MODERN SHIPBUILDING PRACTICE

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MODERN SHIPBUILDING PRACTICE

GROUP TECHNOLOGY/PWBS/IPC

• GT is not new

• Has only had limited application in shipyards.

• Typical uses have been structural part variety reduction and development of pipe piece families.

• Many shipyards say they use it but they only think so as they use Work Breakdown Structures, classification and coding. This is not GT.

• GT is necessary if a shipyard wants to utilize automated pipe shop, Computer Aided Process Planning and/or robotics.

• However, GT is not for everyone. It should not be used unless a • clear understanding of why they need it.

• Many people need a classification and coding system but not GT.

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GROUP TECHNOLOGY/PWBS/IPC (Continued)

• Work Breakdown Structures (WBS) have been used for many years in many industries.

• WBSs are a convenient method to show desired tasks and/or processes to be used to build a product.

• A WBS can be Custom, Group Technology or Standard based.

Custom based is when the product and its components are all

different and no attempt is made to group the tasks or processes.

Group Technology based is when, even though the end

products may be different the tasks or processes can be group into similar categories based on work requirements.

Standard based is when the product is completely made up of

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• A Product Breakdown Structure is a graphic representation of an indented Bill of Material, where the indentations reflect the

order in which the components are assembled.

• The term Product-oriented Work Breakdown Structure (PWBS) refers to the specific case where the product, work and

organization are combined into a system to address a specific industrial product, like ships.

• The concept was introduced into U.S. shipbuilding by the IHI Technology Transfer in 1982 by the NSRP Report “Product-oriented Work Breakdown Structure.”

• Since then most U.S. shipbuilders have adopted the concept to some level, but not to the extent or the way that the report

described. In fact the report is confusing in many ways and has caused implementers considerable trouble.

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• A PWBS can be one of the most important tools in a shipyard’s attempt to improve it’s performance. This is because when it is developed correctly and applied to assist in the integration of the many systems in a shipyard, the benefits are significant.

• Some shipyards develop a more detailed breakdown in the form of an Interim Product Catalog. The catalog can range from a

few basic interim product types to a very comprehensive catalog of all parts through to erection. It can also identify work stations and processes used to manufacture the interim products as well as manhour budget and manning.

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BREAKDOWN STRUCTURES

• A breakdown structure is a structured representation of hierarchical information related to products of work.

• Bills of Material (BOM) are tabular representations of the

components that are required to assemble a product. BOM can be simple sequential lists of all material or they can be indented to represent what components go into higher level components. • A PRODUCT Structure (PS) is formed by making a hierarchical

tree in place of the indented BOM. For convenience it is usually turned 90 degrees to present a vertical cascade.

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BILL OF MATERIAL >>Assembly 1 >>Assembly 2 >>Sub-Assembly 1 >>Sub-Assembly 2 >>Sub-Assembly 3 >>Sub-Assembly 4 >>Part 1 >>Part 2 >>Part 3 >>Part 4 >>Part 5 >>Part 6 >>Part 7

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INDENTED BILL OF MATERIAL

>>Assembly 1 Sub-Assembly 1 Part 1 Part 2 Sub-Assembly 2 Part 3 >>Assembly 2 Sub-Assembly 3 Part 4 Part 5 Sub-Assembly 4 Part 6 Part 7

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WORK BREAKDOWN STRUCTURE

• Work Breakdown Structure (WBS) have been used for many years in many industries

• WBS are a convenient way to show desired tasks and/or processes to be used to build a product

• A WBS can be standard, group technology or custom based

Standard is when the product is completely made up of standard components I the same way every time.

Group technology is when, even though the end products may be

different, the tasks or processes can be grouped into similar categories based on work requirements.

Custom is when the product and its components are all different and no attempt is made to group the tasks or processes.

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WORK BREAKDOWN STRUCTURE (continued)

• There are many other types of breakdown structures used in a shipyard such as Labor Charging Structure and Cost Accounting Structure.

• Combining product and work in the same breakdown structure is illogical and confusing.

• However, there is normally a relationship between the product, the work that is required to manufacture it and the stage in the overall process at which it is done. If these standard

relationships are identified and documented in an Interim

Product Catalog, then only the product structure is required to identify the work required to produce the product. The work and stage naturally “fall out” of the system.

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• A WORK Breakdown Structure (WBS) is a hierarchical

representation of the work that is required to produce a product or interim product.

• A WBS divides the total work into all the tasks to be

accomplished in building a product. The tasks are arranged showing their dependencies of the sequence in which they should be performed.

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Block Erecting On-Block Outfitting Block Painting Block Constructing Assembling Fabricating Preparing

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OTHER BREAKDOWN STRUCTURES

• Product Breakdown Structures (PBS) is a graphic representation of an indented bill of material, where the indentations reflect the order in which the components are assembled.

• The term Product-Oriented Work Breakdown Structure (PWBS) refers to the specific case where the product, work and

organization are combined into a single system to address a specific industrial product, like a ship.

• Since the PWBS concept was introduced into U.S. shipbuilding by the 1982 NSRP Report, most shipbuilders have adopted the concept to some level, but not to the level suggested by the

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PRODUCT BREAKDOWN STRUCTURE

Ship

Grand Block or Construction Zone Block or Outfitting Zone

Assembly or Unit Sub-Assembly

Part

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INTERIM PRODUCTS

• Product Any finished (company deliverable object). • Interim Product An in process object which is the output of a

work stage (process) and is complete in and of itself.

• Interim Product A library of all interim products with

Catalog complete description of physical properties, cost data, manufacturing process, task

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PWBS/IPC REQUIREMENTS

• Based on shipyard practices

• Satisfy as many individual group needs as possible • Support computer-aided systems throughout company • Integrate all shipbuilding information

• As simple as possible - easy to understand • At learning level of all users

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IDENTIFICATION IMPORTANCE

• Identification system has a direct and

SIGNIFICANT

impact on performance of any manufacturing company

• Identification system must be the

INTEGRATOR

for information management system

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IDENTIFICATION NEEDS

Estimating Drawings

Manufactured and purchased parts Bills of material

Purchase specifications In process interim products Design and production zones Work packages Work sequence Material kitting Labor planning Activity scheduling Material control Production control Budgeting

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POTENTIAL APPROACHES

• Product/Work Station Structure

• Interim Product Catalog - Product based

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PRODUCTS/WS STRUCTURES

PRODUCT WORK STATION/PROCESS

PRODUCTION SUPPORT

Blocks- Bottom Stockyard Engineering Bilge Blast & Prime Planning Side Plate Plasma Cut Purchasing Bulkhead Plate Oxy Cut Material Cont. Deck Profile Cut & Mark Production Cont. Loopbelt Tower Plate Flange Transportation

Belt (M) Plate Form Lower Bow Profile Form Upper Bow Sub-Assembly Lower Stern Robot Welder

Upper Stern Panel Line- Plate Butt Tack Mach Space Bottom Plate Butt Weld Mach Space Sides Etc.

Mach Space Flats Block Construction Mach Space Deck Block Hot Outfit Deckhouse Block Clean and Pain

Block Cold Outfit

Outfitting Zones Dock Block Erection, Fit & Weld Package Unit Assembly

Zone Outfit System Test Dock Trial Sea Trial Delivery

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INTERIM PRODUCT CATALOG

PRODUCT BASED PROCESS BASED

Design Designing

Engineering Engineering

Purchase Equipment Planning

Raw Material - Plate Controlling - Material/Production

Profiles Handling - Plate/Profiles/Pipe/Equipment Castings Blasting & Priming - Plate/Profile/Pipe

Forgings Flame Planing Pipe Contour Cutting -

Insulation Profile Cutting - Manual/Robotic Paint Plate Forming

Electric Cable Profile Bending Parts- Structure Sub-Assembling

Machinery Assembling

Electrical Block Constructing Auxiliary Block Painting

Hull Outfit Package Unit Outfitting Sub-Assemblies Block Outfitting

Block Erection

Block Erection Welding Assemblies Zone Outfitting

Testing

Blocks Dock Trialing

Sea Trialing

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