T I T L E :
ANALYSIS ON MALAYSIAN SHIPYARD LAYOUT AND ITS EFFECTIVENESS TOWARDS
IMPROVING THE PRODUCTIVITY
BY:MOHD ZULHILMI BIN ZALIZAN
56267109180BET NAVAL ARCHITECTURE & SHIPBUILDING
SUPERVISOR:
CEngr. AHMAD AZMEER BIN ROSLEE
Introduction Literature Review Research Methodology Data Analysis Proposed Layout & Efficiency Analysis Discussion Recommendation & Conclusion
RESEARCH OUTLINE
INTRODUCTION
INTRODUCTION
Shipyard layout is one of the important elements that determine the productivity of the shipyard.
However, direct relationship between shipyard layout and its productivity is still in grey area due to the fact :
Productivity is a measure of efficiency of production.
Productivity is normally not considered during layout design.
RESEARCH BACKGROUND
What this topic all about?
Analyze how much the layout of a shipyard contribute to its productivity
Main concern : i. Existing Layoutii. Timeiii. Distanceiv. Facilities and Workers
Study its benefits to the whole shipyard process
RESEARCH BACKGROUND
Importance of this studies
Currently, there is not enough information about Malaysian shipyard layout.
Ideal layout for a modern shipyard is based on production flow basis
The study will cover the layout effectiveness in term of its productivity.
RESEARCH BACKGROUND
How to complete the task and achieve accurate result throughout all process during research?
Divided into three parts :i. Visit and Surveyii. Data Collection and Analysisiii. Design Phase
How to calculate productivity :i. By measure on the distanceii. By measure on the time taken
PROBLEM STATEMENT
What is the time consumed for shipbuilding activities based on the current shipyard layout?
How can the productivity increased by changing the layout?
OBJECTIVES OF THE RESEARCH
To identify selected shipbuilding process work flow, distance of movement of workers or products and the time taken for each activity of it.
To study current selected shipbuilding layout effect on the productivity of the shipbuilding.
To do evaluation of productivity for the current shipbuilding layout.
To propose the suitable shipbuilding layout.
SCOPE OF RESEARCH
Selected Shipyard NGV Tech. Sdn. Bhd., Teluk Panglima Garang, Selangor
Nature of Business Aluminium & Steel Vessel Shipbuilding
Productivity will be based on the distance and time measured on the selected shipyard
Project Basis – Steel Tugboats, Workboats, & Supply Boats
LITERATURE REVIEW
“The past two or three decades have seen the emergence of a substantial number of new shipyards, primarily in Asia and Eastern Europe, that have been specifically planned to construct the larger ships being ordered today, using contemporary shipbuilding practices and production methods.”
Ship Construction 6th Edition, DJ Eyres2006, Publisher by Elsevier Ltd.
LITERATURE REVIEW
LITERATURE REVIEW
“ Malaysia’s shipyard productivity data is nowhere to be seen. It is very hard to use this data and if it is there, it is not presentable. Malaysian Industrial Development Authority (MIDA), a government arm to promote local industries does not have any data on shipbuilding industry ”
Malaysian Industrial Development Authority www.mida.gov.my
LITERATURE REVIEW
“Productivity can be termed as an index that measures output (goods or services) relative to the input (labor, materials, energy and other resources) used to produce them.”
William J. StevensonProductions/Operation Management, Sixth Edition,
Irwin/McGraw Hill, US, 1999
LITERATURE REVIEW
“Despite the importance of Productivity Measurement in representing company’s competitiveness, its implementation in Malaysia’s shipyard has not widely known and properly documented.”
Case Study 1Ahmad Azmeer Bin Roslee
Universiti Teknologi MalaysiaMaster in Marine Technology
LITERATURE REVIEW
“Ship production involved many stages of fabrication processes, it is expected that dimension variances could occurred and if it is not managed properly it will cause related problems which will lead to rework and delay.”
Case Study 2Ronny Andalas
Universiti Teknologi MalaysiaMaster in Marine Technology
LITERATURE REVIEW
“Shipyard layout management may justly must be termed as an art when one consider the varying degrees of success attained by one men in the different position and having the same tools with which to work”
Case Study 3Lim Cheng Min
Massachusetts Institute of TechnologyMaster of Science in Naval Construction and Engineering
RESEARCH METHODOLOGY
Title Proposal
Thesis Objective
Research Methodology
Survey Form
Decide Shipyard for Survey
Produced Proposed Layout
Final Report
Literature Review
Task Planning
Result
Accept?
Data Analysis
Survey/Data collected
Shipyard Visit
YES?
NO?
FLOW CHART
Phase 1JULY 2011 – JAN 2012
Phase 2JAN 2012 – MAY 2012
Data Collected
Enough
Data Tabulated
Data Analysis
YES?
NO?
Start
Result
Finish
FLOW CHART (SURVEY)
OPERATION PROCEDURE
Select shipyard and pilot test to develop productivity measurement form.
OPERATION PROCEDURE
Obtain the existing layout.
Record all findings using productivity measurement form. Measure and collect data based on :
i. Distanceii. Time Taken
OPERATION PROCEDURE
• Productivity Measurement Form
OPERATION PROCEDURE
Do an analysis.
Suggest new layout with new improvement :i. Less distanceii. Less time taken
Analysis Work Flow
PROJECT ACTIVITIES (FYP1)
Projection Aug 2011 – Dec 2011
PROJECT ACTIVITIES (FYP2)
Projection Jan 2012 – May 2012
DATA ANALYSIS
CONCENTRATED AREA
CONCENTRATED AREA
Back
CONCENTRATED AREA
Location Description3 Jetty
8 Slipway 1
11 Hangar 3
12 Hangar 4
13 Hangar 5
14 Store 1 (Tools & Equipments)
15 Store 2 (Paintings)
17 Store CO2 (Materials)
21 Workshop 1
25 Client & Contractor Office
27 NGV Main Office
28 Surau
29 Canteen
Area decided based on project consideration (steel-construction)
Currently is the busiest part of shipyard Current activities : 2 x 52m Multipurpose Utility Vessel
: 3 x 30m Offshore Mooring Tug Upcoming : 2 x 52m Multipurpose Utility Vessel
: 2 x Navy Vessel
Area targeted consumed more time based on distance travelled.
CONCENTRATED AREA
PROJECT DESCRIPTION
PROJECT DESCRIPTION
Data taken from observation on movements of workers
Some movements were basically based on rules and regulation of shipyard.
eg. every workers must punched card at main office before and after going to have their rest period (lunch time)
Start-stop point of time calculated from exit-to-entrance of each location
DATA COLLECTION
There are 23 from-to section recorded.
Categorized as Section A-Weg. Section A is movement from Location 27 to Location 25
Section B is movement from Location 27 to Location 21
There are 5 types of movement Walk Motorcycle Car / Van Lorry Forklift
There have been some different paths recorded for walking movements
DATA COLLECTION
FREQUENCY
SectionNo. of Data Collected
A 16B 13C 22D 32E 12F 28G 25H 42I 48J 0K 47L 48M 40N 15O 43P 41Q 6R 40S 49T 41U 37V 43W 24
A B C D E F G H I J K L M N O P Q R S T U V W0
10
20
30
40
50
60
No. of Data Collected
No. of Data Collected
Sequence : S, I, L, K, O, V, H, P, T, M, R, U, D, F, G, W, C, A, N, B, E, Q, J
Time average is calculated based on total time consumed in each section and divided by their frequency
TIME AVERAGE
Back
Time Average (seconds)Section Location covered Distance (m) Walk Motorcycle Car / Van Lorry Forklift
A 27 to 25 33 27.79 9.69 B 27 to 21 39 26.63 10.61 C 27 to 15 72 56.17 15.79 D 27 to 14 114 95.21 29.16 61.37 E 29 to 14 24 36.35 F 29 to 27 102 90.12 29.76 53.60 G 14 to 11 walk:177, others:240 218.27 68.44 127.92 156.66 H 14 to 8 walk:216, others:254.1 330.41 60.75 143.00 157.49 202.26I 14 to 12 366.3 416.20 87.69 198.34 247.53 250.70J 14 to 13 389.4 K 14 to 21 92.4 102.85 25.74 53.42 59.34 57.48L 14 to 17 234.3 215.85 87.69 123.00 140.38 119.24M 14 to 3 534.6 130.39 279.46 323.21 345.60N 17 to 11 72.6 18.91 43.32 45.41 121.57O 17 to 8 49.5 65.02 16.09 31.41 33.60 119.85P 17 to 12 112.2 143.41 28.37 59.95 82.27 138.57Q 17 to 13 138.7 105.25 166.25R 17 to 3 273.9 247.83 89.68 140.58 165.53 248.40S 12 to 3 walk:138.6, others:178.2 130.73 28.95 70.94 71.87 173.83T 8 to 3 walk:150, others:240.9 177.04 52.42 103.68 91.77 223.80U 11 to 3 walk:207.6, others:297 246.79 74.18 131.68 140.87 275.61V 21 to 3 396.0 112.43 141.59 195.42 395.59W 27 to 3 346.5 145.38 167.15
DATA ANALYSIS (STRING DIAGRAM)
From string diagram, we can study on : Repetitive Safety Requirement Cross Traffic
PROPOSED LAYOUT&
EFFICIENCY ANALYSIS
Factors concerned : Distance – affecting times per distance travelled Process Flow Safety Factor (Safe & Mandatory Zone) Transportation Access Backtracking (Actual Layout vs. Proposed Layout) Geographic Requirement (riverside for launching)
PROPOSED LAYOUT
PROPOSED LAYOUT
Back
1 2 3 4 5 = (3 - 4)Section Location covered Distance (m) Distancenew(m) Distance Reduced (m)
A 27 to 25 33.0 32.8 0.2B 27 to 21 39.0 94.5 -55.5C 27 to 15 72.0 126.3 -54.3D 27 to 14 114.0 185.0 -71.0E 29 to 14 24.0 151.5 -127.5F 29 to 27 102.0 36.6 65.4
Gwalk 14 to 11 177.0 55.5 121.5Gothers 240.0 55.5 184.5Hwalk 14 to 8 216.0 41.8 174.2
Hothers 254.1 41.8 212.3I 14 to 12 366.3 83.8 282.5J 14 to 13 389.4 98.9 290.5K 14 to 21 92.4 67.3 25.1L 14 to 17 234.3 37.0 197.3M 14 to 3 534.6 239.6 295.0N 17 to 11 72.6 81.7 -9.1O 17 to 8 49.5 57.1 -7.6P 17 to 12 112.2 61.5 50.7Q 17 to 13 138.7 69.4 69.3R 17 to 3 273.9 207.9 66.0
Swalk 12 to 3 138.6 134.5 4.1Sothers 178.2 175.9 2.3Twalk 8 to 3 150.0 150.0 0.0
Tothers 240.9 218.3 22.6Uwalk 11 to 3 207.6 207.6 0.0
Uothers 297.0 265.4 31.6V 21 to 3 396.0 304.4 91.6W 27 to 3 346.5 422.8 -76.3
Total Total5489.80 3704.40
DISTANCE REDUCED
Total Distance Reduced :5489.8m – 3704.4m= 1785.4m @ 32.5%
EFFICIENCY ANALYSIS
Analysis Table for Walk1 2 3 4 = (3 ÷ 2) 5 6 = (4 X 5)
Section Distance (m) Timeaverage (s) Time per Meter (s/m) Distancenew(m) Timenew (s)A 33.0 27.79 0.84 32.8 27.62B 39.0 26.63 0.68 94.5 64.53C 72.0 56.17 0.78 126.3 98.52D 114.0 95.21 0.84 185.0 154.51E 24.0 36.35 1.51 151.5 229.46F 102.0 90.12 0.88 36.6 32.34G 177.0 218.27 1.23 55.5 68.44H 216.0 330.41 1.53 41.8 63.94I 366.3 416.20 1.14 83.8 95.21J 389.4 98.9 K 92.4 102.85 1.11 67.3 74.91L 234.3 215.85 0.92 37.0 34.09M 534.6 239.6 N 72.6 81.7 O 49.5 65.02 1.31 57.1 75.00P 112.2 143.41 1.28 61.5 78.61Q 138.7 69.4 R 273.9 247.83 0.90 207.9 188.11S 138.6 130.73 0.94 134.5 126.86T 150.0 177.04 1.18 150.0 177.04U 207.6 246.79 1.19 207.6 246.79V 396.0 304.4 W 346.5 422.8
Total Total2626.66 1835.98
Time Average Table
Full Analysis
EFFICIENCY ANALYSIS
Table of Efficiency Analysis
Types of Movement (Total Timeavg - Total Timenew) / Total Timeavg Efficiency Increased (%)
Walk 0.301 30.1
Motorcycle 0.298 29.8
Car / Van 0.368 36.8
Lorry 0.468 46.8
Forklift 0.347 34.7
Types of Movement Efficiencydefault (%) Efficiencynew (%)
Walk 100 130.1
Motorcycle 100 129.8
Car / Van 100 136.8
Lorry 100 146.8
Forklift 100 134.7
EFFICIENCY ANALYSIS
WalkMotorcycle
Car / VanLorry
Forklift
0
20
40
60
80
100
120
140
160
Efficiencydefault (%)
Efficiencynew (%)
Efficiencydefault (%)Efficiencynew (%)
DISCUSSION
Besides manipulating distance to reduce the time, this will eventually contribute to cost effectiveness
eg. less fuel consumed in transportation movement
Some facilities cannot be changed due to restriction based on several factors
Increase “quality” man-hour with the same labor cost
More systematic flow of operation
Proper safety control and management
Less time, higher productivity, more profits
DISCUSSION
RECOMMENDATION&
CONCLUSION
Proper syllabus for studies on shipyard productivity.
Commence current studies to higher degree and relate to the OECD.
Perpetual cooperation between universities and shipyards towards improving the shipbuilding productivity in Malaysia.
Additional supports by universities in terms of
cash, access to information, accommodation, etc
RECOMMENDATION
CONCLUSION
The result from this studies can be a turning point on improving the selected shipyard productivity.
Distance and Time are 2 factors that play an important roles in determining the efficiency of a shipyard layout thus improving the productivity and occasionally increase the profits
The result will also help the shipyard owner to overcome several problems by reducing the time and distance taken.
THANK YOU
Q & A SESSION