.T..

Faculty of Naval Architecture and Ocean Engineering Methods of Ship Production GEM314E

Capacity Planning Calculations for Shipyards

Week 2

Factors Influencing Yard Layouts

Range of ship types to be built and number/year Space required The overall area is governed by the space required for the various stages of the building process. Such spaces should be of a size capable of accommodating the proposed flow of materials through them. The size of the various spaces should be such that there is a level workload through the production process. In practice the workload is not level and it is normal to incorporate buffer areas where materials may be stored before moving on to the next stage in the process. The amount of space required for the various stages can be estimated by considering the building programme of the yard, ie. Number of ships per year, hence steel throughout. Space available In practice, particularly in existing yard, it is often not possible to allocate the ideal size of spaces which have been mentioned above. In this case it is necessary (by careful production planning, possible re-allocation of some areas and changes in basic construction techniques) to improve the flow of material through the various shops.

Factors Influencing Yard Layouts (cont.)

Amount of mechanisation The actual amount of mechanisation and automation will depend on the capital expenditure available, the wage level of the area/country and the availability of labour; for example, if labour is cheap and plentiful it may be advantageous to carry out operations manually in preference to using high cost machinery. Alternatively, if there is a shortage of labour, or labour costs are high then it may be preferable to invest in machinery instead. Materials handling The speed, direction and efficiency of material flow will depend on the type of transportation employed. Ideally, the handling of material should be kept to a minimum. For an efficient flow process it is necessary that the correct item is deposited in the correct place at the correct time using least effort and cost. Construction methods employed Directly related to the foregoing items are the methods of construction employed. The design and construction method should be best suited to the production facilities and vice-versa. For example, the size and layout of the ships, materials handling, etc, will depend on factors such as the amount of pre-fabrication employed, whether flat panel shops are used, the ambient weather which will indicate the amount of work to be carried out under cover, etc. Re-development Strategy Whenever a shipyard is to be modernised, or modified in light of changing demand, (or if a new shipbuilding facility is contemplated) then three, fundamental questions need to be answered: (a) What is the anticipated product mix? (b) What will be annual throughput for this product (mix)? (c) What are the present and projected levels of plant efficiency? From these basic parameters the details of the work content, the necessary layout force, the layout of the facilities and the quantity and type of equipment must be evaluated within the bounds of any physical, financial and corporate guidelines. Of course the six features mentioned in the previous section will also need to be considered in the analysis.

Typical Shipyard

1.Steel Storage, 2.Steel Cutting, 3.Subassembly, 4.Block Assembly, 5.Painting Halls, 6.Outfitting Shops, 7.Preoutfitting, 8.Grand Block Assembly, 9.Dock facilities, 10.Outfitting Quay, 11.Sea trials

STEEL STOCKYARD
Background The steel (plate and section) stockyard is a level space served by rail, road or a large ship. Normally, the plate/section stockyard is arranged for a direct feed of material into the plate/section preparation ship. The stockyard can, therefore, be arranged in series or parallel to this building. Plates in the stockyard, can either be stacked in flat piles or they can be arranged vertically on edge in storage racks. Generally, the former (ie. Flat stacks) is found to be more efficient and hence adopted by most of the yards. Plate storage areas are usually serviced by multiplemagnet gantry or bridge cranes of up to 20T capacity. For transfer of plates from the storage area to the preparation shops, however, flat cars, trailer or roller conveyer are also employed. Factors Influencing Stockyard Layout (a) Holding capacity and turnover (eg. The delivery of plates/sections from the steel mills, which can be in the order of 13 weeks, might determine turnover). (b) Provision of adequate offloading areas (eg. number of piles required for unloading lorries, rail cars, etc). (c) Allocating storage piles for high turnover steel (eg. plates of certain thicknesses or sections of particular dimensions are used more frequently than others). (d) Provision of sorting area (ie. After material has been delivered). (e) Areas for return of outgoing or rejected materials (eg. when material is of inadequate quality of wrong dimensions). Additionally, the following also need analysis: - Number of piles required for standard plates/sections. - Number of piles required for preparation machines. - Number of piles required for weekly loads. - How to deal with priority material. - How to deal with Q.C Inspections.

STEEL STOCKYARD

Plate Stockyard Production Number of Plates/Pile Generally this should not exceed 40 plates/pile in order to avoid the time-consuming operation of sorting through non-standard plates and also to avoid excessive surface loading. As a general guide: Surface Loading = Weight per pile/ Area (Tonnes/m2)

Crane Utilisation
Stockyard efficiency can greatly be affected by the handling facilities, eg: - the number of stockyard cranes available - the transverse/longitudinal travel speed of cranes - capability of crane to lift single or multiple plate lifts using magnets To decide whether or not a crane is over or under/utilised an assessment can be made from: Crane utilisation = (Actual hours worked/Total hours available) 1

Question 1
Example of Production Analysis

A Shipbuilding company is tendering for ten 60,000 DWT tankers all to be delivered within one year. Information is available as follows: SHIP DATA: No. of plates/ship = 5,000 Weight of steel plates/ship = 9,000 tonnes Average plate dimensions = 9m x 3m COMPANY DATA: Stockyard handling facilities = 1 Goliath crane Area available for plate piles = 5,000 m2 Surface loading 3 tonnes/m2 Average stock turnover = 8 weeks Company holidays = 3 weeks (Summer) & 2 Weeks (Winter) Production week = Two 8 hour shifts, 5 days/week (a) Calculate the average number of plates/pile. (b) What is the surface loading of this allocation? (c) What is the crane utilisation? Assume that average number of moves per plate is four (viz. unload 1st sort -= 2nd sort pile) and the average time per move is 3 minutes. (d) Comment upon the results. ie. 1 crane unable to meet demand (e) Recommend either the purchase of two more cranes, or tendering for part of order to match existing crane facilities or creating additional stockyard facility or reduce no. of plate movements in stockyard through planning methods.

Plate (or Section )Treatment Line

Modern plate treatment lines are normally designed to allow an automatic continuous process of material from captivator; hydro-levels; pre-heat unit; shot blast unit; priming machine; drying tunnel; offloading station. That is, plates are lifted from the stockyard, processed and then delivered to the plate preparation areas for subsequent operations. Equipment a)Captivator: The function of this equipment is to uplift material from a selected stack of plates and transport the plate, on automatic sequence, from the stack to the first powered conveyor, see figure below. Alternatively, rather than use the captivator method, if stockyard crane utilisation is low then the crane can directly feed the conveyor line. The advantage of the captivator is that once the stacks are loaded no further manual interface is needed. b) Hydrolevels: The purpose of this is to level, or mangle, the plates normally in one pass operation. When operating at the upper and lower plate thicknesses on the machine, more than one pass might be required. This operation is normally viewed and controlled manually. In addition, the same operator can control the captivator machine. (c) Pre-heat unit: This removes ice and pools of water from the plates, leaving the plate dry and also raising the temperature of the plate, thus improving the shotblast, priming and drying operations. This operation can be carried out using a hot water wash system. (d) Shotblast machine: The function of this machine is to remove scale and rust from the surfaces of the plate thus providing a good surface for the subsequent operation of paint priming. For normal merchant ship production, a good surface is one where at least 90% of the surface area is free from millscale, rust, rust stain, residues of paint or other coating, or any other form of contamination. The common abrasives used in the blasting operation are cast iron or steel grit or steel shot, and various expendable non-metallic abrasives made from slag or mineral mater in which any silica is present is in a combined and harmless form. The use of sand or other abrasives containing uncombined silica is barred in Britain because of the danger to health) the fine dust produced causes silicosis). (e) Priming machine: This sprays a primer paint onto the upper and lower surfaces of the plate. The purpose of applying the primer coat is to protect the steel throughout the preparation, fabrication and erection stages until the final paint system is applied. Generally, most primer paints will protect the blast cleaned plate from 3-12 months under humid conditions. It is important that the paint used is suitable for: continuous spray application, dries quickly and becomes handleable within a short space of time be non-toxic and not give rise to intolerable fumes when heated during burning and welding not unduly affect the quality of welds be compatible with subsequent coatings. (f) Drying tunnel: The function of this machine is to reduce the drying time of the paint primer thus allowing the plates to be stacked immediately after completion on line. This is done by drawing air above and below the surfaces of the plates, with the solvent laden air being discharge to the atmosphere. The conveyor in this region can be of a slot type and angled towards the centre of the machine. This allows the air to flow freely and the plate is supported on its edges only. (g) Offloading station: Various arrangements can be used at this station, e.g. a collocator which is similar to the captivator, only this time the machine is offloading into pre-determined stacks or alternatively, conveyors or cranes can be used. (h) Powered conveyors: The function of this is to link up the individual pieces of equipment (b) (g) and provide a continuous flow for transporting plates through the plate treatment line.

Calculation of utilisation levels Question 2 A plate treatment line is capable of producing a surface finish required by normal merchant ship production standard at an average (conveyer) speed of 3m/min. From the data given in the above example and assuming an average gap between plates moving through the shotblaster to be 3m, calculate the line utilisation for single shift working and state what managerial actions you would take, if any. Question 3 A section treatment line is capable of producing an adequate surface finish at a speed of 3m/min. Based on the data below calculate the line utilisation. Data:
- Production throughput/year 5 multi-purpose ships - No. of sections/ship 6,000 - Average length/depth of sections 8m/200mm - Average gap between sections 3m (in shotblaster) - Effective width of conveyor 1m - Working time @ 40 hours/week, 47 weeks/year

Plate Preparation Area

Area Allocation

Machinery in Plate Preparation Shop

Plate Preparation Shop Layout

Criteria Defining Machine Efficiency

Question 4

Fig.5.6

Table 5.2

Section Preparation Bay Layout (Fig.6.3)

Average Production Rates (Table 6.2)

Question 5

Table 6.1

Question 6
a) Using the information provided in Tables 3.1 and 3.2, calculate the total area required to stow steel sections excluding clearways and walkways but including sorting and buffer areas. Assume that the company operates for 47 weeks in the year and the average steel turnover period is 12 weeks; allow 5.5 % and 11 % of the calculated number of piles for sorting and buffer areas respectively; average length of each bar is 14 m and the spacing of upright dividers is 2 m. b) Comment on the range of section thicknesses to suit the derived number of piles and check that the surface loading does not exceed 25 tonnes/pile. c) Section are delivered in average bundles of 15 and each bundle is moved twice at an average of 3 mins/move and when broken out each section is also moved twice at an average of 2 mins./move. Allowing 10 % for contingencies on the required craneage time calculate the crane utilisation factor if two cranes are in operation during the dayshift and one on nightshift. The normal working week consists of: Dayshift : 5 days at 8 hours/day with 2 nights overtime at 2 hours/night Nightshift : 4 nights at 10 hours/night Table 3.1: Production Mix Ship Type 61000t bulk carrier (BC) 30000t multi-purpose (MP)

No. of Bars/Ship 9000 6000

Weight (tonnes) 3000 1000

Production Mix 1st 2nd 3rd 2 3 4 3 8

Table 3.2: Distribution of Section Types Type Distribution BC MP O.B.P. 50% 35% Flat Bars 30% 30% Ord Angles 10% 20% Misc. 10% 15%

Max Quantity/Pile 150 150 125 100

No. of Thicknesses BC MP 10 8 15 10 11 12 5 7

STEEL WORK FABRICATION

Sub-Assemblies Flat Unit Assemblies Curved Unit Assemblies 3D Unit Assemblies Block Assemblies

Layout for Construction of Small Ships

Layout for Construction of Large Ships

Calculating Area for Assembly of Main Units

Question 7

Question 7

Question 8

Data for Main Assembly Area Calculation

End of Week 2

Questions ?

Assignment 1

Answer all the questions given in this presentation. Use MS-EXCEL for the calculations. Present in Report Format (A4) It is due 06 March 2012
See NINOVA GEM314E