Kul-24.

4130
Shipyard engineering
Heikki Remes

Marine Technology
Course in the study path of marine technology
Intended Learning Outcomes
• After the course, student will
– know main affecting factors on the shipbuilding process
– can separate different phases of the shipbuilding process
– understand the contents and methods for all production phases
– can apply learned knowledge to the preparation of production
plan
• During the course students will learn also
– scientific writing skills
– group working skills
– critical thinking
– independence and responsibility
Assignment work
• Define the production plan for
the Ship project (Kul-24.4110)
1. Preliminary production
plan
2. Hull production plan
3. Outfitting production plan
4. Product hierarchy and
logistics
5. Analysis of the results
and conclusions
Course contents
Production Introduction
planning

Shipbuilding process and

shipyard productivity

Outfitting

Design process
and materials
managements

Hull production
Methods for learning and assessment
Modified problem-based learning approach
Steps 1: Own & group working – Wednesday
• Initial study of assignment task
• Lecture material from my courses webpages
⇒ Outcome: 3-5 main keys questions (understanding of key points and challenges)

Step 2: Workshop and teaching event – Friday

• Workshop about main questions (Lecture & discussion)
⇒ Outcome: Proper tools and knowledge for assignment

Step 3 (Group working) – From Friday to Tuesday

• Assignment work and its delivery
⇒ Outcome: Deeper learning & teacher feedback based on subtask delivery

⇒ Final project report (“Big picture” and self-reflection)

⇒ Final exam to check personal learning outcomes
Kul-24.4130
Shipyard engineering

Lecture 7:
Production management and work planning

Marine Technology
Lecture in course contents
Production Introduction
planning

Shipbuilding process and

ship yard productivity

Outfitting

Design process
and materials
management

Hull production
Objectives, contents and literature
• Learning objective:
– Understand the production management from the ship design
and building process point of view
– Understand the main tools used in the work planning
• Contents:
– Production planning
– Planning principles and hierarchy
– Work planning
• Literature
– Laivatekniikka. Räisänen toim., 2000
– Ship production, Storch et al., SNAME, 1995
– Journal of Ship Production and Design
Students’ questions

• What are the most important issues in different management

levels (shipyard, ship, zone and team level)?
• How often the plans for these different levels are updated?
• How to keep track the overall process, who is responsible?
• Is push or pull control more common?
• What is the margin in cost estimation in preliminary and
concept design phases?
• How we take into account the uncertainty of material and
equipment delivery?
Planning principles

• Planning based on sales plan

• Planning based on contract book

• Push control
– Fixed production program for each production phase

• Pull control
– Previous production stage give impulse to the next stage
Planning hierarchy
• Strategic (long- & medium-term planning)
– Sales strategy
– Ship delivery schedule
– Production development programs
• Tactical (short-term planning)
– Block erection schedule
– Area outfitting schedule
• Operational (short-term planning)
– Drawing schedule, workshop schedule
– Work planning
Planning objective
• Good project
management, which
creates the conditions for
productive work
– Materials An outfitted block

– Suitable construction
– Productive building method
– Adequate resources
– Progress of other work
tasks according to
schedule
Area outfitting
Partition of the ship project
• Ship project management requires that the work is
divided into subtasks using a commonly understood
approach since
– Project duration is long
– Project is a large amount of work
– Project involves a large number of people, including
subcontracting
• Approaches for work partition:
– Systems, blocks, areas
• Planning levels:
– Shipyard, ship, area, team
Approaches for work partition
Three different views on a ship
Planning levels

Design and Status & plan

planning refinements

Operation Shipyard level Operation

planner planner

Operation
planner Ship level
Production
planner
Production
planner
Area level
Team work
planner
Team work
planner
Team level
Ship project planning and scheduling
Project phase Design phase Production phase
Scheduling objectives
• Recourse
– Shipyard level
– Department level; the next process phase is a customer
• Capacity
– Machine capacity, setting times, flexibility of workshop-layout (a typical machine shop
problems)
– Human resources, flexibility, additional capacity (problem for outfitting)
• Material
– Demand forecasting
– Interchangeable
– Delivery time
– Delivery confidence (time and amount)
– Quality shortcoming

• Influence of the price of unfinished work, the use of capacity, and the
delivery capability  Main challenge for outfitting planning
Work breakthrough structure (WBS)
 Operational planning
Strategic planning
Project planning
Offer
decision Design planning

Production unit
Concept and preliminary planning
design phase

Contract

Basic design phase

Detail design phase

After ship delivery
Production
starts

Production phase
Modified from
Fransman 2004
Concept and preliminary design phase
• Production planning at the sales stage aims to ensure
– 1) the delivery capability,
– 2) the reliable cost estimation (work, design, material)
• Planning work Contents:
– Total schedule, hard point for scheduling
– Preliminary work-hour estimations => workload analysis
– Preliminary block and area division
– Schedule for expensive materials
– Plans for Turnkey and special areas

Production planning unit is responsible (Consultation with other departments)

Total schedule, hard point for scheduling
Toiminan suunnittelu
Total schedule, hard point for scheduling
Toiminan suunnittelu
Basic design phase

• Final drawing for block-, area-, space division

• Construction method description
• Turnkey delivery plan
• Design schedules
• Hull and outfitting production schedules
• Material purchase scheduling
• Drawing scheduling
…
Basic design phase
• Nomination of responsibility
– Persons in charge
– For each systems, blocks, and areas
• Material budgets
• Hour budgets for design
• Hour budgets for production
• Workload analysis for department and groups
– Subcontracting plans for design departments

Production planning unit is responsible

(Acceptance in cooperation with the departments)
Detail design phase

• Monitoring of design progress

• Target size for working teams
– Workload analysis
– Subcontracting plans
• Work planning
Work planning
• Review of workshop drawings and parts lists
• Material verification and prefabrications
• Material orders and delivery control
• Work distribution and work instructions
• Material delivery to the installation place
• Drawing delivery for work supervisors
• Work place scheduling and hour estimates
• Reporting of the schedule status and hour usage
• Reporting of work-related feedback
• Development of productivity measures and working
methods
Production phase
• Work progress monitoring and reporting
• Status reporting
– Hour reports
– Status points for schedules
– S-curves; actuals, progress → estimation
– Workload histogram

• Schedule refinements
• Special schedules
Hour report

YHTEENSÄ

2.12.2016
S-curve
Actual, progress → estimation
Current plan

Original plan

Actual
man-hours

Actual
progress
S-curve
Completion date the same as originally planned
S-curve
Completion date determined by the shipbuilder
 Workload histogram

2.12.2016
After ship delivery

• Summaries for hour

data
• Updating of statistical
databases
• Collection of feedback
from the applied
construction method
• Analysis of feedback
Operational planning
Design of production planning
• Operational planning is a big job and it requires
scheduling, resources, etc.

Operational
planning schedule
 Operational planning
Strategic planning
Project planning
Offer
decision Design planning

Production unit
Concept and preliminary planning
design phase

Contract

Basic design phase

Detail design phase

After ship delivery
Production
starts

Production phase
Modified from
Fransman 2004
 Operational planning
Business /
Contract
capacity
planning
book Strategic planning

Company delivery Company action Project planning

Offer proposals with plan and
decision Sales projects workload data recourse usage Design planning
planning and
scheduling Production unit
planning
Work and cost Project
Construction plan
calculation for organization Recourse
(place, block, KT-
sales projects reservation
delivery, modules)

Contract Project
Definition of budget
Pre-contract for
subcontracting product hierarchy
Project Plans for risk Outfitting planning
realization plan management (schedule, recourses,
Schedule for construction method)
basic design
Master
schedule
Planning and Work
Hull production
scheduling of A-materials planning
scheduling
procurement delivery schedule
Database
Commissioning
Progress
Sea trial schedule Production reporting
Block production
planning (schedule, starts
recourses,
Feedback construction method)
Cost accounting Project control
Status report and instruction

Work Plan
planning refinements Adjustment
Modified from and extra work
Fransman 2004
Questions?
Students’ questions

• Is push or pull control more common?

• What are the most important issues in different management
levels (shipyard, ship, zone and team level)?
• How often the plans for these different levels are updated?
• How to keep track the overall process, who is responsible?
• What is the margin in cost estimation in preliminary and
concept design phases?
• How we take into account the uncertainty of material and
equipment delivery?
Research activity examples
Simulation based planning
Research activity examples
Simulation based planning
Research activity examples
Simulation based planning
ROPAX ship
Research activity examples
Construction methods

Based on Master’s Thesis of Lauri Kujala 2014

Research activity examples
Construction methods
Research activity examples

Production Efficiency and

Organization in Cruise
Shipbuilding

Defence of dissertation in the field of Marine

Technology, Sisko Hellgren M.Sc.(Eng)

Thursday 15.12.2016 at 12:00

Aalto University
Lecture Hall A1, Undergraduate Centre,
Otakaari 1, 02150, Espoo