INTRODUCTION TO SHIP TECHNOLOGY

LDD 10102

..\..\..\Syllabus\LDD 10102 Introduction to Ship Technology SLT.doc ..\..\..\Lesson Plan\Standard QA Lesson Plan Intro Ship Technology LDD 10102SLT.doc

REMEMBER TO WRITE THE IMPORTANTANT NOTES

SECTION 6- TOPIC 6
The methods of ordering and modes of transportation of materials in a shipbuilding facility The procurement and materials ordering process The criteria for selecting construction materials Transportation methods and material handlings in a store and yard

ST1 Sect 4

Lesson Plan 1
Introduction

Procurement Process

The shipbuilding industry caters to customers individual needs. The ship or boat is built to order and is usually a one-off product. This requires implementation of a unique procurement process in the shipyard during ship construction. The ordering process is usually determined by the particular project plan and the suppliers production and delivery program.

Procurement Process
A modern shipyard consists of the following key departments: Design Project Control/Planning Production Procurement may also be known as the ordering or purchasing department.

ST1 Sect 4

Design The design department issues drawings with specifications of the components required. The project control department establishes a master schedule for the shipbuilding program. This schedule includes target dates and milestones. The procurement department follows this schedule to plan the procurement process. Procurement Department The procurement department is at the centre of the shipyards business organisation. This department interfaces with all of the other shipyard departments. Fig. M103.4.1 shows the interfaces between the various departments and the procurement departments.

CUSTOMER REQUIREMENTS

ST1 Sect 4
MARKETING

FORECASTS

ENGINEERING DESIGN

CONFIGURATION MANAGEMENT

ESTIMATES SPECIFICATIONS VALUE ANALYSIS

MATERIAL PLANNING

TIMING QUANTITIES

PURCHASING

QUALITY INSPECTION

PRODUCT AVAILABILITY

MANUFACTURING PRODUCTION

QUALITY COMPLAINTS

MARKETING

Fig. M103.4.01 Internal Interfaces of the Procurement Department

Procurement for the construction of ships may include the following: raw materials i.e. steel plates and bars subcontracted work i.e. installation of navigation equipment components tools and equipment.

ST1 Sect 4

Engineering Design and Procurement Departments The design department issues the drawings and associated bills of materials relating to the construction of the ship. These drawings and materials lists are then transmitted to the planning and control department, which issues a material requisition to the procurement department. The procurement department creates a procurement schedule. The relationship between the design and procurement departments ensures that: there is an uninterrupted flow of materials and services materials are purchased at a competitive price inventory investment and inventory losses are kept at a practical minimum effective and reliable sources of supply are developed good relationships with the supplier community and good continuing relationships with active suppliers are developed there is maximum integration with the other departments of the organization the procurement and supply function is managed proactively in a professional, cost-effective manner.

ST1 Sect 4

The Engineering Design department greatly influences the amount of time available for the procurement department to handle a procurement assignment.
The Engineering Design department has the responsibility for preparing the technical specifications of the ship and of the materials required to construct the ship. The quality, the prices paid for production materials, and the costs to fabricate are inextricably related to the specifications. The materials specified should be both economical to procure and economical to fabricate. It should be noted that cost effective procurement is dependant on the design and procurement departments working together to obtain the best product for the cheapest price.

Lesson Plan 2

Material Selection Criteria

ST1 Sect 5

Evaluation of Materials
Introduction Materials commonly used in shipbuilding are shown in the following table. Refer to Section 5 for additional information.
Material Application examples

Ferrous metals and alloys (iron is the prime constituent) Cast Iron Engines, winches, anchor Steel Frames Alloy Steel , superstructure Nonferrous metals and alloys (iron is not the prime constituent) Aluminium , mast, superstructure Copper Electrical cabling, pipes Titanium Light, strong but very expensive material used in the manufacture of racing yachts Plastics Laminated plastics Nylon PVC Glass Reinforced Plastics (GRP) Rubber Glass Wood Leather Stern tube Sails, mooring ropes, rigging Electrical conduits and pipes , fittings (used extensively in ship construction) Gaskets, flooring Port holes, windows , superstructure, panelling Seating

Criteria for Selecting Construction Materials There is no standard checklist for evaluating materials. Each material has a different application and must therefore have a unique checklist prepared for that application. When selecting material for a particular application the following criteria should be used: shape consideration mechanical properties physical properties operating environment

ST1 Sect 5

Shape Consideration When considering the shape of a particular item the following issues should be kept in mind: the relative size of the item the complexity of the shape what are the axes or planes of symmetry? are there any uniform cross sections? can the item be divided into sub-components to facilitate manufacture? what are the dimensions of the item? are the dimensions precise? how many are restrictive, and which ones? is there geometric interaction with other components? what are the surface finish requirements? what is the tolerance, and normal wear and tear, acceptable for change in item dimensions? could minor modification to the geometry of the item increase the ease of manufacture?

ST1 Sect 5

Mechanical Properties During material selection the following properties of materials need consideration: what is the static strength requirement? an item may fail due to fracture or plastic deformation is one type preferred or unacceptable? what is the type and magnitude of the maximum impact loading? what is the frequency and magnitude of the cyclic loading anticipated? is wear resistance required, if so - where? - how much? - how deep? what temperature range will the item be used in? what are the maximum bending and compression forces to be accommodated?

ST1 Sect 5

Physical Properties
The following physical properties of components used in manufacture, must be considered in order to select the correct materials: what are the electrical requirements, for example conductivity, resistivity? what are the magnetic properties? what are the thermal requirements, thermal conductivity? are their any optical requirements? what are the weight considerations? what exterior appearance, colour and surface finish is required?

ST1 Sect 5

Operating Environment
When selecting materials for ship construction purposes, the operating environment plays a vital role in the service life of that component. Factors to be considered are listed below: what is the temperature range of operation? will temperature changes be cyclic? how fast will changes occur? is the operating environment of the boat or ship seawater or freshwater? what is the preferred service lifetime? what are the maintenance requirements? what is the liability if the product fails? what are the EPA requirements for disposal of faulty components?

ST1 Sect 5

Manufacturing Concerns When a suitable raw material is selected the following manufacturing concerns must be addressed: how many items and at what rate are the items to be manufactured? what is the standard shape of the raw material and the final product? has the design addressed the manufacturing capability of the shipyard? machinability, castability and weldability. what is the section thickness? what is required level of quality compared to similar products in the market place? what are the quality control and inspection requirements? are there any assembly and disassembly concerns?

ST1 Sect 5

Costs An important selection criteria for any material is the cost of manufacturing the material from raw product compared to the cost of manufactured material available in the market place. Analyses should also be made to compare alternative materials that may be costly but could enhance performance. Over the lifetime of the product these materials could prove more efficient and economical. Material Availability Manufacturers supply their raw materials in fixed sizes and quantities. These factors must be taken into consideration for cost-effective manufacturing. Another consideration is the availability of material and substitution of materials where possible.

ST1 Sect 5

SAMPLE MATERIAL EVALUATION FORM MATERIAL SELECTION CRITERIA POSSIBLE MATERIALS Purpose Location Due Date Weight restrictions Thermal Properties

Fabrication Method Cost constraints Strength Requirements Summary of Possible Materials

Suggested Material

Sample Matl Evaluation Form

Fig. M103.5.01 Twisted Rectangular Duct

ST1 Sect 5

Example Project
This project involves manufacturing a piece of ducting normally used in a ship. Using the criteria described in this section, trainees are required to select suitable material and define the manufacturing process

The twisted rectangular duct is turned off-centre in two directions, so that two sides may lie flat against two bulkheads forming a corner. Alternatively, two sides may lie flat against the bulkhead and deck.

Fig. M103.5.01 Twisted Rectangular Duct

ST1 Sect 5

Fig. M103.5.02 Development View Trainees are to cut out the enlarged development view and fold it along the internal lines. This will give the trainees a better understanding of the twisted ducting in this project.

ST1 Sect 5

Fig M103.5.03 Plan and elevation (1st Angle)

Consider the following for selection of the material: shape mechanical property physical property operating environment. In this example, aluminium sheeting should be selected as the raw material. It is readily available and suitable for the marine environment as it does not corrode. It can be easily shaped and cut. Aluminium is high in ductility and malleability.

ST1 Sect 4

Lesson Plan 3
Introduction

Transportation methods and materials handling in store and yard

A typical shipyard includes wide-ranging material handling equipment to transport a wide variety of materials ranging from large metallic objects to gas cylinders. Material handling equipment can be classified into the following four broad groups: Conveyors Industrial Trucks Cranes Containers. Conveyors Conveyors are useful for moving material between two fixed workstations. They are mainly used for continuous or mass production. Conveyors consist of rollers, wheels and belts to move material from one point to another. Most conveyors are power-driven. Typical examples of conveyors are shown in Fig.M103.4.02 and Fig. M103.4.03.

ST1 Sect 4

Fig.M103.4.02 Belt Conveyor

Fig.M103.4.03 Screw Conveyor

ST1 Sect 4

Industrial Trucks Forklifts are used extensively to move heavy items. They are easy to operate and manoeuvre. Fig. M103.4.04 shows a typical forklift used in a shipyard.

Forklift trucks can vary in: Size: from small manual models to large trucks that can handle shipping containers Power source: manually operated, electric battery, LPG, petrol or diesel Operator: the operator may ride on the forklift or walk beside it Handling devices: there are number of special devices which can be mounted on the forklift instead of the forks, for example: hoist jib, drum clamp.

ST1 Sect 4

Manual trucks and skates These are used to move heavy or awkward loads on reasonably smooth floors. Certain models are powered. The truck may also be used as a jig or worktable to hold materials while it moves through the manufacturing process. A typical skate is shown in Fig. M103.4.05.

Fig. M103.4.05 Skate

ST1 Sect 4 Cranes Several types of cranes and hoists are used in a shipyard. Some examples are shown below:

CHAIN BLOCK: Manually operated and portable.

HOISTS: These are powered and operated from a push button pendant. The hoists are normally fitted on a monorail so that they can travel. POST PANAMAX CONTAINER: Commonly used to move containers. The crane sits on rails on which it can travel. The load can travel along the width of the crane. STRADDLE CARRIER: This crane can pick up containers between its legs and move them around the shipyard.

ST1 Sect 4

Containers There are two typical types of containers. Some containers are used for holding materials these are fixed and cannot be moved. Other types such as wagons and trolleys not only contain materials but they can be moved from one place to another. Figure.M103.4.06 shows some examples:

Fig M103.4.06. Typical Containers

ST1 Sect 4

Lesson Plan 4 Materials handling equipment

There are three typical types of materials handling equipment found in a plate and bar stockyard. The functions of these three types of equipment are to: hold objects lift heavy objects move objects. Equipment to hold objects Examples of equipment used to hold objects are shown below;

LIFTING ELECTRO MAGNETS

SUCTION GRIPS

ST1 Sect 4

SLINGS

LIFTING STRAPS

CLAMPS

ST1 Sect 4

Equipment to lift heavy objects The lifting equipment described previously, such as cranes, forklifts and skates can be used inside the store providing space is available. However special lifting equipment, such as drum-lifters as shown in Fig.M103.4.07, will be located in a store

Fig M103.4.07. Drum Lifters

Equipment to move objects Cranes and hoists were described previously

Materials Managment.ppt