Kul-24.4130ShipyardengineeringLecture1-1:ShipbuildingprocessMarineTechnologyAppliedMechanicsLectureincoursecontentsIntroductionOutfittingProductionplanningShipbuildingprocessandshipyardproductivityDesignprocessandmaterialsmanagementsHullproductionObjectives,contentsandliterature•Learningobjective:–Understandshipbuildingprocess–Recogniseshipbuildingprocessstages–Knowthebasictermsofshipbuildingprocess•Contents:–Productionstrategy–Theoreticalshipbuildingmodel–Shipbuildingprocessstages–Basicterminology•Literature–Laivatekniikka.Räisänentoim.,2000,Kappale30–Shipproduction,Storchetal.,SNAME,1995,ChapterI-IIProductionstrategy•Mainchallengeofproductionstrategy:–Theaimoftheproductioninvestmentistocreateacompetitiveadvantageforthecompany,notjustthebestfactoryintheworld•Ifownfactorydoesnotcreateacompetitiveadvantage,itisbettertobuyaproductthantomakeyourselfProduct?•Materialversusimmaterial(carvs.experience)•Productvs.Services(shipvs.repairservice)•Consumptionvs.investment•Partvs.productpackage•One-offvs.standardpart•Standard,customized,personalized...•Productfamily,variation,extension•Combinationvs.selectionProductionobjective•Theaimistoachieveatthesametimeagood–productivity(addedvalue/cost,…)–controllability(lead-time)–flexibility(tomanageoverproduction)–sensitivity–capitalefficiency(efficientuseofcapital)–loanedcapital/productivity-ratio(profit,cost)–qualityProductioncustomisationslevelDesignintensityandcustomisationOne-off-akindproductsorsystemsStandard,volumeproductsProductionefficiency/RepetitionWarehousevs.design-to-orderCustomisationslevelCustomisationlevelVolumevs.one-offproductionDesignFabricationAssemblyDistributionWAREHOUSEDesignFabricationAssemblyDistributionPACK-TO-ORDERDesignFabricationAssemblyDistributionASSEMBLY-TODesignFabricationAssemblyDistributionFABRICATE-TODesignFabricationAssemblyDistributionDESIGN-TO-ORDERBeforeorder–AfterorderProductandtypeofmarketCharactericsDemandstableDemanddynamicProductlifecycleLong(2+Y)Short(<1.5Y)ProductvarietyLowHighForecastingerrorSmall(5-10%)Big(40%)ContributiontomarginSmall(5-10%)Big(30-60%)Lead-timeformake-to-order6-12months1-14daysDevelopmenttrendsofFinnishandEuropeanmaritimeindustry•Strongnetworkingoftheshipbuilding–Shipyardsfocusesontheircorebusinessandutilizesub-contractors,modularsolutionsandintegratedsuppliers–Extremeexampleisanassembleyardconcept•Suppliersfocusondevelopingtheirownproductandsupportiveactivities•Theship'sownerslookfornewsolutionstoreducelifecyclecostsandimprovecompetitivenessTheoreticalshipbuildingmodelTheproductionfunctionqt=q(Kt,Lt,Et)qt=productionrateattimetKt=capitalutilizationrateattimetLt=labourutilizationrateattimetEt=efficiencyeffectsduetoproductionratechangeattimetCumulativeproductionProductionratemanningTimeTimeLabourutilisationrate•LabourutilizationrateLtisdefinedasquality-adjustedlabour–Shipsequencenumber(experienceeffect*)–Numberofworkers(manninglevel)–Changerateoftheworkersnumber–Lengthoftheworkday(overtime)–Workers'skilllevel*)Experiencecurveeffect(ExperienceCurve)•Costsisreducedbyaconstantamounteachtimetheaccumulatedproductionisdoubled•Inshipbuildingindustry,thisconstantisnormally5-10%Efficiencyeffects•DistractionsaffecttheefficiencyeffectsEt–Incompleteormissingplans–Interruptionsintheuseoflabour–Interruptionsinsupportfunctions–Workermora...
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