View
217
Download
0
Category
Preview:
Citation preview
7/29/2019 Section 6 Materials Ordering & Handling SHO
1/30
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
http://localhost/var/www/apps/Syllabus/LDD%2010102%20%20Introduction%20to%20Ship%20Technology%20SLT.dochttp://localhost/var/www/apps/Syllabus/LDD%2010102%20%20Introduction%20to%20Ship%20Technology%20SLT.dochttp://localhost/var/www/apps/Lesson%20Plan/Standard%20QA%20Lesson%20Plan%20Intro%20Ship%20Technology%20LDD%2010102SLT.dochttp://localhost/var/www/apps/Lesson%20Plan/Standard%20QA%20Lesson%20Plan%20Intro%20Ship%20Technology%20LDD%2010102SLT.dochttp://localhost/var/www/apps/Lesson%20Plan/Standard%20QA%20Lesson%20Plan%20Intro%20Ship%20Technology%20LDD%2010102SLT.dochttp://localhost/var/www/apps/Lesson%20Plan/Standard%20QA%20Lesson%20Plan%20Intro%20Ship%20Technology%20LDD%2010102SLT.dochttp://localhost/var/www/apps/Lesson%20Plan/Standard%20QA%20Lesson%20Plan%20Intro%20Ship%20Technology%20LDD%2010102SLT.dochttp://localhost/var/www/apps/Lesson%20Plan/Standard%20QA%20Lesson%20Plan%20Intro%20Ship%20Technology%20LDD%2010102SLT.dochttp://localhost/var/www/apps/Lesson%20Plan/Standard%20QA%20Lesson%20Plan%20Intro%20Ship%20Technology%20LDD%2010102SLT.dochttp://localhost/var/www/apps/Lesson%20Plan/Standard%20QA%20Lesson%20Plan%20Intro%20Ship%20Technology%20LDD%2010102SLT.dochttp://localhost/var/www/apps/Lesson%20Plan/Standard%20QA%20Lesson%20Plan%20Intro%20Ship%20Technology%20LDD%2010102SLT.dochttp://localhost/var/www/apps/Lesson%20Plan/Standard%20QA%20Lesson%20Plan%20Intro%20Ship%20Technology%20LDD%2010102SLT.dochttp://localhost/var/www/apps/Lesson%20Plan/Standard%20QA%20Lesson%20Plan%20Intro%20Ship%20Technology%20LDD%2010102SLT.dochttp://localhost/var/www/apps/Lesson%20Plan/Standard%20QA%20Lesson%20Plan%20Intro%20Ship%20Technology%20LDD%2010102SLT.dochttp://localhost/var/www/apps/Lesson%20Plan/Standard%20QA%20Lesson%20Plan%20Intro%20Ship%20Technology%20LDD%2010102SLT.dochttp://localhost/var/www/apps/Lesson%20Plan/Standard%20QA%20Lesson%20Plan%20Intro%20Ship%20Technology%20LDD%2010102SLT.dochttp://localhost/var/www/apps/Syllabus/LDD%2010102%20%20Introduction%20to%20Ship%20Technology%20SLT.dochttp://localhost/var/www/apps/Syllabus/LDD%2010102%20%20Introduction%20to%20Ship%20Technology%20SLT.dochttp://localhost/var/www/apps/Syllabus/LDD%2010102%20%20Introduction%20to%20Ship%20Technology%20SLT.dochttp://localhost/var/www/apps/Syllabus/LDD%2010102%20%20Introduction%20to%20Ship%20Technology%20SLT.dochttp://localhost/var/www/apps/Syllabus/LDD%2010102%20%20Introduction%20to%20Ship%20Technology%20SLT.dochttp://localhost/var/www/apps/Syllabus/LDD%2010102%20%20Introduction%20to%20Ship%20Technology%20SLT.dochttp://localhost/var/www/apps/Syllabus/LDD%2010102%20%20Introduction%20to%20Ship%20Technology%20SLT.dochttp://localhost/var/www/apps/Syllabus/LDD%2010102%20%20Introduction%20to%20Ship%20Technology%20SLT.dochttp://localhost/var/www/apps/Syllabus/LDD%2010102%20%20Introduction%20to%20Ship%20Technology%20SLT.dochttp://localhost/var/www/apps/Syllabus/LDD%2010102%20%20Introduction%20to%20Ship%20Technology%20SLT.doc7/29/2019 Section 6 Materials Ordering & Handling SHO
2/30
REMEMBER TO WRITE THE
IMPORTANTANT NOTES
7/29/2019 Section 6 Materials Ordering & Handling SHO
3/30
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
7/29/2019 Section 6 Materials Ordering & Handling SHO
4/30
Lesson Plan 1 Procurement Process
Introduction
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 planand 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
7/29/2019 Section 6 Materials Ordering & Handling SHO
5/30
Design
The design department issues drawings with
specifications of the components required. The projectcontrol 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 theshipyards 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.
ST1 Sect 4
7/29/2019 Section 6 Materials Ordering & Handling SHO
6/30
MARKETING
ENGINEERINGDESIGN
PURCHASINGMATERIALPLANNING
QUALITYINSPECTION
MANUFACTURINGPRODUCTION
MARKETING
FORECASTS
CONFIGURATIONMANAGEMENT
CUSTOMER REQUIREMENTS
ESTIMATESSPECIFICATIONSVALUE ANALYSIS
TIMINGQUANTITIES
QUALITYCOMPLAINTS
PRODUCTAVAILABILITY
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.
Fig. M103.4.01 Internal Interfaces of the Procurement Department
ST1 Sect 4
7/29/2019 Section 6 Materials Ordering & Handling SHO
7/30
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 andmaterials 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
7/29/2019 Section 6 Materials Ordering & Handling SHO
8/30
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 andeconomical 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.
ST1 Sect 4
7/29/2019 Section 6 Materials Ordering & Handling SHO
9/30
Lesson Plan 2 Material Selection Criteria
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 , superstructureNonferrous 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 Stern tubeNylon Sails, mooring ropes, rigging
PVC Electrical conduits and pipes
Glass Reinforced Plastics (GRP) , fittings (used extensively in ship construction)
Rubber Gaskets, flooring
Glass Port holes, windows
Wood , superstructure, panellingLeather Seating
ST1 Sect 5
7/29/2019 Section 6 Materials Ordering & Handling SHO
10/30
Criteria for Selecting Construction Materials
There is no standard checklist for evaluating materials. Eachmaterial 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
7/29/2019 Section 6 Materials Ordering & Handling SHO
11/30
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
7/29/2019 Section 6 Materials Ordering & Handling SHO
12/30
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
ST1 S t 5
7/29/2019 Section 6 Materials Ordering & Handling SHO
13/30
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
ST1 S t 5
7/29/2019 Section 6 Materials Ordering & Handling SHO
14/30
Operating Environment
When selecting materials for ship construction purposes, theoperating 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
ST1 S t 5
7/29/2019 Section 6 Materials Ordering & Handling SHO
15/30
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 similarproducts in the market place?
what are the quality control and inspection
requirements?
are there any assembly and disassembly concerns?
ST1 Sect 5
ST1 Sect 5
7/29/2019 Section 6 Materials Ordering & Handling SHO
16/30
Costs
An important selection criteria for any material is the cost ofmanufacturing 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 theproduct 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
ST1 Sect 5
7/29/2019 Section 6 Materials Ordering & Handling SHO
17/30
SAMPLE MATERIAL EVALUATION FORM
MATERIAL SELECTION CRITERIA POSSIBLE MATERIALS
Purpose
Location
Due Date
Weight
restrictions
Thermal
Properties
Fabrication
MethodCost constraints
Strength
Requirements
Summary of Possible Materials
Suggested Material
Sample Matl Evaluation Form
ST1 Sect 5
ST1 Sect 5
7/29/2019 Section 6 Materials Ordering & Handling SHO
18/30
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 DuctFig. M103.5.01 Twisted Rectangular Duct
Fig. M103.5.01 Twisted Rectangular Duct
ST1 Sect 5
ST1 Sect 5
7/29/2019 Section 6 Materials Ordering & Handling SHO
19/30
Trainees are to cut out the enlarged development view and fold it along theinternal lines. This will give the trainees a better understanding of the
twisted ducting in this project.
Fig. M103.5.02 Development View
ST1 Sect 5
ST1 Sect 5
7/29/2019 Section 6 Materials Ordering & Handling SHO
20/30
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 5
ST1 Sect 4
7/29/2019 Section 6 Materials Ordering & Handling SHO
21/30
Lesson Plan 3Transportation methods and materials handling
in store and yardIntroduction
A typical shipyard includes wide-ranging material handling equipment totransport 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 fixedworkstations. 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
ST1 Sect 4
7/29/2019 Section 6 Materials Ordering & Handling SHO
22/30
Fig.M103.4.02 Belt Conveyor
Fig.M103.4.03 Screw Conveyor
ST1 Sect 4
ST1 Sect 4
7/29/2019 Section 6 Materials Ordering & Handling SHO
23/30
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
ST1 Sect 4
7/29/2019 Section 6 Materials Ordering & Handling SHO
24/30
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 skateis shown in Fig. M103.4.05.
Fig. M103.4.05 Skate
ST1 Sect 4
Cranes ST1 Sect 4
7/29/2019 Section 6 Materials Ordering & Handling SHO
25/30
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
ST1 Sect 4
7/29/2019 Section 6 Materials Ordering & Handling SHO
26/30
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
7/29/2019 Section 6 Materials Ordering & Handling SHO
27/30
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
7/29/2019 Section 6 Materials Ordering & Handling SHO
28/30
SLINGS
LIFTING STRAPS
CLAMPS
ST1 Sect 4
7/29/2019 Section 6 Materials Ordering & Handling SHO
29/30
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
7/29/2019 Section 6 Materials Ordering & Handling SHO
30/30
Materials Managment.ppt
http://localhost/var/www/apps/conversion/tmp/scratch_3/Materials%20Managment.ppthttp://localhost/var/www/apps/conversion/tmp/scratch_3/Materials%20Managment.pptRecommended