Section 6 Materials Ordering & Handling SHO

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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
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REMEMBER TO WRITE THE

IMPORTANTANT NOTES


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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


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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.

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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.

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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

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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.

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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.

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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

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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


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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?

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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?

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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?

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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?

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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?

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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.

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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

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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

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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

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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.

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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.

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Fig.M103.4.02 Belt Conveyor

Fig.M103.4.03 Screw Conveyor

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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.

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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

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Cranes ST1 Sect 4


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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.

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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

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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

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SLINGS

LIFTING STRAPS

CLAMPS

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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


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Section 6 Materials Ordering & Handling SHO

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