Lecture 3-1: Hull production - Product hierarchy and block division

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1 Kul Shipyard engineering Lecture 3-1: Hull production - Product hierarchy and block division Applied Mechanics Marine Technology

2 Lecture in course contents Production planning Introduction Shipbuilding process and ship yard productivity Outfitting Design process and materials management Hull production

3 Objectives, contents and literature Learning objective: You understand the hull product hierarchy and the main aspects which affect it You are able to form a ship s block division and understand the main factors affecting it Contents: Hull product hierarchy Advantages of block construction method Block division Examples Literature Laivatekniikka. Räisänen toim., 2000 Ship production, Storch et al., SNAME, 1995

4 Background Ship hull is built in blocks, but why?

5 Definition of a block Block is defined as a part of the hull or superstructure, which is jointed to other similar parts in the building dock Block is composed of sub-blocks sub-assemblies or parts

6 Product hierarchy Ref: Ship production, Storch et al., SNAME, 1995

7 Stages of hull production Hull erection Block assembly Sub-block assembly Part assembly Part fabrication Block 101 Hull Block 102 Block 103 Block 104 Block 105 Sub-block 103A Sub-block 103B Sub-block 103C Web frame KA. 321 Bulkhead KA. 123 Plates Frames Beams Web plate Flange Stiffener Standard parts Block 106 Work flow

8 Part fabrication

9 Part assembly

10 Sub-block assembly

11 Block assembly

12 Block assembly

13 Block assembly

14 Block assembly

15 Block assembly

16 Block assembly

17 Advantages of block construction method Productivity Automation (welding, production lines) Ability to turn the blocks Specialization (e.g. painting hall ) Ability to outfit (block openness) Short transporting distances Good working environment (working inside: lighting, temperature, noise, air quality) Environmental issues (paint, shielding gases) Delivery time, invested capital Shorter lead-time of steel (Shorter hull erection time, numerous blocks are worked in parallel) Fewer launching platforms, but more block assembly areas Outfitting overlaps with steel production, and thus the ship lead-time is shorter

18 Block size Extreme cases: The hull is assembled on a building dock from individual parts, which are produced by part manufacturing The ship is lifted into the water as one block In practice, when new shipyard is designed, the solution is somewhere between these two!

19 Block division Affecting factors?

20 Block division Criteria when shipyard is known: Weight restrictions (lifting, transporting, turning, center of gravity) Scantling restrictions (length, width, height) Plate length (production line, delivery of material) Hull construction Production suitability (location and length of weld seam) Strength of block (transportation, lifting)

21 Block division Assembly suitability Location of weld seam in sub-block Existence of reference plane Utilization of shipyard equipment Productivity Number of similar blocks Weight of outfitting

22 Influence of block division on outfitting Well designed block division is essential for succeeding in block outfitting The location of equipment with respect to block boundaries Hauling of equipment into the block Hauling of equipment in the hull erection stage, before the lifting of the next covering block Hauling possibilities within the hull Late lifting of expensive equipment Timing of materials Painting (e.g. tanks should be intact within block) Building method Drawing method Timing of drawings

23 Examples

24 Examples

25 Examples

26 Examples

27 Examples

28 Example assignment Divide the cruise ship cross-section into blocks, taking into account block s Weight (< 300 ton) Size (h<10m, b<20m) Suitability for production and assembly Productivity

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