Technical and Economical Analysis of Shipyard Re-Layout for Product-Oriented Work Breakdown Structure Implementation

Abstract

The ship building method used by many shipyards in the world has led to work effectiveness and efficiency. One of them is Product-Oriented Work Breakdown Structure Concept (PWBS). PWBS belongs in group technology. In this method the parts that will be produced for ship building are categorized based on the similarity in form and production process. In Indonesia, not many shipyards have implemented this method. If a shipyard will change its production method, layout adjustments will be required. This research was conducted to analyze the technical and economic changes in the layout of the PT X with study in the case of 2 × 1800 HP tugboat. The technical analysis is done by observing the conditions of the production process and the existential shipyard layout. Furthermore, it also analyzes the investment costs to make changes of the shipyard’s layout and analyzes the feasibility value of the investment. Fabrication parts of tugboat are grouped into 4 categories, those are category A: internal parts from plate or part piece of plate, B: parallel parts, C: curved parts (bent plates) and D: shapes (miscellaneous operation). The new layout can reduce the distance of material handling in category A by 2-19%, category B by 29%, category C by 57% and category D by 2-56%. Fabrication costs are estimated to be reduced to IDR 36,152,935 and sub assembly cost reduced to IDR 27,178,200 by applying this group technology concept. Investment costs to make changes the layout is IDR 7,471,954,000. This project is worth to do with 11% IRR value and payback period will occur in the 3rd year.