IHOP

Product Work Breakdown Structure
(PWBS)
A.Y.Odaba 2009
Glossary
Cycle time
: the length of time it takes a process to cycle once
Effectiveness
: ability to use a resouce in best possible way (or ability to solve a

problem in best possible way)
Efficiency
:the degree of effectiveness as it applied to a process
Process
: the blending and transformation of a specific set of inputs into a

more valuable set of outputs
Reliability
: the consistency of an output
Rework
: any unnecessary, repeated operational steps
Waste
: all non-value adding process activities except those required to satisfy

rules, regulations etc.
Work
: actions that move a process forward or directly add value
Work efficiency
: a mathematical expression of how much work versus waste

exists in a process
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Work Efficiency
WORK
WORK + WASTE
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x 100 %
Utilization
Relation between the time when the equipment actually is used for productive time
(machine time) and the total time available
What is AVAILABLE time ?
Utilization 40 %
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15 %
Breakdowns and stops
15 %
Personal allowances
15 %
Technical allowances
15 %
Manual time
40 %
Machine time
Definitions
Machine UTILIZATION =
Personnel PRODUCTIVITY
Project PERFORMANCE
A.Y.Odaba 2009
MACHINE TIME
TOTAL AVAILABLE TIME
USED MANHOURS
TOTAL QUANTITY
ALLOCATED MANHOURS
USED MANHOURS
Process Re-enginering
The goal: is to decrease the the amount of waste in any work process
Before
Work
A
Waste
Work
After
Waste
Work
Work
B
Waste
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Waste
More work
in the same
amount of time
Same amount
of work
in much
less time
Key Process Characteristics
Effectiveness : Do outputs meet customer requirements ?

Customer wants
z
Customer gets
Efficiency
: Is process cycle time acceptable ?

Process cycle time is
Process cycle time should be
Reliability
: Do outputs always meet customer approval?
zzzz
z z
Customer always wants

Customer usually gets
Cost
: Are process costs acceptable ?

Process costs
Process should cost
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3h 25 min.
1h 15 min.
$ 55 per output
$ 36 per output
Production Flow - Shop Floor
Plate
Cutting
Plate
Forming
Curved Panel
Line
Profile
Forming
Steel
Stockyard
Shotblasting &
Priming
Web & Comp.
Line
Profile
Cutting
Block
Construction
Miscellaneous
Assemblies
Large Panel &
Double Bottom
Line
Small Panel
Line
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Main Activities in Ship Construction - Functional Approach
Ship
Hull
Structure
Hull Form
Shell
Plating
Bulkheads
Machinery
Decks
Outfit
------
Main
Machinery
Auxiliary
Machiney
------
Piping
Frame
Body Plan
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Profile &
Buttocks
------
------
HVAC
Mechanical
Electrical
------
Group Technology in Shipbuilding - Definition
A technique for manufacturing

small to medium lot size batches of parts
of similar process,
of somewhat dissimilar materials,
geometry and size,
which are produced on a committed small cell of machines,
which have been grouped together physically,
specially tooled and scheduled as a unit [Storch et el. 1995]
A.Y.Odaba 2009
Group Technology in Shipbuilding - Benefits
Reduction in engineering drawings

Company standardization
Reduction in design and engineering man-hours
Better utilization of facilities
Simplified and automated planning
Simplified scheduling and production control
Improved productivity
A.Y.Odaba 2009
Build Strategy - A Group Technology Approach
What is to be done?
When is it to be done?
How is it to be done?
What resources are needed to do the task?
Build Strategy
An agreed design, engineering, materials management,
production, planning and testing plan
prepared before the work starts
so as to identify and integrate
all the necessary processes [T.Lamb, 1996]
A.Y.Odaba 2009
Product Oriented Work Breakdown Structure (PWBS)
PWBS provides indentation levels within production tree structure

PWBS classifies the ship on the basis of its interim product
Parts and subassemblies are grouped by common characteristics
and classified by both design and manufacturing attributes.
Benefits
Provide mechanism to enter into and come out of SWBS
Communicate amongst design, material procurement and
production departments using a common framework and
description of both the material and labor for a particular interim
product.
Stagewise testing and acceptance
Assistance in configuration and change management
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Product Oriented Work Breakdown Structure - Requirements
Type of work
Hull construction
Outfitting
Painting
Resources
Material
Manpower
Facilities
Control of
Production
Process
Product Structure (Zones)

Work Type (or system based)
Work Stage
A.Y.Odaba 2009
Components of Integrated Hull, Outfitting and Painting (IHOP)
Product Work
Breakdown Structure
(PWBS)
Pipe Piece Family

Manufacturing
(PPFM)
Hull Block
Construction Method
(HBCM)
A.Y.Odaba 2009
Zone Outfitting Method

(ZOFM)
Zone Painting Method

(ZPTM)
Integrated Hull, Outfitting and Painting (IHOP)
HMCM
ZOFM
The ship is dived and subdivided into blocks

Blocks are the basis for control of the production
Blocks are also used for ZOFM and ZPTM
Blocks:
simple & logical boundaries
min. number of blocks
provide min. scaffolding
provide max. accessibility
Works in conjunction with HBCM

Uses similar logic of zone division as in HBCM
Outfit components are assembled either independent of
the hull blocks or based on the hull blocks
On-unit
On-block
On-board
ZPTM
Uses same logic of group technology as employed in HBCM & ZOFM

Considers painting work as an assembly process with different
painting work at different levels
PPFM
Classifies pipe-pieces
Organized independently of the hull structural block
A fabrication process rather than the assembly work of HBCM/ZOFM/ZPTM
A.Y.Odaba 2009
Integrated Hull, Outfitting and Painting (IHOP) - Benefits
HMCM
ZOFM
ZPTM
PPFM
A.Y.Odaba 2009
The ship is dived and subdivided into blocks

Blocks are the basis for control of the production
Blocks are also used for ZOFM and ZPTM
Outfitting and installation work in closed & covered areas

Better and safer work conditions
Easy supervision of work
Reduced idle time
Maximum amount of down hand or vertical plane paint work
Better control of temperature and humidity for paint work
Safer worker environment
Utilization of same scaffolding with block assembly
Large variety pipe-piece parts with number of common elements can be
grouped into families or batches having similar design and manufacturing
attributes
Testing and coating of pipes are done at the place where the final pipe piece
assembly and pipe piece joining takes place
Hull Block Construction Method (HBCM) Manufacturing Levels
Hull
Erection
Complete hull is considered as a zone;

fore, hull, aft hull, cargo hold, engine room, superstructure;
work stage:erection, test
Post-block assembly stage;
two or more block assemblies are joined
to create a larger block;
work stage:joining, pre-erection
Grand-block
Joining
Main Work Flow

Block
Assembly
Block
Assembly
BLOCK = KEY ZONE

Flat, curved, superstructure blocks;
work stage:joining, assembly, back assembly
Pre-block assembly stage;
assists to assemble
partial zones to main block
Semi-block
Assembly
Sub-block
Assembly
Part
Assembly
Part
Fabrication
Part
Assembly
Part
Fabrication
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Part
Fabrication
Sub-block
Assembly
Part
Assembly
Part
Fabrication
Part
Fabrication
Part
Assembly
Part
Fabrication
Part
Fabrication
Assembled structural parts

(e.g. transverses, girders, floors)
work s.: assembly, back assy.
Built up sections
or stiffened brackets
work s.: assembly, bending
Produce non-subdividable
Part
Fabrication components&piece parts;
work stages: marking,
cuting & bending
Production Stages Steel Hull
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Parts Fabrication
Marking
Line Heating
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Marking & cutting NC Machine
Press Bending
(courtesy NSNet Shipbuilding Pictures Database& personal library of Mr. Louis D. Chirillo)
Sub-Block Assembly
Assembly of small sub-blocks

by gravity-feed welding
Welding a sub-block
A completed sub-block being moved to

a block assembly facility
Palletized sub-assemblies
awaiting block assembly
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Block Assembly
The first stage of flat-panel

block assembly
Curved block assembly on

an adjustable pin jigs
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Block transportation with

heavy-lift transporters
Block assembly shop

with process lanes
Hull Erection
Keel laying - Past !!
Pyramid erection system outfitted and painted blocks
Erection of machinery-space blocks
Erection of stern block containing

rudder horn
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Zone Outfitting Method (ZOFM) Manufacturing Levels

Testing of outfitted units
Operation
& Test
Outfit work carried out on the hull of the ship

either during pre-launch erection stage or
during the post launch outfitting stage
On-board
Outfitting
On-block
Outfitting
Main Work Flow
On-unit and grand-unit outfitting assembly

are fitted to the structural blocks
defined by the HBCM
Manufacturing level for
on-unit outfitting work
Semi-block
Assembly
Grand-Unit
Assembly
Unit
Assembly
Component
Procurement
Unit
Assembly
Component
Procurement
A.Y.Odaba 2009
Component
Procurement
Grand-Unit
Joining
Unit
Assembly
Component
Procurement
Component
Procurement
UNIT = KEY ZONE

on-unit outfitting work
Unit
Assembly
Component
Procurement
Component
Procurement

on-unit outfitting work)
Component
Procurement
The work packages and

material requisition for
component procurement
are grouped by zone & area
Outfit Components
100 foot diameter LNG sphere
Nuts & bolts
Ventilation ducts
A.Y.Odaba 2009
Cables; pre-cut, identified and palletized
On-Unit Outfitting
1) Tack welded supports for pipe unit

on a platen
2) A pipe piece secured to supports

with U bolts
4) Completed pipe units

ready for landing on block
3) Two nearly completed pipe units
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On-Block Outfitting
Fitting out of electrical cable trays
Fitting out of
ventilation-duct pieces
View of outfitted block

An outfitted and painted block
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On-Board Outfitting
On-board outfitting
Flanges for large & medium diameter

pipes are in alignment
On-board outfitting
On-board outfitting - traditional way
A.Y.Odaba 2009
PWBS - Outfit Units Assembly
Outfit units which are dissimilar in arrangement and in

functions incorporated, have the same classification in
a product-oriented work breakdown structure because
the problems associated with their assembly are the
same.
A.Y.Odaba 2009
PWBS - Outfit Units Assembly
Unit : Standard Machinery Unit

Resources:
30 pipe pieces
5 walkway sections +
handrail
8 supports
a smaller unit consisting

of 2 interconnected
pumps on a common
foundation.
Time : 2 worker assembly team
for one week
Weight : 10 tons
A.Y.Odaba 2009
Zone Painting Method (ZPTM) Manufacturing Levels
Final stage in the ZPTM;

no block turnover,
application of anti-corrosive paints
Finish
Paint
Finish
Under-coat
Paint
Primer
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Primer
Primer
Shop
Primer
Shop
Primer
Finish
Under-coat
Paint
Primer
Painting of various outfitting items

(masts, cargo booms, hatch covers),
application of anti-corrosive paints
Unit
Assembly
Shop
Primer
Application of
anti-corrosive paints
Surface preparation
and primer coating
for plates and sections
Zone Painting
Priming of steel plate
An extensivelt outfitted and painted block

A.Y.Odaba 2009
Pipe Piece Family Manufacturing Method (PPFM) Manufacturing Levels

Grouping of pipes according to
the requirements for a specific pallet
(e.g. Hull, machinery, superstructure)
Palletizing
Pickling and coating

of pipe assemblies
Coating
Testing
Pipe Piece
Assembly
Pipe
Fabrication
Pipe
Fabrication
Pipe
Receiving
Pipe
Receiving
A.Y.Odaba 2009
Checks for quality

of the assembled pipes
Testing
Pipe Piece
Joining
Joining of main pipe sub-assembly to

branch pipe sub-assembly
to produce pipe assembly
Pipe Piece
Assembly
Flange and collar attachment

(excludes joining of main
and branch assemblies)
Marking, cutting and
machining of pipes
Pipe
Fabrication
Pipe
Receiving
Pipe
Receiving
Pipe
Receiving
Different arriving
materials are grouped
according to the
type of material
Pipe-Piece Family Manufacturing
PPFM Classification :
Straight
Pipe receiving area
PPFM Classification:
Unit assembled
PPFM Classification: Penetrations

A.Y.Odaba 2009
Palletizing areas
Integrated Schedule for Hull Construction, Outfitting and Painting
Principle Event
Schedule
Block Erection
Master Schedule
Integrated Hull Construction

Outfitting & Painting
Master Schedule
Block Assembly
Master Schedule
On-board Outfitting
Master Schedule
On-unit Outfitting
Master Schedule
On-block Outfitting
Master Schedule
Monthly Schedule
Monthly Schedule
Monthly Schedule
Weekly Schedule
Weekly Schedule
Weekly Schedule
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Hull Construction Progress
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Producibility
Reduce labor cost by

reducing number of steps
to perform the task
Reduce the number of
piece parts varity
Incorporate
standardization
Increase repetitive jobs
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The reduction in costs

as a result of the effort put in to
make ship cheaper to build
by
making it cheaper to construct
without compromising
on its desired capabilities
like size, speed, displacement,
payload, stability, strength etc.
A.Y.Odaba 2009
PWBS, statistical control and line heating are

interdependent. In accordance with a product
work breakdown blocks which are assembled on
a flat panel are a distinct problem category
regardless of their design differences. In
Avondale Shipyards, Inc., they are assembled on
a dedicated process lane.
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Building Progression: Keel Laying + days
PWBS - Erection Level
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11

Landing the Block
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13

Engine-room Tank-top blocks
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15

Blue sky outfitted control
console and diesel generators
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19

Landing the Cant Block
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22

Landing the grand block
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22
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24

Landing the main engine
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24

Landing the aft superstructure
half
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27

Finish paint application to the
undersides of hatch-covers
28
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Aft half of superstructure being
fitted
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29

Landing the aft half of
superstructure on board
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29
PWBS - Operation and Test Level
A.Y.Odaba 2009
IRON STURT - Ship No: 2728, IHI Kure Shipyard

LBP= 163.0m, B=22.9m, D=13.6m, d=10.0m, DWT=22,093, HP=9000
Launching
43
Start
Fabrication
A.Y.Odaba 2009
Keel Laying
workdays in
building dock !!!
Delivery

IHOP

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Product Work Breakdown Structure

: the length of time it takes a process to cycle once

: ability to use a resouce in best possible way (or ability to solve a

:the degree of effectiveness as it applied to a process

: the blending and transformation of a specific set of inputs into a

: the consistency of an output

: any unnecessary, repeated operational steps

: all non-value adding process activities except those required to satisfy

: actions that move a process forward or directly add value

: a mathematical expression of how much work versus waste

Breakdowns and stops

Key Process Characteristics

Effectiveness : Do outputs meet customer requirements ?

: Is process cycle time acceptable ?

: Do outputs always meet customer approval?

Customer always wants

: Are process costs acceptable ?

Production Flow - Shop Floor

Main Activities in Ship Construction - Functional Approach

Group Technology in Shipbuilding - Definition

A technique for manufacturing

Group Technology in Shipbuilding - Benefits

Reduction in engineering drawings

Build Strategy - A Group Technology Approach

Product Oriented Work Breakdown Structure (PWBS)

PWBS provides indentation levels within production tree structure

Product Oriented Work Breakdown Structure - Requirements

Product Structure (Zones)

Components of Integrated Hull, Outfitting and Painting (IHOP)

Pipe Piece Family

Zone Outfitting Method

Zone Painting Method

Integrated Hull, Outfitting and Painting (IHOP)

The ship is dived and subdivided into blocks

Works in conjunction with HBCM

Uses same logic of group technology as employed in HBCM & ZOFM

Integrated Hull, Outfitting and Painting (IHOP) - Benefits

The ship is dived and subdivided into blocks

Outfitting and installation work in closed & covered areas

Hull Block Construction Method (HBCM) Manufacturing Levels

Complete hull is considered as a zone;

Main Work Flow

BLOCK = KEY ZONE

Assembled structural parts

Production Stages Steel Hull

Marking & cutting NC Machine

Assembly of small sub-blocks

A completed sub-block being moved to

The first stage of flat-panel

Curved block assembly on

Block transportation with

Block assembly shop

Keel laying - Past !!

Pyramid erection system outfitted and painted blocks

Erection of machinery-space blocks

Erection of stern block containing

Zone Outfitting Method (ZOFM) Manufacturing Levels

Outfit work carried out on the hull of the ship

Main Work Flow

On-unit and grand-unit outfitting assembly

UNIT = KEY ZONE

Manufacturing level for

The work packages and

100 foot diameter LNG sphere