TITLE :

ANALYSIS ON MALAYSIAN SHIPYARD LAYOUT AND ITS EFFECTIVENESS TOWARDS IMPROVING THE PRODUCTIVITY

B Y:

MOHD ZULHILMI BIN ZALIZAN 56267109180 B E T N AVA L A R C H I T E C T U R E & S H I P B U I L D I N G

S U P E RV I S OR :

C E n g r. A H M A D A Z M E E R B I N R O S L E E

RESEARCH OUTLINE
Introduction

Literature Review
Research Methodology Data Analysis

Proposed Layout & Efficiency Analysis

Discussion Recommendation & Conclusion

INTRODUCTION

INTRODUCTION
Shipyard

layout is one of the important elements that determine the productivity of the shipyard. direct relationship between shipyard layout and its productivity is still in grey area due to the fact :

However,

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 Layout ii. Time iii. Distance iv. 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. ii. iii.

Visit and Survey Data Collection and Analysis Design Phase

How to calculate productivity :

i. ii.

By measure on the distance By measure on the time taken

PROBLEM STATEMENT
What

is the time consumed for shipbuilding activities based on the current shipyard layout? can the productivity increased by changing the layout?

How

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
Bhd., Teluk Panglima Garang, Selangor

NGV Tech. Sdn.

Nature

of Business
Steel Vessel Shipbuilding

Aluminium & Productivity

will be based on the distance and time measured on the selected shipyard Basis Steel Tugboats, Workboats, & Supply Boats

Project

LITERATURE REVIEW

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 Eyres 2006, Publisher by Elsevier Ltd.

LITERATURE REVIEW
Malaysias 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. Stevenson Productions/Operation Management, Sixth Edition, Irwin/McGraw Hill, US, 1999

LITERATURE REVIEW

Despite the importance of Productivity Measurement in representing companys competitiveness, its implementation in Malaysias shipyard has not widely known and properly documented.

Case Study 1 Ahmad Azmeer Bin Roslee Universiti Teknologi Malaysia Master 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 2 Ronny Andalas Universiti Teknologi Malaysia Master 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 3 Lim Cheng Min Massachusetts Institute of Technology Master of Science in Naval Construction and Engineering

RESEARCH METHODOLOGY

FLOW CHART
Title Proposal Thesis Objective Research Methodology

Phase 1 JULY 2011 JAN 2012

Task Planning Survey Form Decide Shipyard for Survey Accept?
YES?

Literature Review
NO?

Shipyard Visit Survey/Data collected Data Analysis Result Produced Proposed Layout Final Report

Phase 2 JAN 2012 MAY 2012

FLOW CHART (SURVEY)

Start Data Collected
NO?

Enough

YES?

Data Tabulated

Data Analysis

Result

Finish

OPERATION PROCEDURE
Select

shipyard and pilot test to develop productivity measurement form.

OPERATION PROCEDURE
Obtain Record

the existing layout.

all findings using productivity measurement form. Measure and collect data based on :
i. ii. Distance Time Taken

OPERATION PROCEDURE

Productivity Measurement Form

OPERATION PROCEDURE
Do

an analysis.

Analysis Work Flow

Suggest
i. ii.

new layout with new improvement :

Less distance Less time taken

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 Description

3
8 11 12 13 14 15 17 21

Jetty
Slipway 1 Hangar 3 Hangar 4 Hangar 5 Store 1 (Tools & Equipments) Store 2 (Paintings) Store CO2 (Materials) Workshop 1

25
27 28 29

Client & Contractor Office

NGV Main Office Surau Canteen

CONCENTRATED AREA
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.

PROJECT DESCRIPTION

PROJECT DESCRIPTION

DATA COLLECTION
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-W

eg. 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

FREQUENCY
Section A B C D E F G H I J K L M N O P Q R S T U V W No. of Data Collected 16 13 22 32 12 28 25 42 48 0 47 48 40 15 43 41 6 40 49 41 37 43 24

No. of Data Collected

60

50

40

30

No. of Data Collected

20

10

0 A B C D E F G H I J K L M N O P Q R S T U V W

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
Section A B C D E F G H I J K L M N O P Q R S T U V W Location covered Distance (m) 27 to 25 33 27 to 21 39 27 to 15 72 27 to 14 114 29 to 14 24 29 to 27 102 14 to 11 walk:177, others:240 14 to 8 walk:216, others:254.1 14 to 12 366.3 14 to 13 389.4 14 to 21 92.4 14 to 17 234.3 14 to 3 534.6 17 to 11 72.6 17 to 8 49.5 17 to 12 112.2 17 to 13 138.7 17 to 3 273.9 12 to 3 walk:138.6, others:178.2 8 to 3 walk:150, others:240.9 11 to 3 walk:207.6, others:297 21 to 3 396.0 27 to 3 346.5 Walk 27.79 26.63 56.17 95.21 36.35 90.12 218.27 330.41 416.20 Time Average (seconds) Motorcycle Car / Van Lorry 9.69 10.61 15.79 29.16 61.37 29.76 68.44 60.75 87.69 53.60 127.92 143.00 198.34 Forklift

156.66 157.49 247.53

202.26 250.70

102.85 215.85

65.02 143.41 247.83 130.73 177.04 246.79

25.74 87.69 130.39 18.91 16.09 28.37

89.68 28.95 52.42 74.18 112.43 145.38

53.42 123.00 279.46 43.32 31.41 59.95

140.58 70.94 103.68 131.68 141.59 167.15

59.34 140.38 323.21 45.41 33.60 82.27 105.25 165.53 71.87 91.77 140.87 195.42

57.48 119.24 345.60 121.57 119.85 138.57 166.25 248.40 173.83 223.80 275.61 395.59

Time average is calculated based on total time consumed in each section

and divided by their frequency

Back

DATA ANALYSIS (STRING DIAGRAM)

From string diagram, we can study on :

Repetitive Safety Requirement Cross Traffic

PROPOSED LAYOUT & EFFICIENCY ANALYSIS

PROPOSED LAYOUT
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

Back

DISTANCE REDUCED
1 Section A B C D E F Gwalk Gothers Hwalk Hothers I J K L M N O P Q R Swalk Sothers Twalk Tothers Uwalk Uothers V W 2 Location covered 27 to 25 27 to 21 27 to 15 27 to 14 29 to 14 29 to 27 14 to 11 14 to 8 3 Distance (m) 33.0 39.0 72.0 114.0 24.0 102.0 177.0 240.0 216.0 254.1 366.3 389.4 92.4 234.3 534.6 72.6 49.5 112.2 138.7 273.9 138.6 178.2 150.0 240.9 207.6 297.0 396.0 346.5 Total 5489.80 4 Distancenew(m) 32.8 94.5 126.3 185.0 151.5 36.6 55.5 55.5 41.8 41.8 83.8 98.9 67.3 37.0 239.6 81.7 57.1 61.5 69.4 207.9 134.5 175.9 150.0 218.3 207.6 265.4 304.4 422.8 Total 3704.40 5 = (3 - 4) Distance Reduced (m) 0.2 -55.5 -54.3 -71.0 -127.5 65.4 121.5 184.5 174.2 212.3 282.5 290.5 25.1 197.3 295.0 -9.1 -7.6 50.7 69.3 66.0 4.1 2.3 0.0 22.6 0.0 31.6 91.6 -76.3

14 to 12 14 to 13 14 to 21 14 to 17 14 to 3 17 to 11 17 to 8 17 to 12 17 to 13 17 to 3 12 to 3
8 to 3 11 to 3 21 to 3 27 to 3

Total Distance Reduced : 5489.8m 3704.4m = 1785.4m @ 32.5%

EFFICIENCY ANALYSIS
1 Section A B C D E F G H I J K L M N O P Q R S T U V W 2 Distance (m) 33.0 39.0 72.0 114.0 24.0 102.0 177.0 216.0 366.3 389.4 92.4 234.3 534.6 72.6 49.5 112.2 138.7 273.9 138.6 150.0 207.6 396.0 346.5 Analysis Table for Walk 3 4 = (3 2) Timeaverage (s) Time per Meter (s/m) 27.79 0.84 26.63 0.68 56.17 0.78 95.21 0.84 36.35 1.51 90.12 0.88 218.27 1.23 330.41 1.53 416.20 1.14 102.85 215.85 1.11 0.92 5 Distancenew(m) 32.8 94.5 126.3 185.0 151.5 36.6 55.5 41.8 83.8 98.9 67.3 37.0 239.6 81.7 57.1 61.5 69.4 207.9 134.5 150.0 207.6 304.4 422.8 6 = (4 X 5) Timenew (s) 27.62 64.53 98.52 154.51 229.46 32.34 68.44 63.94 95.21 74.91 34.09

65.02 143.41 247.83 130.73 177.04 246.79

1.31 1.28 0.90 0.94 1.18 1.19

75.00 78.61 188.11 126.86 177.04 246.79

Time Average Table Full Analysis

Total 2626.66

Total 1835.98

EFFICIENCY ANALYSIS
Table of Efficiency Analysis Types of Movement Walk Motorcycle Car / Van Lorry Forklift (Total Timeavg - Total Timenew) / Total Timeavg 0.301 0.298 0.368 0.468 0.347 Efficiency Increased (%) 30.1 29.8 36.8 46.8 34.7

Types of Movement Walk Motorcycle Car / Van Lorry Forklift

Efficiencydefault (%) 100 100 100 100 100

Efficiencynew (%) 130.1 129.8 136.8 146.8 134.7

EFFICIENCY ANALYSIS

160 140 120 100 80 60 40 20 0 Walk Motorcycle Car / Van Efficiencydefault (%) Lorry Forklift Efficiencynew (%) Efficiencydefault (%) Efficiencynew (%)

DISCUSSION

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

RECOMMENDATION & CONCLUSION

RECOMMENDATION
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

CONCLUSION
The

result from this studies can be a turning point on improving the selected shipyard productivity. 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

Distance

The

result will also help the shipyard owner to overcome several problems by reducing the time and distance taken.

THANK YOU

Q & A SESSION