Shipyard Management Research Articles

Multi-objective green vehicle scheduling problem considering time window and emission factors in ship block transportation

Logistics distribution is one of the main sources of carbon dioxide emissions at present, and there are also such distribution problems in the shipbuilding process. With the increasing attention paid to environmental problems, how to effectively reduce the energy consumption of block transportation and improve the utilization rate of resources in the factory is the key problem that China’s shipbuilding industry needs to solve at present. This article considers the time windows for block transportation tasks, as well as the self-loading constraints of different types of flat cars, and establishes an optimization model that minimizes the empty transport time and energy consumption of the flat cars as the optimization objective. Then, an Improved Genetic Whale Optimization Algorithm is designed, which combines the cross and mutation ideas of genetic algorithms and proposes a whale individual position updating mechanism under a mixed strategy. Furthermore, the performance and computational efficiency of the algorithm are verified through comparative analysis with other classical optimization algorithms on standard test examples. Finally, the shipyard’s block transportation example proves that the energy-saving ship block transportation scheduling method can effectively improve the efficiency of shipbuilding enterprise’s block transportation and reduce the energy consumption in the block transportation process. It proves the engineering practicality of the green dispatching method proposed in this paper, which can further provide a decision-making method for shipyard managers.

Using interpretive structural modelling and quality cost model to solve project completion delay in shipyard case study in PT X

Purpose – This research proposes an alternative method to solve completion delay issue and optimized the strategy using ISM technical method and Quality Cost Model application. Design/methodology/approach – Data was acquired from 120 questions from company key persons that involved in project for last 5 years. The instruments processed using ISM analysis to measure the relationship among causes, then using Quality Cost Model to solve. Findings – This research shows that factors of late payment from client, delays in bank credit processing, bad weather, and design changes by owners are the root causes of delays. Further analysis using the Theory of Constraint (TOC) shows that financial constraint issues influence the decreased throughput and increase operating cost. Further management use five sequential steps to improve the management and P-A-F models as one of strategic cost management tools applied to the root causes to determine the optimum cost strategy to solve the problem. Research limitations/implications – This research was conducted using a case study method, and the conclusion related to problem and root cause may not be applied totally to other companies, but the framework may be applicable. Future research can investigate other issue using TOC framework, combine TOC with other models to conduct root cause analysis, and the COQ model implementation in shipyard management. Practical implications – This research demonstrates that management can use Interpretative Structural Modelling (ISM) analysis to determine the root cause, then analyse and overcome the issues using TOC framework. COQ model approach to sharpening the decision, and prioritize the resources allocation. Originality/value – This research combine ISM, TOC, and PAF Quality Cost Model approach for decision making which can be a management tool in strategic cost management.

Towards Digital Twinning of Fabrication Lines in Shipyards

The digital twinning concept stands as a remarkable opportunity to integrate sophisticated mathematical models within the context of existing manufacturing systems. Such models may provide shipyard management with predictive analytics, improving the final results at the strategic, tactical, and operational levels. Therefore, the possibility of integrating the Markovian-framework-based finite-state method into the context of ship production is presented in this study, including its outline, digital thread, and factory-floor data reliance. First, the predictive analytics problem is addressed by the finite-state method in the case of the shipyard’s fabrication line, and the obtained results are validated afterward using a numerical model through discrete-event theory. The predictive analytics indicate an almost ideal balancing of the fabrication line, except for the buffers storing stiffeners before the coat-dying and marking operations. In addition, the improvability analysis of the shipyard’s fabrication lines extended the scope of the predictive analytics using bottleneck identification and affecting the key performance indicators through a digital thread, as well as by improved maintenance strategies.

SWOT-AHP HYBRID METHOD FOR RANKING THE STRATEGIES IN THE SHIPBUILDING SECTOR

The paper outlines the most important shipbuilding strategies in Romania that would allow this industry to increase its performance to be competitive. The research is mainly based on the collection of information from experts in the field from ANCONAV (Romanian Shipbuilders Association), specialists in design and production, and shipyard managers in Romania. The SWOT analysis was based on this information and was the starting point in formulating the strategies. The quantitative determination of the importance of each factor and sub-factor from the SWOT matrix in view of ranking the strategies, but also the verification of the points of view of the experts in the field were performed using the Analytical Hierarchy Process Method (AHP), using Excel applications. The obtained results consisted in identifying the internal and external environmental factors and formulating the main strategies with positive effects on the Romanian naval sector (the development of a Romanian cluster, the consolidation of the position on the global ship market through aggressive marketing, investments regarding the construction of ecological ships, the development of centers of excellence for exploiting the research-development-innovation capacity, the limitation of highly-skilled labor migration, expanding the digitalization, and developing a marketing policy to promote the national shipbuilding companies globally).

THE PROSPECTIVE POSTURE OF MARITIME EDUCATION IN SUPPORT OF SMART SHIPPING

"Maritime education covers the main seafarer’s education, but after emerging of a new profession in the maritime sector it has started to cover some other aspects of the industry such as port management, fleet management, shipyard management, etc. Additionally, the exponential development of technology enforced education planners to review and revise their programs frequently to meet the expectation of new technological and management structures. Realizing this situation, academicians in the maritime field should understand the new posture of the maritime industry and define their role and missions in the light of the new requirements of the maritime sector. This research aims to investigate the new role and the missions of maritime education institutes considering developments in science and technology in the next decade. In the first step, it is important to understand technological development affecting the maritime sector and imagine the future structure and requirements of the sector. Based on the results of this study a comprehensive study must be done to define what must be done in the education system to respond to new requirements. This research must be exhaustive and detailed. The problem areas are clearly defined and summarized as findings at the end of this step. These requirements must be adopted with academic programs. Adaptation of these corrective proposals to existing academic programs should be discussed considering how these new proposals are associated with the existing programs and/or matched with other related programs This study will assist the academicians and researchers who work on the development of the maritime education and training system using the results of this study. "

ANCHOR WINDLASSES: A DESIGN PROPOSAL TO STANDARDISE REGULATIONS

Shipbuilding is an increasingly competitive field. As the key players in this activity, shipyard managers have to make their counterparts in related industries aware of two conflicting needs. On the one hand, they must produce high quality components that are technologically advanced. On the other, they need equipment that lets them build vessels at a reasonable price. With this second aim in mind, it would be useful to standardise both design and manufacturing processes. At the same time, ship owners always impose regulations. The manufacturers of deck equipment must therefore adapt their product designs to comply with these regulations, some of which have aspects in common. However, guidelines also differ on many points. This makes it difficult to reach desirable levels of standardisation in equipment design. The situation can be summed up in a phrase: for each vessel, a specific design. This article will first provide a comparative overview of current legislation. A proposal for anchor windlass design is then presented in an attempt to make the various regulations more cohesive. The objective here is to reach an acceptable degree of standardisation and, consequently, lower costs by applying economies of scale.

INVESTIGATION OF WELDER SELECTION PARAMETERS BASED ON FUZZY ANALYTIC HIERARCHY PROCESS IN SHIPBUILDING

Today, it is very significant to select appropriate welders in shipbuilding industry. The fact that there is a really tough competition between shipyards triggers the increasing of welder quality. Higher welder quality means higher quality welding workmanship. If a shipyard has a high quality workmanship, it has bigger competitive power than its rivals. Therefore, shipyard management must take welder selection into more consideration. In this study, the weights of welder selection parameters of shipyards were determined by utilizing Chang’s extent analysis method. In this way, it is aimed to understand the point of view of shipyards in selecting welder. In addition, taking into account the important parameters in welder selection, the welders can improve their weak sides. Consequently, the results obtained from this study are believed to be a guide for the people who want to work as a welder in shipyards.

Evaluation of the genetic damage to workers in a Greek shipyard.

Shipyards are industrial areas where workers are likely exposed to environmental pollutants such as welding fumes, fine organic solvent and dye dust, that render the occupational environment a high risk one. Assessing the risk that workers are exposed to is a high critical factor in improving their working conditions. The present study aims to investigate the potential genetic damage to workers exposed to a harsh environment in a Greek shipyard. It is focused on assessing the percentage of induced micronuclei, as well as on changes in the various cell types of shipyard workers’ oral mucosa epithelium by implementing the buccal micronucleus cytome assay. Exposed workers appeared with statistically significant induced micronuclei as compared to office employees. Statistically, significant cell lesions were detected and are related to workers’ exposure to environmental conditions. The workers’ smoking habit contributed as well to the observed buccal epithelial cell alterations. The observed data signify the high-risk workers are exposed; resulting in the shipyard’s management the need to implement measures improving the working environment conditions and to reevaluate the workers’ personal protective equipment requirements.

Modelling of maritime ship repairs processes in shipyards, using the linear regression and correlation theory

The tendering and programming-planning activities carried out in the shipyards for the execution of the repair works of the maritime vessels are the result of estimates that operate with fixed data, conditioned by variables belonging to a wide spectrum of conditions and limitations. In the documentation made for the elaboration of the present work and the resolution of the chosen research topic, the studies were directed to the fundamental theoretical fields of: probabilities and statistics; modelling and numerical simulations. The objective assumed by the authors was to find a well-founded method for estimating the retention period of the ship in the shipyard, to exploit the information held in the portfolio of repair works performed to various clients, over time. This gives the perspective of optimizing the decisions of the shipyard management with reference to the problem of anticipating and programming the duration of the repair works of the maritime vessels. The purpose of the research consists in proposing an analytical function for analyzing the linear dependence of the time period, as a dependent variable, on the works carried out in the shipyard, considered as independent variables. The role and importance of the technical specification of the works prepared by the owner / technical manager of the ship, from the perspective of the management of the repair works of the maritime vessels in a repair yard, are highlighted, as well as the importance of the selection of variables with significant influence in the forecast of the duration of the repair works of the maritime vessels in a shipyard.

WORLD SHIPBUILDING: DRIVING FORCES AND RELEVANT DEVELOPMENT VECTORS

The purpose of the paper is to find out under the influence of which external impulses and according to which vectors events in the field of shipbuilding are taking place in our time. Concentrating attention on them, the authors sought to provide shipbuilders-practitioners with guidelines useful for making weighted and sometimes fateful business decisions. The conducted research seems timely from the viewpoint of the formation by the owners and management of the development strategy of domestic shipyards. Especially those related to the “new wave.” In the overwhelming majority, it is represented, paradoxically, by small and mediumsized enterprises. In recent years, they have been striving to find their own place in the international market for engineering, construction, repair, conversion, operation, and recycling of products whose line makes the structure of the chosen industrial specialization. The fact that the prospects for this business, despite the known difficulties, are optimistic is evidenced by the dynamics of the absolute volume of cargo transportation by sea and the construction of new vessels it has caused. Methodology. The performed generalizations are based on the analytical processing and systematization of data obtained by the authors from available information sources. As a result, substantiation of the arguments confirming the formulated working hypothesis regarding fundamental changes in the global shipbuilding – a key type of marine economic activity – has been obtained. Among its many features – a high level of competition, in which more and more new rivals are drawn. The study outlines the factors, under the influence of which the identified metamorphoses occur. This creates the prerequisites for identifying causal relationships between the first and second ones. In particular: humanity’s facing with the realities of the Fourth Industrial Revolution, signs of which are easily detected in shipbuilding; awareness by governments, socially responsible business, the public of the fatal consequences of neglecting environmental safety, affecting the natural environment and people employed in the maritime industry or residing in its area; advances in the sectoral international division of labour, accompanied by the emergence of new shipbuilding centres; the rising cost of marketing and building ships and the desire of shipowners to get an effect on the scale of the facilities used. At the same time, obstacles that occur along the way are identified. Practical implications. In support of the conclusions, we analyse the experience of leading enterprises, which serve as an example for imitation and deserve further development. They are not limited solely to technical and technological innovations but find the use of new organizational forms of mobilization of accumulated potentials. Among them are shipbuilding clusters. Turning to their creation, the initiators seek to strengthen the competitive positions of participants in developed segments and actively form new promising markets. Value/originality. As a result of systematization of the key areas of the drift of world shipbuilding, an information platform has been created, based on which shipyard management is able to foresee the future of the business under its care.

Lean Methodology to Transform Shipbuilding Panel Assembly

The core competence of any medium-to-large sized shipyard includes the panel assembly line. Ship panels are the basic building blocks of well over 60% of the interim products of typical commercial ships. Therefore the improvement of the panel assembly process could greatly reduce the number of man-hours of all assembled panels, thereby yielding significant savings to the shipyard. Using a lean methodology to make kaizen improvements to traditional panel assembly lines will greatly reduce the costs in ship production. This means that shipyards, which are barely keeping earnings above costs, will be able to increase profits. Value stream mapping is a key way of determining how lean a production process is. The wastes in production assembly are readily identified as well as the takt time and the areas where there is push as opposed to pull. In this paper, a case study of a typical commercial shipyard, which builds a product mix of vessels is analyzed. The present state panel assembly line is mapped and then using lean tools and avantgarde technologies, such as hybrid laser arc welding, the new transformed panel assembly line is demonstrated to bring man-hour reductions of over 80%, so that a typical panel is assembled using 12 man-hours as opposed to the present 72 man-hours. 1. Introduction The core competence of virtually any medium-to-large sized shipyard includes a panel assembly line. Many times shipyard management takes for granted that the panel assembly line is just fine as is and therefore it is not necessary to make analysis to improve this core shipbuilding assembly process any further. However, since flat panels make up well over 60% of the building blocks of most commercial ships, any type of significant improvement to the panel assembly line will result in important cost savings for the shipyard.

Ship Block Logistics Simulation Based on Discrete Event Simulation

The load of resources in the block logistics process influences the mid-term planning and scheduling of shipyard management. Therefore, load analysis must be conducted before confirming the plans. However, conducting the analysis using the traditional mathematical model is difficult. This study suggests using the discrete event simulation (DES) method for load analysis in advance. The simulation model of actual shipyard block logistics is established by the DES software. Data on the structure of the product, process, resource, and schedule are clearly defined to match the DES model. Partial results through the simulation are discussed in terms of real production activities. The outputs prove that the proposed simulation model can help planners arrive at reasonable and rational decisions related to shipbuilding plans. This simulation method can contribute in strengthening the competitiveness of shipyards.

Anchor Windlasses: A Design Proposal to Standardise Regulations

"Shipbuilding is an increasingly competitive field. As the key players in this activity, shipyard managers have to make their counterparts in related industries aware of two conflicting needs. On the one hand, they must produce high quality components that are technologically advanced. On the other, they need equipment that lets them build vessels at a reasonable price. With this second aim in mind, it would be useful to standardise both design and manufacturing processes. At the same time, ship owners always impose regulations. The manufacturers of deck equipment must therefore adapt their product designs to comply with these regulations, some of which have aspects in common. However, guidelines also differ on many points. This makes it difficult to reach desirable levels of standardisation in equipment design. The situation can be summed up in a phrase: for each vessel, a specific design. This article will first provide a comparative overview of current legislation. A proposal for anchor windlass design is then presented in an attempt to make the various regulations more cohesive. The objective here is to reach an acceptable degree of standardisation and, consequently, lower costs by applying economies of scale."

Evaluation of the performance of contemporary shipbuilding industries in Bangladesh

In this paper, an effort has been made to evaluate the present shipbuilding industries in Bangladesh. To do this, at first an overall picture of this industries have been depicted by identifying the actual shipbuilding practice in both public and private sector. Relevant data have been explored through extensive review of literature, field visits, interacting with shipyard and Ship owners, shipyard managers, Government regulatory and monitoring bodies using structured, unstructured and open ended questionnaires. Existing and upcoming yards have been identified and yards have been categorized by describing the shipyard in terms of modern shipbuilding requirements. The labor cost, labor hour, relative labor rate, productivity etc. have been quantified and compared with other nations. An investigation of cost breakdown of a sample exportable quality ship has been assessed to find out percentage of local components of total cost structure. The potentiality, capability and problems of the shipbuilding sector of Bangladesh have been identified & some recommendations have been made in line with this study.DOI: 10.3329/jname.v7i2.5407

Multi-objective topology and size optimization of high-speed vehicle-passenger catamaran structure by genetic algorithm

Ship structural design has become recently an ever more important and difficult task, because it should always take into account several estimation criteria which are a crucial element of shipyard management, as the hull structural strength is one of the most important factors of overall ship safety, and the total cost of structural materials used for the construction of a ship is a significant part of her total construction cost. Simultaneously, a complete definition of the optimal structural design requires a formulation of size-topology-shape-material optimization task unifying the optimization problems from these four areas and giving an effective solution of this problem. So far, a significant progress towards a solution of this problem has not been achieved. An objective of the underlying paper was to develop an evolutionary algorithm for multi-objective optimization of both topology and scantlings of structural elements of large spatial sections of ships. In the paper an evolutionary algorithm where selection takes place based on the scalar objective function is proposed and applied to solve the problem of structural elements weight and cleaned and painted surface area on a high-speed vehicle-passenger catamaran structure with several design variables, such as plate thickness, scantlings of longitudinal stiffeners and transverse frames, and spacing between longitudinal and transversal members. The results of numerical experiments with the use of the developed algorithm are presented. They show that the proposed genetic algorithm can be an efficient multi-objective optimization tool for simultaneous design of the topology and sizing of ship structures.

Shipyard production cost structure optimisation model related to product type

Establishing a shipbuilding production cost structure is a fundamental management activity, concerning materials and fabrication. Shipyards compete in world market niches regarding vessel type and dimensions. Therefore, the vessel's market price has a tremendous influence on the shipyard's determination of the price of the vessel offered to buyers. For this reason, shipyard management is forced to concentrate its efforts on production cost structure optimisation in order to achieve the goal of a profitable shipyard. In this paper, a computer-integrated cost structure optimisation model for defining an optimal and profitable vessel production cost structure is presented. Statistical analysis of the data was performed for a sample of tankers, built in selected shipyards. Probabilistic theory was applied and several results, such as expectation for aggregate figures, are presented. Such a tool for obtaining an optimal production cost structure enables shipyard management to carry out more effective decision-making, and also better cost control within model parameters. Furthermore, dynamical control of costing figures for the whole shipbuilding process is possible and has a significant influence on the final results. The mathematical model for achieving an optimal structure of the production costs was verified and tested against a real example of the construction of tankers.

Weak seams: Controversy over welding theory and practice in american shipyards, 1938-1946

At the height of World War II, America's record-setting shipyards were stunned when several merchant ships literally cracked in half. Worried that endemic manufacturing defects might endanger the entire wartime merchant marine, engineers argued that poor workmanship by shipyard welders had contributed to the accidents, that their own technical expertise should be more highly valued, and that they should be granted greater authority over the shipyard workforces. However, administrators in US Maritime Commission rejected these arguments. Instead, federal officials and shipyard managers assumed that many factors had contributed to the fractures and chose to implement a few modest, practical measures which soon stopped the fracture epidemic: improved worker training, the elimination through redesign of certain structural flaws in the endangered ships' hulls, and especially the installation of reinforcing devices at weak points in the ships. This episode not only draws attention to the way warfare heightens the stakes of technical controversies, but demonstrates the utility and resilience, even and especially at highly-charged moments, of practical knowledge and straightforward craftsmanship.

New Building Production CostsStructure Optimisation

Establishing newbuilding production costs structure represents a fundamental management activity, concerning materials and fabrication in shipbuilding. Shipyards are competing in world market niches, regarding vessel types and dimensions. Therefore, vessel's market price has a tremendous influence at shipyard's determination of vessel price offered to buyers. For this reason shipyard management is forced to concentrate its effort to act upon newbuilding production costs structure optimisation as to achieve the goal of profitable shipyard enterprise. In this paper, a computer integrated mathematical model of costing engineering of vessel production founded by authors is presented. Model concept is based on both, functional and technological, vessel breakdown structures. Statistical analysis of data was performed for a sample of tankers population, built in Croatian shipyards. Probabilistic theory was applied and several results such as of expectation for aggregate figures are presented. Such developed tool for obtaining an optimal production costs structure enables shipyard management besides more successful managing and decision making, also latter through the process a better costs control within model parameters. Dynamical control is needed of costing figures within optimised structure of production costs, that for assigned conditions, for the whole shipbuilding process and product, have significant influence upon performance final results. Mathematical model for achieving optimal structure of production costs was verified and tested against real example for tanker newbuilding. Transactions on the Built Environment vol 42, © 1999 WIT Press, www.witpress.com, ISSN 1743-3509

Productivity: How to Organize the Management and How to Manage the Organization

Thanks to an accident in timing, the National Shipbuilding Research Program (NSRP) facilitated access to an extraordinary organization before, during, and after the 1973 Oil Shock served notice that individual shipyards as well as entire shipbuilding industries had to be reformed. In Japan, the decade before was referred to as "The Golden Age of Shipbuilding." The reference was made not just because of the great and unprecedented peacetime shipbuilding market that had existed. It was also made to acknowledge the extremely effective management practices that evolved while building ship after ship without interruption from the late fifties through the early seventies. A more appropriate name is "The Golden Age of Shipyard Management Development." This paper reviews both the basic and condensed production organization of a Japanese shipyard, examines management accounting practices, and discusses the versatility and significance of a product work breakdown approach.

Product Work Breakdown: An Essential Approach for Ship Overhauls

Some North American shipyard managers have successfully adopted a product work breakdown structure for ship construction. Adoption by those who would compete is inevitable. But, none have applied the same product-oriented approach for ship overhauls. Yet, significant progress is being made by a naval shipyard. In yards which accept both challenges, continuing to employ a system work breakdown structure for overhauls while applying a product work breakdown structure for construction doesn't make sense. Two different management information systems are required. Thus, this paper identifies how the same product-oriented logic successfully applied to improve construction productivity, also applies for overhauls.2