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"Just give us the plans and material on time and we can build ships as productively as anyone." So say traditional production bosses. Nothing could be further from the truth because a critical element is missing. Managers of the most productive shipyards have succeeded in getting their production people highly involved in design matters starting with development of contract plans. Thus, each of their design efforts begins and continues in the context of a premeditated building strategy for integrated hull construction, outfitting and painting. Design is truly an aspect planning. As compared to traditional shipyards, the organizations of people, information and work processes are different, interdependent and comprise constantly self-improving shipbuilding systems. Very much is dependent on continuous hiring of recent-graduate engineers who start in shops as process engineers and are systematically transferred to achieve both production and design experiences in hull construction, outfitting and painting. Members of this intelligent cadre are assigned successively as shop managers, senior production engineers and department managers while shifting between organizations responsible for different types of work. The integrated methods described herein were developed by Ishikawajima-Harima Heavy Industries (IHI) of Japan. An aspect that is particularly noteworthy is frequent reference to statistical control of manufacturing, i.e., accuracy control. As early as 1967, the Japanese Society of Naval Architects reported that accuracy control "epoch makingly" laid the foundation of modern ship construction methods.
Shipbuilders throughout the world have difficulty in retaining people experienced enough to create complex machinery arrangements and simultaneously incorporate building strategies for integrated hull construction, outfitting and painting into designs. In the Third World, cheap-labor shipbuilding industries are becoming more effective in high volume standardized production. This forces shipyards in expensive-labor countries to address flexible manufacturing and construction systems. Such systems feature product oriented work breakdowns and statistical control of production. The resulting methods, developed to build ships, are also applied for effective construction of diverse products such as chemical and waste-treatment plants in any quantity, particularly one of a kind. Thus, any tools which facilitate integration of design and production-engineering for a wide variety of end products are of great interest. Computer-aided design (CAD) has developed remarkably in recent years. The most advanced employ hidden-line and shading techniques so that a computer-generated three dimensional picture is presented as if it were of a physical model. Where CAD capabilities exist they have to some extent replaced need for physical models. However, there are inherent limitations. Complex three-dimensional arrangements cannot be readily perceived on a two-dimensional surface of a cathode-ray tube. Also, screen sizes limit teams of designer-planners from viewing and discussing all aspects of a complex arrangement simultaneously. For complicated arrangements, the need for physical models persists. The need is amplified by the revolution in shipbuilding methods which began in the U.S. shipbuilding industry in 1979. Simply described, the revolution features a shift in logic, i.e., from system to zone orientation for most design and production-engineering efforts.
Covering recent developments in maritime transportation and exploitation of sea resources, encompassing ocean and coastal areas, this book is intended for academics and professionals involved in the development of marine transportation and the exploitation of sea resources.
Shipbuilding is a multi-faceted industry, requiring the coordination of many activities and relying on ever evolving technology. Painting is an integral, and costly, part of operation. This paper describes the Zone Painting Method; a concept in ship construction which is based on the Product this new Work Breakdown Structure. The essence of the Zone Painting Method is proper planning and scheduling, in coordination with hull construction and outfitting. Design and planning structures, as related to zone painting, are presented. Departmental responsibilities for those segments of the shipyard organization which impact painting are detailed. The paper then proceeds to delineate the planning process according to the three phases of contract planning, system planning and zone planning. These phases examine the painting process in ever-increasing detail.