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1. Introduction 1
INTRODUCTION
Nowadays, there are many process created by shipbuilders in order to save cost and
money. In this assignment, the modular construction and lean shipbuilding process had been
chosen to be our topic. Below, the topic was explained in details in what, why and how the
shipbuilding process implemented in order to save both cost and time consumption.
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The reason why modular construction process become popular in ship building industry
is because there is no other method available that allows you to start and finish a project in a
more-timely manner than modular.
Mod Space takes full advantage of a controlled production environment combined with
the design flexibility of traditional building methods to produce high-quality permanent or
temporary prefabricated structures for any demand. The result is a prefabricated modular
building product that is faster, more affordable and environmentally-friendly, with the all the
same architectural aesthetics you would expect from traditional building methods.
Less than 5% of the markets previously defined as conventional currently utilize modular
construction concepts. Given these numerous advantages, it’s only a matter of time before
modular becomes the convention method.
2. Preparation
To prepare plates and section before being weld, cut, mark and other.
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3. Sub assembly
Sub assemblies include fitting, welding, fairing and many other sub assembly process
4. Assembly
This shop takes the products from the panel fabrication area and assembles them to
favricate the unit.
5. Fabrication
Including marking, cutting, bending
This shop is designed to fabricate the parts from the parts making area. These includes:
7. Basin/Afloat
By launching ship on a slipway to ensure ship able to float correctly.
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In addition, lean shipbuilding derived from the concept of lean production is lean
production theory in ship Industry, first proposed by the U.S. shipbuilding industry, shipbuilding
contract, that contract from the beginning to the delivery of the ship completed the
construction of the entire process, through motivation and mobilization of all employees to
continuously improve and perfect the process of shipbuilding, ship construction to reduce all
the waste, to reduce the shipbuilding cycle, reduce shipbuilding costs and improve shipbuilding
quality.
Value Adding Activity - An activity that transform shapes or converts raw material to meet
customer requirements.
Non-Value Adding (Waste) - Those activities that take time, resources, or space, but do not add
value.
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There are 7 Non-Value Adding that have been recognized which slow the process in
shipbuilding industry and which leads to rising in terms of cost and time consumption. It
includes:
Overproduction Producing faster than the rate of consumption and make more product
more than the materials needed for the shipbuilding.
Inventory Unnecessary materials, cause the inventory in storage is to be full.
Motion When workers are not efficient because have to walk or moving in order
to do their jobs. For example, workers have to walk to get a tool or piece
of material.
Waiting Workers being idle between operations, waiting for a machine to cycle or
waiting for the preceding operator to finish their work.
Over Processing Having to perform more operations than are
Necessary. Example, painting prior to welding.
Correction Scrap, rework, sort, & repair add unnecessary costs.
Conveyance Unnecessary transportation can also increase money consumption.
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The above diagram shows how different traditional shipbuilding and lean shipbuilding process.
In the research made by Toyota, it majorly affects those 5 fields which are quality, productivity,
maintenance, employees and simplicity.
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One-Piece Flow
AKT Time
Pull Systems
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CONCLUSION
From what we had learned from both of the topics, which is modular construction
process and lean shipbuilding process, it is obvious that both process are new in the world of
shipbuilding and is gaining popularity in shipbuilding construction.
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