MUHAMAD IKHWAN AZIZIE

CONTENT

NO TITLE PAGE(S)

1. Introduction 1

2. Topic 1: Modular Construction Process 2

Why Implement Modular Construction

How To Implement Modular Construction

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3. Topic 2: Lean Shipbuilding Process 8

Why Implement Lean Shipbuilding Process

How To Implement Lean Shipbuilding Process

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4. Conclusion 12

MUHAMAD IKHWAN AZIZIE

INTRODUCTION

Shipbuilding is the construction of ships. It normally takes place in a specialized facility

known as a shipyard. Shipbuilders, also called shipwrights, follow a specialized occupation that

traces its roots to before recorded history. Shipbuilding and ship repairs, both commercial and

military, are referred to as the naval engineer. The construction of boats is a similar activity

called boat building. The dismantling of ships is called ship breaking.

Nowadays, there are many process created by shipbuilders in order to save cost and

money. In this assignment, the modular construction and lean shipbuilding process had been

chosen to be our topic. Below, the topic was explained in details in what, why and how the

shipbuilding process implemented in order to save both cost and time consumption.

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TOPIC 1: Modular Construction Process

The reason why modular construction process become popular in ship building industry

is because there is no other method available that allows you to start and finish a project in a

more-timely manner than modular.

Modular construction process is one of the popular method uses in shipbuilding

industry. Modular construction, or prefabricated construction, is a process that uses a

prefabricated building process that is assembled on-site to produce a permanent or temporary

prefab building.

Mod Space takes full advantage of a controlled production environment combined with

the design flexibility of traditional building methods to produce high-quality permanent or

temporary prefabricated structures for any demand. The result is a prefabricated modular

building product that is faster, more affordable and environmentally-friendly, with the all the

same architectural aesthetics you would expect from traditional building methods.

Picture 1 and 2: Pictures of modular construction in progress of a naval ship

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WHY IMPLEMENT MODULAR CONSTRUCTION

Traditional construction versus modular construction time

Advantages of modular construction process are:

Short build times

Typically 50-60% less than traditional on-site

Construction, leading to an earlier return on

Investment and saving in preliminaries.

Low weight

Compared to site construction, modular

construction is about 30% of the weight of

Conventional masonry construction.

Superior quality

Achieved by factory-based quality control and

Pre-design of similar modules.

Economy of scale

Repetition of prefabricated units leads to

considerable economy of scale in production.

Environmentally less sensitive

Efficient factory production techniques are

Much less wasteful and installation is less

disruptive on site.

Reduced site labor requirement

The erection and finishing teams, which

install and complete modular buildings,

Involve fewer workers on site than traditional

buildings.

Safer construction

Modular construction sites have proved to be

significantly safer than traditional on-site

Building.

Services and bathrooms

Service modules can be used, even in

traditional formed buildings.

Reduced professional fees

Standardized design details for modular

Buildings simplify and reduce the need for specialist design input.

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Less than 5% of the markets previously defined as conventional currently utilize modular

construction concepts. Given these numerous advantages, it’s only a matter of time before

modular becomes the convention method.

Ship divided into segment

HOW TO IMPLEMENT MODULAR CONSTRUCTION

MODULAR CONSTRUCTION PROCESS

In sequence:

1. Stockyard

Plates and sections were stored in the shipyard stockyard, ideally undercover.

2. Preparation

To prepare plates and section before being weld, cut, mark and other.

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3. Sub assembly

Sub assemblies include fitting, welding, fairing and many other sub assembly process

4. Assembly

This shop takes the products from the panel fabrication area and assembles them to

favricate the unit.

5. Fabrication

Including marking, cutting, bending

This shop is designed to fabricate the parts from the parts making area. These includes:

Deep transverse frames

Watertight bulkheads

Longitudinal bulkheads

Shellpanels

Longitudinal double bottom panels

Transverse double bottom panels

Major and minor foundations.

6. Erection Berth (Modular Sectional Area)

This shop takes units from the unit’s assembly area to fabricate into modules

7. Basin/Afloat

By launching ship on a slipway to ensure ship able to float correctly.

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TOPIC 2: LEAN SHIPBUILDING PROCESS

Definition of lean shipbuilding process is a strategy for achieving significant continuous

improvement in performance through the elimination of all waste of resources and time in the

total shipbuilding process.

Lean Shipbuilding Concept

A concept between lean manufacturing and lean construction

A completely new production concept

Inspired by a number of sources: Shingo, Toyota, Goldratt, Womack, and IGLC.

In addition, lean shipbuilding derived from the concept of lean production is lean

production theory in ship Industry, first proposed by the U.S. shipbuilding industry, shipbuilding

contract, that contract from the beginning to the delivery of the ship completed the

construction of the entire process, through motivation and mobilization of all employees to

continuously improve and perfect the process of shipbuilding, ship construction to reduce all

the waste, to reduce the shipbuilding cycle, reduce shipbuilding costs and improve shipbuilding

quality.

Value Adding Activity - An activity that transform shapes or converts raw material to meet

customer requirements.

Non-Value Adding (Waste) - Those activities that take time, resources, or space, but do not add

value.

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WHY IMPLEMENT LEAN SHIPBUILDING PROCESS

There are many reasons why shipbuilding process lean was implemented in shipbuilding

industry. Some of the factors included below:

1. Faced with an environment characterized by low build rates.

2. Rising costs for such things as materials and workers’ medical care.

3. Rising cost of building and repairing ships

There are 7 Non-Value Adding that have been recognized which slow the process in

shipbuilding industry and which leads to rising in terms of cost and time consumption. It

includes:

Overproduction Producing faster than the rate of consumption and make more product

more than the materials needed for the shipbuilding.

Inventory Unnecessary materials, cause the inventory in storage is to be full.

Motion When workers are not efficient because have to walk or moving in order

to do their jobs. For example, workers have to walk to get a tool or piece

of material.

Waiting Workers being idle between operations, waiting for a machine to cycle or

waiting for the preceding operator to finish their work.

Over Processing Having to perform more operations than are

Necessary. Example, painting prior to welding.

Correction Scrap, rework, sort, & repair add unnecessary costs.

Conveyance Unnecessary transportation can also increase money consumption.

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HOW TO IMPLEMENT LEAN SHIPBUILDING PROCESS

LEAN VS TRADITIONAL SHIPBUILDING

PPM: Production Preparation Process The above diagram shows how different traditional shipbuilding and lean shipbuilding process.

In the research made by Toyota, it majorly affects those 5 fields which are quality, productivity,

maintenance, employees and simplicity.

Lean shipbuilding process can be implemented in methods by:

Producing a return on investment by reducing waste and improving quality in

several processes on and above the shop floor.

Cutting costs and/or cycle times as much as 40 percent in some shops.

In all cases, implementing lean processes has mitigated a trend of growing ship

construction and repair costs that is driven by external factors.

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There are 3 principles of lean

One-Piece Flow

AKT Time

Pull Systems In this technical report, we emphasis on push and pull system.

Production Schedules (Push) Pull Systems (KanBan)

Issue production schedules to all of the processes,

Using the parts from one process to drive the work at the next process.

Stagger schedules so that parts are ready ahead of need.

Let an operation or process “withdraw” parts from a preceding process - Pull the parts through.

Preceding Process replenishes.

Keep Direct Labor busy at all costs. Eliminate Delays and Waste in the Product Flow

Improve the Flow of Purchased Materials

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CONCLUSION From what we had learned from both of the topics, which is modular construction process and lean shipbuilding process, it is obvious that both process are new in the world of shipbuilding and is gaining popularity in shipbuilding construction.

The benefits of modular constructions have demonstrated it abilities to be cost effective against traditional method, and has led to financial savings and reduced disruption on site. While the benefit of lean shipbuilding process shows us that it could help to reduce the time usage to built ship, rather than using traditional ways of constructing ship and thus, eliminate unnecessary waste of time and money.

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