940’s, where ship construction

really took off all over the world. Constant danger posed by the heavy machinery is what

is third problem faced by shipyard workers.

Asbestos is used as one of the construction materials for most ships even till

today. Shipyard workers involved in work of manufacturing of ships and even those not

specifically into that particular aspect of shipyard jobs often receive extremely high

exposure to asbestos, making them quite vulnerable to diseases caused by it. Asbestosis,

along with mesothelioma which can cause cancer caused exclusively by asbestos

exposure are very serious diseases found mostly in workers working in close proximity to

this substance. It is one of the biggest problems faced by workers working in the ship

industry especially so since there is still no perfect solution to this problem.

One of the bigger problems with this particular aspect of job is that the symptoms

caused due to exposure to asbestos can surface even after many years. Reports of these

symptoms showing up in a person up to 50 years after exposure to it have been found.

This adds a whole new dimension to this problem making it much more serious.

The Shipyard Layout

A perfect layout of this shipyard is indicated in Figure.1 which might be appropriate for a

small yard specializing in one or two standard type of ships with a fairy high throughput so that

one covered building dock or berth was sufficient. At this point, it may be convenient to mention

the advantages and disadvantages of building docks as opposed to building berths. Building

docks can be advantage in the building large vessels where launching costs are high and there is

a possibility of structural damage owing to the large stresses imposed by a conventional launch.

The yard also gives good crane clearance for positioning units. The greatest disadvantage of the

building dock is its high initial cost.

Many yard reconstructions and upgraded have incorporated undercover construction

facilities in the form of docks or slipways within the building halls. Others have building halls at

the head of the slipway with advanced transfer systems installed so that the hull can be extruded

out of the hall onto the slipway for launching. Such facilities permit ship construction in a

factory type environment providing protection from the worst effects of weather and darkness.

The shipyard in this case is located on the area of 13.2 hectares and in addition

encompasses 2.5 hectares of water surface area with the depth of 4 meters. This allows the access

of river-sea vessels of no more than 10,000 DWT with empty ballast. Major shipyard equipment

includes:

751 m of mooring lines equipped with compressed air lines, water supply, power

supply as well as berth cranes with capacities of 10, 20 and 25 tones

Floating dock allowing to perform the repair of vessel underwater parts with docking

weight 2,000 t, length 115 m, width 16 m and draft 5 m;

The slipway allowing repairs of vessels with weight up to 1,000 tones and length up

to 70 m.

The current arrangement of the shipyard allows simultaneous repair works for 4-5 vessels

of above 100 m length, on the shipyard’s land territory and a float.

The Improvement Plans.

The shipyard should have the effective layout to ensure a smooth flow of work, material,

and information through the system. The requirements for effective layout such as:

Minimize material handling costs

Utilize space efficiently

Utilize labor efficiently

Eliminate bottlenecks

Facilitate communication and interaction between workers, between workers and their

supervisors, or between workers and customers

Reduce manufacturing cycle time and customer service time

Eliminate wasted or redundant movement

Facilitate the entry, exit, and placement of material, products, and people

Incorporate safety and security measures

Promote product and service quality

Encourage proper maintenance activities

Provide a visual control of operations or activities

Provide flexibility to adapt to changing conditions

This type of shipyard is known as the process layout where it is a group of similar

activities together in departments of work centers according to this process or function is that

they perform characteristic of operations that serve different customers different needs. This is

the most common layout for a small or medium size of manufactures. This typical process layout

would group lathes in one area, drills in one area, milling machines in one area and so on which

shown in Figure 1.

Figure 1: Shipyard Layout

In order to stay competitive in the increasingly demanding commercial, military, leisure

markets, and shipyard must continuously improve their overall performance and productivity.

Their approach to shipyard design and development to ensure that the facilities, processes and

practices will allow the yard to achieve the level of performance required for market success.

They use the same tools to analyze the existing yards and to assist them develop effective

performance improvement programs. This shipyard is internationally acclaimed the shipyard

benchmarking system that are allows the processes and practices employed in shipbuilding, ship

repair and naval vessel support to be quickly analyzed, compared to international best practice

and the performance improvement priorities identified. But still, the efficient analysis is just the

beginning for this shipyard is improved.

Eventually, the experts will assist their customers develop every aspect of the

performance improvement program and then, it will transfer the necessary technology and, if

required, to provide the training and operational assistance to this shipyard. They can also help to

find experienced people to join their team for full time. They place the particular emphasis on

optimizing the strategy and approach prior to recommending expenditure on expensive facilities

and equipment. The shipyard service includes:

Cost structure review, financial analysis and business strategy development

Industry benchmarking and technology profiling

Operational benchmarking and identification of technology gaps

Development and implementation of performance improvement programs

Implementation of modern shipbuilding and repair technology

Management and staff retraining program

Moreover, the shipyard’s location is the important reasons why this shipyard is more

competitive than the others shipyard in term of delivering the long term economic viability of the

shipyard business. It also make shipyard layout is the best layout which can access to markets,

accessibility for shipping, and depth of surrounding waters, suitability of land surface and the

marine environment are all factors to be considered and are crucial to the success of your

shipyard development project. When they are in the process of explore and choose the location

for the shipyard, they were follow some selection criteria such as shipping traffic pattern

analysis, topographic, bathymetric and ground studies, the environment impact as well as the

ancillary industry and the labor availability.

Therefore, the competitiveness that has been study by this shipyard has established the

correlation between the use of best practice, output performance and profitability. To achieve the

desired performance, a shipyard must be correctly configured and employ appropriate processes

and practices for its product mix and cost base. Most importantly the shipyard’s benchmarking

system, the best layout and the cost structures as well as the capacity models determine the

overall characteristics of new and redeveloped shipyards. Likes this shipyard which they used to

specify the processes and practices required achieving market success through optimizing the

facilities, the production technology and in particular the pre-production technologies employed.

Berthing and Docking Arrangements

Berthing arrangement refer to a place where a ship needs to tie up at alongside a wharf or

a pier structure. With regards to a shipyard, a berth is a place where a ship is moored within a

shipyard’s perimeter before or after down-slipping and usually the ship is meant to undergo pre

or post slipping works that cannot be done in the docks or on the slipway or further outfitting

works after launching while afloat. While berthed in the shipyard, works that require lifting

operations are usually provided for shipside cranes and ship may be pulled conveniently to other

nearby outfitting berths if required.

Large ships are usually launched down a slipway or flooded up in a dock where they are

built. In the case of a shipyard with a building dock the large hull blocks that comprise the ship

are assembled on a level line of building blocks which are similar to docking blocks. Building

docks tend to be shallower than graving docks as the ship is flooded up considerably lighter than

the lightship condition. Usually, the building dock has concrete ramps built into the head end of

the dock to allow for the construction of more than one vessel at the same time. A docking plan

must be made by the ship owner to a dock master to enable him to plan the necessary docking

arrangement with regards to correct placement of keel blocks and bilge blocks to avoid placing

them at the wrong places.

Mooring lines - is a thick rope or cable which is used to tie a watercraft in place. Usually

multiple mooring lines are used on the same vessel to distribute the stress, and to act as

redundant systems in case a mooring line snaps. Mooring lines may also be known as

hawsers. A number of materials can be used to make a mooring line, and most marine

supply companies carry an assortment of options which can be customized as needed.

Mooring a vessel requires some coordination.

Figure 2: Mooring Lines

The mooring lines need to be thrown to shore, but they are sometimes too heavy and

awkward to be thrown easily, especially in the case of lines used on large ships. As a

result, sailors use an attachment called a heaving line, a lightweight cord which can be

tossed to shore. People on shore can use the heaving line to pull the mooring line over so

that the boat can be moored in place. With a very large ship, a large crew on land may be

involved to coordinate the mooring process. For smaller craft, a single sailor can handle

mooring independently.

Slipway – will consists a ground way and a sliding way that support the cradle on which

the ship is to be launched. The slipway is constructed with concrete, wood, steel or the

combination of these all materials. Ground ways area is from the building space into the

water. They may be permanently left in place or removed and stored between launchings.

Figure 3: Slipway

Ground ways – width is restricted by the width of the sliding ways where they are slightly

wider than sliding ways. Frequently, there are only two ground ways are used for

endways launches but it is possible to used more than two.

Sliding ways- is a structure on which the ship travels into the water. It is traditionally

made of timber where nowadays, the ways are made from steel. The bottom edge of the

sliding way and the top edge of the ground ways are usually lad in a slippery surface. A

slipway provides for an inclined building berth which it is inclined at an angle and the

launch way will facilitate either end launching or side launching operations.

End launching- takes space and occupies areas outside of the yard during the operation of

launching. The past thought that end launching was the only method of getting a ship into

the water has now given way to advantages of the level building dock and the flood up

method. There is the approximate number of inclination of the building berth that is

0.045-0.065 to 1.000. The vessel is initially constructed on curved body blocks and center

line blocks to hold the structure in place. As the structure grew, the keel block, bilge and

cribbing blocks were built around the vessel. Then, the vessel weight is transferred from

the center line blocks to the launching cradle. The cradle sides are designed to slide down

the launching ways into the water stern first and on the time of launching, the vessel

slides backwards down the slipway on the frame until it floats by itself.

Floating docks- are have the capability of being moved to many locations and are

considered by some to be greater value for money than graving docks. Floating docks are

really ships themselves. The structure that was usually made up by the steel is mainly a

set of floating tanks serviced by ballast lines to pump rooms. The floating docks is

moored and submerged in the water to permit ships to enter. It is also has the capability to

be brought to a vessel that is badly damaged and unseaworthy.

The dock can be maneuvered underneath ships and has the ability to change its own trim

to coincide with that of the ship to be docked. Most floating docks have workshop,

facilities and accommodation to allow full support for refit activities at the docks. The

dock has its own electric power system, making it entirely independent from shore supply

for all docking operations.

Figure 4: Floating Dock

Figure 5: Floating Dock

Fabrication workshop - is a dedicated area with an assortment of equipment to make

possible the creation of sheet metal and structural fabrications. It is the place where the

material will be cut, rolled, bend, pressed and others.

Figure 6: Fabrication Workshop

Stockyard- is the place where the materials received from external sources such as plates,

structural bars and other construction materials are kept before being conveyed or passed

on to the various working bays.

Figure 7: Stockyard

Construction Hall - situated adjacent to the ship-repair facilities and features direct river

access via a conventional slipway launch, or vehicular access for large modules to the dry

docks. The hall offers an un-rivaled under-cover building environment allowing large

steelwork units such as complete hulls or project specific modules to be constructed

without environmental interference as well as the various front and side loading fork lift

trucks.

Figure 8: Construction Hall

Welding Workshop – is the place where cut parts are fabricated into sub-assemblies, all

types of welding such as MMAW (Manual Metal Arc Welding), GMAW (Gas Metal Arc

Welding) and GTAW (Gas Tungsten Arc Welding) are carried out automatically or

manually, sub-assemblies being formed into larger assemblies with compartments, piping

systems and conduits for cabling and larger assemblies being formed into block

assemblies or modules.

Figure 9: Welding

Warehouse- is a commercial building for storage of goods. Warehouses are used by

manufacturers, importers, exporters, wholesalers, transport businesses, customs, etc.

They are usually large plain buildings in industrial areas of cities and towns and villages.

They usually have loading docks to load and unload goods from trucks. Sometimes

warehouses are designed for the loading and unloading of goods directly from railways,

airports, or seaports. They often have cranes and forklifts for moving goods, which are

usually placed on ISO standard pallets loaded into pallet racks. Stored goods can include

any raw materials, packing materials, spare parts, components, or finished goods

associated with agriculture, manufacturing and production.

Figure 10: Warehouse

Main Office- is place that serves as the administrative center of an enterprise. This is

where the management and administration staff carries out their duties.

Security – is to make sure that the shipyard materials and equipment are protected as well

as to ensure the safety of the staff and monitoring of people entering or leaving the

shipyard premises.

Yard Services – is to ensure that the shipyard is operated smoothly such as the provision

of tug boat services, transportation of materials within the shipyard, all internal technical

needs such as electrical and mechanical services as well as the landscaping and cleaning

services.

Technical and Electrical Services – is one of the support team on the technical matters for

example engineering, drawing office, planning and control. These people don’t actually

build the ships but without them the ship can’t be built.

The Material Flow within the Upgraded Shipyard

In shipbuilding, the ship is built to order and is usually one-off product. This requires

implementation of the unique procurement process for all the materials required and work flow

requirements in the shipyard during ship construction. The procurement materials or services for

the construction of ships may include the following:

raw materials such as ferrous and non-ferrous plates, bars, timbers and fiber glass

paints for underwater hull, superstructure and interior

sub-contract works such as installation of navigation equipment, tiling and

cabling

spares for ship equipment and ancillaries

special tools, equipment and related spares

Material flowing from the warehouse to the shops and ultimately the ship is shown in

Figure 11 below. In shipyards, there are holding places (usually open spaces) for material to be

used for work in progress (WIP). These places should be located to minimize travel distance and

time for delivery flow by locating them closest to the point of use locations. But this is not

always the case. Sometimes the holding places are located according the available space in the

shipyard. Production Control (PC) which also shown in Figure 11, prepares work packages and

orders the appropriate material required to complete the job and maintain even workloads

throughout the various workstations within the construction process.

They are help to determine where the material will go, whether immediately to the work

station, or to the holding places if craft is not ready to use it immediately. Many times the

material may sit in the holding places for long extended periods because the material was not

actually needed. And when it is needed, work must stop until that material is located, loaded up

and then brought to the workstation. The time it takes to perform this task is dependent on the

location of the holding place and its distance from the workstation or the ship. This of course

Causes a slip in the schedule for the work to be performed and time is money. Also if the

material is not taken straight to the workstations or ship, then the transportation (usually trucks,

possibly cranes) will have to make multiple trips and cost the shipyard additional money.

Figure 11: Basic Shipyard Material Flow Model

CONCLUSION

The range of services offered by the shipyard includes repairs as well as the construction

and modernization of vessels. Repair works for ships weighing up to 1,000 tones comprise of:

Arrangement of the defect finding and ship repair process,

Ship’s hull defects detection,

Replacement of shell plating areas with deck plating framing,

Defect finding and repair of shaft lines and propellers, ship systems piping, valves and

other fixtures, auxiliary machinery and ship electrical equipment,

Building-up welding and mechanical treatment,

Mounting and alignment of shaft lines on a vessel.

The shipyard’s capabilities allow the various types of vessels including sea-river and sea

going vessels (up to 115 m length), fishing vessels; dry cargo carriers and tankers used the

services offered in shipyard. There is also the benefit of a good layout which may include:

smooth material flow

reduced inventories

better scheduling

effective space utilization

fewer production bottlenecks

reduced material handling costs

RECOMMENDATIONS

The success of shipyard depends on the decisions that are made at the design stage. Their

capability includes the process design and the others necessary such as civil, structural,

mechanical and electrical systems design. Besides that, they also should have great infrastructure

facilities that may include dry docks including dock gates, ship lifts, floating docks, ship launch

systems, piers, quays, breakwaters, dredging, fabrication halls, and the offices.

The ultimate shipyard is design from a few people from different expertise which are

later combined. This will provide all detailed shipyard infrastructure design requirements,

improving performance and on how to reduce construction and maintenance costs. Prior than

that, their initial concept designs will help the customers to make informed decisions before

committing to the cost of final detailed facility design. The design concepts components in the

best shipyard are often interchangeable, which means that the customers can combine attributes

from two or more concepts to arrive at the concept of the customer’s choice.

REFERENCES

1. http://www.iieom.org-

2. http://www.maritime-rh.com/areas-of-expertise/benchmarking.html-

3. http://www.ingentaconnect.com/content/sname/jspd/2010/00000026/00000002/art00007-

4. http://www.slideshare.net/agnikhil/shipyard-layout-improvement

5. http://www.sasape.com/slipway-services/shipyard-layout.html

6. Shipyard management and project planning book 4 th Edition. Prepared by: En. Aziz

Abdullah