NEWFOUNDLAND MEETING: Design for Production
Course Outcome Summary
Project Type / NSRP - Advanced Ed Module
Organization / University of South Alabama and the University of Wisconsin - Marinette
Development Date / 10/8/2008
Revised By / Kim Vosicky - WIDS
Revised Date / 10/20/2008
Revision History / Met with Bollinger SMEs to examine competency prompts developed at 8/08 NSRP Quarterly Meeting in Marinette. Input minimal - will wait to see what comes out of Newfoundland meeting on 10/7-8/08; Bollinger's version of this course was used to prompt discussions with Marinette Marine on 10/1/08; Kim Vosicky - WIDS Learning Design Consultant with SMEs who attended the DFP meeting in Newfoundland including: Drew Hains - Murray; Leonard Pecore - Genoa Designs; Tom Neyhart - Northrup Grumman; Vickie - Bollinger; Bruce Whitelaw - Marine Institute, Newfoundland
Competencies
Unit A. / Introduction to Design for Production/Manufacturing (Prerequisite unit to all advanced disciplines)
Explore the purpose of design for production (DFP) in shipbuilding industry
Learning Objectives
a.Relate how design is used to consider production cost reduction while still designing compatible with the requirements of the vessel to fulfill its operational functions with acceptable safety, reliability and efficiency
b.Determine how DFP helps to reduce overall costs
c.Reduce production lead times
d.Reduce production cycle times
e.Establish a consistent approach to shipbuilding, based on the assembly method of production
f.Define the maximum amount of work at the detailed definition stage
g.Control production through the effective control of material and engineering information
h.Ensure that, while there is a rigid approach to maintaining schedule adequate flexibility within the overall strategy to achieve this objective
i.Change attitudes through appropriate training methods so that the necessity for change and the importance of team discipline
j.First is to design out work, that is to reduce the amount of work which has to be performed
k.Then make the work that remains easier to perform. This is achieved by making things simpler to produce and easier to install in a comfortable, safe position
l.Reducing production cycle time overlapping the steel and outfit work cycles
m.Reducing the steel work content at berth/dock assembly
n.reducing the outfit installation work content after berth/dock assembly
o.Designer’s duty quote from the Appledore DFP papers (Looked for it, but could’ find it yet. Will see if I (VD) can come up with it)
p.Explore the history of designing for production
q.Examine various design phases
r.Determine why decisions are made at various phases of design
Design for Facility, Workstation, and Equipment Capabilities
Learning Objectives
a.Determine what types of facility considerations affect a ship's dimensions
b.Examine how facility capabilities impact block size, panel line capacity, shop sizes, door sizes, erection site, structure, plate cutting, welding, break, burning, lifting capabilities (outside or shop cranes), transportation (Transporters, dollies) and turning
c.Distinguish among types of facility constraints
d.Compare workstation considerations such as physical size limits, lift capacity, workstation flow sequence, and build strategy related to workstation sequence
e.Relate equipment considerations to the design for production process
Explore the importance of minimizing part production
Learning Objectives
a.Discuss the benefits of a more simplified overall ship design Helps simplify business processes Understand tradeoffs
b.Examine the purpose behind increase welding vs. outfitting & assembly
c.Examine cost considerations ost of labor vs. cost per ton steel
d.Determine the importance of standard parts, assemblies such as mirror burns, and the use of a common parts catalogue are part of DFP considerations
e.Minimize the use of fitting for pipe bends
f.Relate at auto nesting as a consideration for minimizing part production
g.Examine how costs add up regardless the size of a part
h.Determine how standardized parts lead to standardized sub-assemblies and processes
Consider how standardized material types or grades impact design for production
Learning Objectives
a.Explore common size of pipe, steel, electrical, HVAC
b.Recognize how different materials can cause more complex assembly process and equipment needs
c.Discuss the importance of minimizing material handling, warehousing, process flows
d.Recognize the need tradeoffs for cost of materials, cost of material handling, cost of assembly, maintenance, other customer needs, Metric vs. imperial
e.Identify different material types, faying surfaces, specific design needs, production needs; e.g. metallic strip
f.Identify standard interfaces
Determine how to minimize lifting and handling of parts
Learning Objectives
a.Determine how minimizing the lifting and handling of parts correlates with nesting of parts and material handling
b.Examine the importance of strengthening assemblies during lifts
c.Explore the safety needs for both lifting and handling of parts way to create a M&S examp
d.Identify how an increase of lifting needs to allow for additional down-hand welding
e.Relate the handling of parts to work packages
f.Distinguish among Just in Time production by unit, panel, assembly, workstation
Explore how welding minimizes....
Learning Objectives
a.Identify the type and purpose of various welds
b.Discuss the need for minimal welds
c.Discuss why the need to minimize out of position welding and number of weld sequencing
d.Contrast how an increase in automatic and robotic welding might optimize ..
e.Compare intermediate vs. continuous welding
f.Identify the need for weld clearances
g.Look at different types of weld prep
h.Identify weld information standards
i.
j.
Explore how layout and measuring impact DFP
Learning Objectives
a.Discuss how to minimize measuring in shops
b.....master control lines
c.Identify the different types of measurements
d.Relate how accuracy impacts production costs
e.Identify the use of NC marking
f.Relate company standards to....
g.Examine an example weld shrinkage
h.Minimize pipe spool complexity (easier to check accuracy of spools)
Identify how to minimize fabrication or assembly complexity
Learning Objectives
a.Identify parameters of block breaks (Optimize for steel vs. outfitting and Size of blocks vs. outfitting)
b.Minimize different plate thickness minimizes plate chamfer requirements
c.Minimize complex shapes
d.Minimize pipe bends
e.Minimize number of bends and fittings
f.Recognize how installing pipes in double bottoms minimizes assembly complexity
g.Identify standard production information
h.Use standard drawing layouts
i.Prepare to design to available requirements/ details
j.Examine keel cooler example
Determine how to prepare for optimal outfitting and assembly
Learning Objectives
a.Examine why we perform work at earliest stage as possible
b.Explore how the design is based on current available information
c.Identify the importance of outfitting
d.Identify how to maximize pre-outfitting as early in build process as possible
e.Discuss why to perform hot work as early as possible
f.Develop right-of-way drawings
g.Explain the importance of coordination between different outfitting groups
h.Identify how to access holes for assembly
i.Identify assembly clearances
j.Examine common pipe supports
k.Distinguish among machinery and pipe subassemblies
l.Explore the outfit zone breakdowns
Apply Shipyard Standards (THIS IS COVERED IN THE INTRO COURSE. IS IT NECESSARY HERE? IF SO, I'LL DEVELOP FURTHER USING DFP MEETING MATERIALS)
Simplify engineering and design process (CAN WE FOLD THIS INTO ANOTHER COMPETENCY? IF NOT, I'LL EXPAND ON THIS USING DOCS FROM DFP MEETING MATERIALS)
Learning Objectives
a.Drive design towards use of preferred parts/ common parts
b.The engineering design development process established for a reason
c.Provide proper information
d.Minimizes mistakes and rework
e.Product models typically have standard ways of designs that will help maximize capabilities of the software
Prepare for inspection and testing
Learning Objectives
a.Provide proper clearances for inspection, test and quality control
b.Set dimensions for ease of layout
c.Explore ways to assure for accuracy
d.Contrast the use of metric vs. imperial
e.Allow for earliest testing possible in production e.g. tank testing
f.Recognize the limits for oil and water stops
g.Identify take-down joints
h.Identify accessibility areas