Modularization Analysis Presentation Revised.pdf

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Extended Modularization ofExtended Modularization ofExtended Modularization ofExtended Modularization ofExtended Modularization ofExtended Modularization ofExtended Modularization ofExtended Modularization of

Ship Design & Build StrategyShip Design & Build StrategyShip Design & Build StrategyShip Design & Build StrategyShip Design & Build StrategyShip Design & Build StrategyShip Design & Build StrategyShip Design & Build Strategy

The National Shipbuilding Research Program

Shipbuilding Opportunities in Short Sea Shipping WorkshopOctober 21-23, 2008

Charleston, SC

Laurent DeschampsLaurent DeschampsLaurent DeschampsLaurent DeschampsLaurent DeschampsLaurent DeschampsLaurent DeschampsLaurent Deschamps

President, SPAR Associates, Inc.President, SPAR Associates, Inc.President, SPAR Associates, Inc.President, SPAR Associates, Inc.President, SPAR Associates, Inc.President, SPAR Associates, Inc.President, SPAR Associates, Inc.President, SPAR Associates, Inc.

Annapolis, MarylandAnnapolis, MarylandAnnapolis, MarylandAnnapolis, MarylandAnnapolis, MarylandAnnapolis, MarylandAnnapolis, MarylandAnnapolis, Maryland


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NearNearNearNearNearNearNearNear--------inininininininin--------time procurement schedulingtime procurement schedulingtime procurement schedulingtime procurement schedulingtime procurement schedulingtime procurement schedulingtime procurement schedulingtime procurement scheduling

Improved vendor relations & pricing agreementsImproved vendor relations & pricing agreementsImproved vendor relations & pricing agreementsImproved vendor relations & pricing agreementsImproved vendor relations & pricing agreementsImproved vendor relations & pricing agreementsImproved vendor relations & pricing agreementsImproved vendor relations & pricing agreements

Material work order kittingMaterial work order kittingMaterial work order kittingMaterial work order kittingMaterial work order kittingMaterial work order kittingMaterial work order kittingMaterial work order kitting Standardized material parts & componentsStandardized material parts & componentsStandardized material parts & componentsStandardized material parts & componentsStandardized material parts & componentsStandardized material parts & componentsStandardized material parts & componentsStandardized material parts & components

Material buffer storage nearer to worksitesMaterial buffer storage nearer to worksitesMaterial buffer storage nearer to worksitesMaterial buffer storage nearer to worksitesMaterial buffer storage nearer to worksitesMaterial buffer storage nearer to worksitesMaterial buffer storage nearer to worksitesMaterial buffer storage nearer to worksites

Improved Procurement &Improved Procurement &Improved Procurement &Improved Procurement &Improved Procurement &Improved Procurement &Improved Procurement &Improved Procurement &Material ControlMaterial ControlMaterial ControlMaterial ControlMaterial ControlMaterial ControlMaterial ControlMaterial Control


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Integrated design & engineering systemsIntegrated design & engineering systemsIntegrated design & engineering systemsIntegrated design & engineering systemsIntegrated design & engineering systemsIntegrated design & engineering systemsIntegrated design & engineering systemsIntegrated design & engineering systems Standardized (repeatable) components &Standardized (repeatable) components &Standardized (repeatable) components &Standardized (repeatable) components &Standardized (repeatable) components &Standardized (repeatable) components &Standardized (repeatable) components &Standardized (repeatable) components &

interim productsinterim productsinterim productsinterim productsinterim productsinterim productsinterim productsinterim products

Simplified ship & ship systems designsSimplified ship & ship systems designsSimplified ship & ship systems designsSimplified ship & ship systems designsSimplified ship & ship systems designsSimplified ship & ship systems designsSimplified ship & ship systems designsSimplified ship & ship systems designs

Improved Ship Designs &Improved Ship Designs &Improved Ship Designs &Improved Ship Designs &Improved Ship Designs &Improved Ship Designs &Improved Ship Designs &Improved Ship Designs &EngineeringEngineeringEngineeringEngineeringEngineeringEngineeringEngineeringEngineering


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Modules can be developed in aModules can be developed in aModules can be developed in aModules can be developed in aModules can be developed in aModules can be developed in aModules can be developed in aModules can be developed in awide variety of ways:wide variety of ways:wide variety of ways:wide variety of ways:wide variety of ways:wide variety of ways:wide variety of ways:wide variety of ways:

Outfit and equipment modules,Outfit and equipment modules,Outfit and equipment modules,Outfit and equipment modules,Outfit and equipment modules,Outfit and equipment modules,Outfit and equipment modules,Outfit and equipment modules,

Hull assembly blocks,Hull assembly blocks,Hull assembly blocks,Hull assembly blocks,Hull assembly blocks,Hull assembly blocks,Hull assembly blocks,Hull assembly blocks,

Outfitted hull blocks, andOutfitted hull blocks, andOutfitted hull blocks, andOutfitted hull blocks, andOutfitted hull blocks, andOutfitted hull blocks, andOutfitted hull blocks, andOutfitted hull blocks, and Outfitted panel assembliesOutfitted panel assembliesOutfitted panel assembliesOutfitted panel assembliesOutfitted panel assembliesOutfitted panel assembliesOutfitted panel assembliesOutfitted panel assemblies


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Typical Hull Modular BlocksTypical Hull Modular Blocks


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Accommodation ModuleAccommodation Module

Turbocharger Lube Oil ModuleTurbocharger Lube Oil Module

Alfa Laval ModuleAlfa Laval Module Lube Oil w/Pumps ModuleLube Oil w/Pumps Module Westfalia Separator ModuleWestfalia Separator Module


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Hydrophore ModuleHydrophore ModuleSewage Treatment ModuleSewage Treatment Module

Refrigeration Compressor ModuleRefrigeration Compressor Module


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Expanded application of ship modulesExpanded application of ship modules

have been successfully developed byhave been successfully developed by

various European shipbuilders (forvarious European shipbuilders (for

example, Thyssen Nordseewerke, Scheldeexample, Thyssen Nordseewerke, Schelde

Naval Shipbuilding, Blohm & VossNaval Shipbuilding, Blohm & VossGmbh, Abeking & Rasmussen).Gmbh, Abeking & Rasmussen).


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Modules provide more flexibility for a standardModules provide more flexibility for a standardModules provide more flexibility for a standardModules provide more flexibility for a standardModules provide more flexibility for a standardModules provide more flexibility for a standardModules provide more flexibility for a standardModules provide more flexibility for a standard

ship platformship platformship platformship platformship platformship platformship platformship platform

Modules allow more focus of purpose forModules allow more focus of purpose forModules allow more focus of purpose forModules allow more focus of purpose forModules allow more focus of purpose forModules allow more focus of purpose forModules allow more focus of purpose forModules allow more focus of purpose forspecific operating requirementsspecific operating requirementsspecific operating requirementsspecific operating requirementsspecific operating requirementsspecific operating requirementsspecific operating requirementsspecific operating requirements

Modules may minimize need for incorporatingModules may minimize need for incorporatingModules may minimize need for incorporatingModules may minimize need for incorporatingModules may minimize need for incorporatingModules may minimize need for incorporatingModules may minimize need for incorporatingModules may minimize need for incorporating

unnecessary systems.unnecessary systems.unnecessary systems.unnecessary systems.unnecessary systems.unnecessary systems.unnecessary systems.unnecessary systems.

Ship Operations BenefitsShip Operations BenefitsShip Operations BenefitsShip Operations BenefitsShip Operations BenefitsShip Operations BenefitsShip Operations BenefitsShip Operations Benefits


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AircraftAircraftAircraftAircraftAircraftAircraftAircraftAircraftF4 began modularization; F35 extensive useF4 began modularization; F35 extensive useF4 began modularization; F35 extensive useF4 began modularization; F35 extensive useF4 began modularization; F35 extensive useF4 began modularization; F35 extensive useF4 began modularization; F35 extensive useF4 began modularization; F35 extensive use

of modulesof modulesof modulesof modulesof modulesof modulesof modulesof modules

CarsCarsCarsCarsCarsCarsCarsCarsparts and components, often interchangeableparts and components, often interchangeableparts and components, often interchangeableparts and components, often interchangeableparts and components, often interchangeableparts and components, often interchangeableparts and components, often interchangeableparts and components, often interchangeablebetween different modelsbetween different modelsbetween different modelsbetween different modelsbetween different modelsbetween different modelsbetween different modelsbetween different models

Home appliancesHome appliancesHome appliancesHome appliancesHome appliancesHome appliancesHome appliancesHome appliancesparts and componentsparts and componentsparts and componentsparts and componentsparts and componentsparts and componentsparts and componentsparts and components

Other industries have long exploitedOther industries have long exploitedOther industries have long exploitedOther industries have long exploitedOther industries have long exploitedOther industries have long exploitedOther industries have long exploitedOther industries have long exploitedthe benefits of modularthe benefits of modularthe benefits of modularthe benefits of modularthe benefits of modularthe benefits of modularthe benefits of modularthe benefits of modular

construction:construction:construction:construction:construction:construction:construction:construction:


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Requires better than normal engineeringRequires better than normal engineeringRequires better than normal engineeringRequires better than normal engineeringRequires better than normal engineeringRequires better than normal engineeringRequires better than normal engineeringRequires better than normal engineering

Requires better than normal quality assuranceRequires better than normal quality assuranceRequires better than normal quality assuranceRequires better than normal quality assuranceRequires better than normal quality assuranceRequires better than normal quality assuranceRequires better than normal quality assuranceRequires better than normal quality assurance

Requires higher level of design standards to minimizeRequires higher level of design standards to minimizeRequires higher level of design standards to minimizeRequires higher level of design standards to minimizeRequires higher level of design standards to minimizeRequires higher level of design standards to minimizeRequires higher level of design standards to minimizeRequires higher level of design standards to minimize

interferences and disconnects.interferences and disconnects.interferences and disconnects.interferences and disconnects.interferences and disconnects.interferences and disconnects.interferences and disconnects.interferences and disconnects.

There are precautions that mustThere are precautions that mustThere are precautions that mustThere are precautions that mustThere are precautions that mustThere are precautions that mustThere are precautions that mustThere are precautions that mustbe taken in order to minimizebe taken in order to minimizebe taken in order to minimizebe taken in order to minimizebe taken in order to minimizebe taken in order to minimizebe taken in order to minimizebe taken in order to minimize

failures in applying modularfailures in applying modularfailures in applying modularfailures in applying modularfailures in applying modularfailures in applying modularfailures in applying modularfailures in applying modular

construction techniques:construction techniques:construction techniques:construction techniques:construction techniques:construction techniques:construction techniques:construction techniques:


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The cost estimates were producedThe cost estimates were producedThe cost estimates were producedThe cost estimates were producedThe cost estimates were producedThe cost estimates were producedThe cost estimates were producedThe cost estimates were produced

for a notionalfor a notionalfor a notionalfor a notionalfor a notionalfor a notionalfor a notionalfor a notional

HST140HST140HST140HST140HST140HST140HST140HST140--------5353535353535353 TrailershipTrailershipTrailershipTrailershipTrailershipTrailershipTrailershipTrailership


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The CCDoTT HST140The CCDoTT HST140--5353 TrailershipTrailership


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Material & equipment prices are escalated/deMaterial & equipment prices are escalated/deMaterial & equipment prices are escalated/deMaterial & equipment prices are escalated/deMaterial & equipment prices are escalated/deMaterial & equipment prices are escalated/deMaterial & equipment prices are escalated/deMaterial & equipment prices are escalated/de--------escalatedescalatedescalatedescalatedescalatedescalatedescalatedescalated

by type commodity. Escalation factors (graphic below),by type commodity. Escalation factors (graphic below),by type commodity. Escalation factors (graphic below),by type commodity. Escalation factors (graphic below),by type commodity. Escalation factors (graphic below),by type commodity. Escalation factors (graphic below),by type commodity. Escalation factors (graphic below),by type commodity. Escalation factors (graphic below),both historical and predicted, are obtained from U.S.both historical and predicted, are obtained from U.S.both historical and predicted, are obtained from U.S.both historical and predicted, are obtained from U.S.both historical and predicted, are obtained from U.S.both historical and predicted, are obtained from U.S.both historical and predicted, are obtained from U.S.both historical and predicted, are obtained from U.S.

Government and industryGovernment and industryGovernment and industryGovernment and industryGovernment and industryGovernment and industryGovernment and industryGovernment and industry--------recognized commercial andrecognized commercial andrecognized commercial andrecognized commercial andrecognized commercial andrecognized commercial andrecognized commercial andrecognized commercial and

foreign sources.foreign sources.foreign sources.foreign sources.foreign sources.foreign sources.foreign sources.foreign sources.


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Margin, Bonds & Insurance1000

Shipyard Services900

Technical Support800

Armament700

Outfit & Furnishings600

Auxiliary Systems500

Electronics & Navigation400

Electrical300

Propulsion200

Structures100

SWBS

Jigs, Cradles, & Templates, Tools & Instruments

Miscellaneous Material & Support

Contract Detail Design Package (Optional)Contingency Labor:

Contract Engineering Management

ILS, Spares & Load Items

Purchase Specs & Support

Production Planning & Scheduling

Production Engineering & Construction Drawings

Functional Design

Preliminary Design

Basic Research - Concept Design

NonNonNonNonNonNonNonNon--------Recurring CostsRecurring CostsRecurring CostsRecurring CostsRecurring CostsRecurring CostsRecurring CostsRecurring Costs Recurring CostsRecurring CostsRecurring CostsRecurring CostsRecurring CostsRecurring CostsRecurring CostsRecurring Costs

The cost model generates costThe cost model generates costThe cost model generates costThe cost model generates costThe cost model generates costThe cost model generates costThe cost model generates costThe cost model generates cost

estimates at approximately SWBSestimates at approximately SWBSestimates at approximately SWBSestimates at approximately SWBSestimates at approximately SWBSestimates at approximately SWBSestimates at approximately SWBSestimates at approximately SWBSlevel 3 detail and summarizes them aslevel 3 detail and summarizes them aslevel 3 detail and summarizes them aslevel 3 detail and summarizes them aslevel 3 detail and summarizes them aslevel 3 detail and summarizes them aslevel 3 detail and summarizes them aslevel 3 detail and summarizes them as

follows:follows:follows:follows:follows:follows:follows:follows:


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The cost model also producesThe cost model also producesThe cost model also producesThe cost model also producesThe cost model also producesThe cost model also producesThe cost model also producesThe cost model also produces

estimated average costs forestimated average costs forestimated average costs forestimated average costs forestimated average costs forestimated average costs forestimated average costs forestimated average costs formultiple ship constructionmultiple ship constructionmultiple ship constructionmultiple ship constructionmultiple ship constructionmultiple ship constructionmultiple ship constructionmultiple ship construction

programs developed withprograms developed withprograms developed withprograms developed withprograms developed withprograms developed withprograms developed withprograms developed with

expected learning factors.expected learning factors.expected learning factors.expected learning factors.expected learning factors.expected learning factors.expected learning factors.expected learning factors.


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Cost risk of applied CERsCost risk of applied CERsCost risk of applied CERsCost risk of applied CERsCost risk of applied CERsCost risk of applied CERsCost risk of applied CERsCost risk of applied CERs

ShipbuilderShipbuilderShipbuilderShipbuilderShipbuilderShipbuilderShipbuilderShipbuilders experience risks experience risks experience risks experience risks experience risks experience risks experience risks experience risk

Engineering performance riskEngineering performance riskEngineering performance riskEngineering performance riskEngineering performance riskEngineering performance riskEngineering performance riskEngineering performance risk Cost risk due to compressed productionCost risk due to compressed productionCost risk due to compressed productionCost risk due to compressed productionCost risk due to compressed productionCost risk due to compressed productionCost risk due to compressed productionCost risk due to compressed production

scheduleschedulescheduleschedulescheduleschedulescheduleschedule

Cost risk of rework due to immature detailCost risk of rework due to immature detailCost risk of rework due to immature detailCost risk of rework due to immature detailCost risk of rework due to immature detailCost risk of rework due to immature detailCost risk of rework due to immature detailCost risk of rework due to immature detail

engineering when overlapping with productionengineering when overlapping with productionengineering when overlapping with productionengineering when overlapping with productionengineering when overlapping with productionengineering when overlapping with productionengineering when overlapping with productionengineering when overlapping with production

Cost RiskCost RiskCost RiskCost RiskCost RiskCost RiskCost RiskCost Risk::::::::The models develop cost risk withinThe models develop cost risk withinThe models develop cost risk withinThe models develop cost risk withinThe models develop cost risk withinThe models develop cost risk withinThe models develop cost risk withinThe models develop cost risk within

several focus areasseveral focus areasseveral focus areasseveral focus areasseveral focus areasseveral focus areasseveral focus areasseveral focus areas


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Modular construction promotes costModular construction promotes costand schedule benefits from early stageand schedule benefits from early stage

construction.construction.

There are a number of rules of thumbThere are a number of rules of thumb

that have been applied to estimate thethat have been applied to estimate the

savings. Labor costs on board can besavings. Labor costs on board can be

33--5 times and higher than equivalent5 times and higher than equivalentwork done in the shop or on the platen.work done in the shop or on the platen.


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As modules become more and more standardized,As modules become more and more standardized,As modules become more and more standardized,As modules become more and more standardized,As modules become more and more standardized,As modules become more and more standardized,As modules become more and more standardized,As modules become more and more standardized,

still more cost and schedule benefits can bestill more cost and schedule benefits can bestill more cost and schedule benefits can bestill more cost and schedule benefits can bestill more cost and schedule benefits can bestill more cost and schedule benefits can bestill more cost and schedule benefits can bestill more cost and schedule benefits can begarnered as efficiency increases from repetitivegarnered as efficiency increases from repetitivegarnered as efficiency increases from repetitivegarnered as efficiency increases from repetitivegarnered as efficiency increases from repetitivegarnered as efficiency increases from repetitivegarnered as efficiency increases from repetitivegarnered as efficiency increases from repetitive

manufacturing.manufacturing.manufacturing.manufacturing.manufacturing.manufacturing.manufacturing.manufacturing.

Use of standard modules also can reduce the costUse of standard modules also can reduce the costUse of standard modules also can reduce the costUse of standard modules also can reduce the costUse of standard modules also can reduce the costUse of standard modules also can reduce the costUse of standard modules also can reduce the costUse of standard modules also can reduce the cost

and schedule of nonand schedule of nonand schedule of nonand schedule of nonand schedule of nonand schedule of nonand schedule of nonand schedule of non--------recurring ship design andrecurring ship design andrecurring ship design andrecurring ship design andrecurring ship design andrecurring ship design andrecurring ship design andrecurring ship design and

engineering.engineering.engineering.engineering.engineering.engineering.engineering.engineering.


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% Total Onboard On Block On Unit

Work Type Modularized Factor Factor Factor

Piping - OMS 85.00% 1.000 0.530 0.280

HVAC - Rectangual Duct 85.00% 1.000 0.800 0.400

HVAC - Spiral Duct 85.00% 1.000 0.650 0.325HVAC - Fans 85.00% 1.000 0.650 0.325

HVAC - Air Handlers 85.00% 1.000 0.800 0.400

HVAC - Spools 85.00% 1.000 0.650 0.325

HVAC - Fire Dampers 85.00% 1.000 0.750 0.375

Electric Cable (Local) 85.00% 1.000 0.500 0.200

Auxiliaries - IMS 85.00% 1.000 0.650 0.325

Piping - IMS 85.00% 1.000 0.800 0.400

Cable Trays - IMS 85.00% 1.000 0.800 0.400

Staging - IMS 85.00% 1.000 0.800 0.400

Exhaust Casing - IMS 95.00% 1.000 0.500 0.500Casing Vent Trunk 95.00% 1.000 0.500 0.500

Foundations 100.00% 1.000 0.830 0.390

Seats - IMS 100.00% 1.000 0.750 0.375

Paint - Excluding Block Paint 85.00% 1.000 0.690 0.170

Paint - Block Paint 40.00% 1.000 0.800

Paint - Unit Paint 20.00% 1.000 0.500

Propulsion Machinery 90.0% 1.000 0.700

Outfit Machinery 90.0% 1.000 0.500 0.250

Electronics 85.00% 1.000 0.300

Outfit Equipment 85.00% 0.300

Armament 85.00% 0.300

Structures 85.00% variable variable

Cable, Machinery Spaces 80.00% 0.50

Cable, Accommodations Spaces 80.00% 0.50

Cable, Superstructure 80.00% 0.50

Cable, Exterior Decks 50.00% 0.85

% Total Modularization =% Total Modularization =% Total Modularization =% Total Modularization = Estimated Maximum Percentage of Work that can be Modularizedbeyond conventional methods.

Onboard Factor =Onboard Factor =Onboard Factor =Onboard Factor = Maximum Labor Cost at Onboard Stage of Construction

On Block Factor =On Block Factor =On Block Factor =On Block Factor = Percentage Labor Cost for On-Block Work Relative to Onboard Cost

On Unit Factor =On Unit Factor =On Unit Factor =On Unit Factor = Percentage Labor Cost for On-Unit Work Relative to Onboard Cost


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Estimated Reduced Labor Hours from Extended Modularization

98.0%

73.0%

47.7%

40.5%44.6%

56.9%

0.0%

71.4%

66.9%

77.2%

0%

20%

40%

60%

80%

100%

120%

100 200 300 400 500 600 700 800 900 1000 TOTAL

SWBS Group

PercentageofCo

nventionalLaborH

ours

(IncludesMo

duleManufacture)


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Estimated Reduced Labor Hours from Extended Modularization

2.0%

27.0%

52.3%

59.5%

55.4%

43.1%

0.0%

28.6%

33.1%

22.8%

0%

10%

20%

30%

40%

50%

60%

70%

100 200 300 400 500 600 700 800 900 1000 TOTAL

SWBS Group

P

ercentSavingsofC

onventionalLaborHours

(IncludesMo

duleManufacture)


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Breakdown of Modular Labor versus Remaining Production Work(Conventional Hull Block Construction Labor Included as "Other")

1.3%

63.0

%

33.1

%

25.5

%

29.6

%

20.5

%

0.0%

0.0% 10

.0%

96.7

%

10.0

%

14.6

%

15.0

%15.0

%

36.4

%

71.4

%

66.9

%67.2

%

0%

20%

40%

60%

80%

100%

120%

100 200 300 400 500 600 700 800 900 1000 TOTAL

Labor

Cost

SWBS Group

PercentageofConventionalLabo

rCost

Other Production

Modular Production


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Reduced Labor Cost Risk

33.1% 34.2%

58.7%

41.1%

74.0%

45.6%

0%

10%

20%

30%

40%

50%

60%

70%

80%

Co

nstru

ctio

nCo

stEstim

ateRi

sk:

Prod

uctio

n/Eng

inee

ringOv

erla

pRew

orkRi

sk:

Ship

yard

Exp

erienc

eRisk:

E

ngin

eerin

gPe

rform

ance

Risk:

P

rodu

ctio

nSche

dule

CostR

isk:

TotalE

stim

ated

CostR

isk:

Type Labor Cost Risk

P

ercentSavingsove

rLaborCostRisk

ofConventionalBuild


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Extending ship design and buildExtending ship design and buildExtending ship design and buildExtending ship design and buildExtending ship design and buildExtending ship design and buildExtending ship design and buildExtending ship design and build

strategies that advance the use ofstrategies that advance the use ofstrategies that advance the use ofstrategies that advance the use ofstrategies that advance the use ofstrategies that advance the use ofstrategies that advance the use ofstrategies that advance the use of

standard modules can reducestandard modules can reducestandard modules can reducestandard modules can reducestandard modules can reducestandard modules can reducestandard modules can reducestandard modules can reducedesign and construction costs,design and construction costs,design and construction costs,design and construction costs,design and construction costs,design and construction costs,design and construction costs,design and construction costs,

shorten delivery times, and benefitshorten delivery times, and benefitshorten delivery times, and benefitshorten delivery times, and benefitshorten delivery times, and benefitshorten delivery times, and benefitshorten delivery times, and benefitshorten delivery times, and benefitship operators with lowership operators with lowership operators with lowership operators with lowership operators with lowership operators with lowership operators with lowership operators with lower

maintenance and overhaul costs.maintenance and overhaul costs.maintenance and overhaul costs.maintenance and overhaul costs.maintenance and overhaul costs.maintenance and overhaul costs.maintenance and overhaul costs.maintenance and overhaul costs.


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35 Years Serving the Shipbuilding &35 Years Serving the Shipbuilding &Repair IndustryRepair Industry

PH 410.263.8593 FX 410.267.0503PH 410.263.8593 FX 410.267.0503

URL:URL: www.sparusa.comwww.sparusa.com Email:Email: [email protected]@sparusa.com

Modularization Analysis Presentation Revised.pdf

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