STUDY ON QUALITY MANAGEMENT OF BLOCK CONSTRUCTION IN INDONESIA *) (CASE STUDY: ACCURACY CONTROL OF BLOCK CONSTRUCTION AT DPS SHIPYARD) Buana Ma‘ruf ? ABSTRACT During the last two years, this study has been focused on dimensional accuracy of block construction of ship building in Indonesia. From case studies carried out at DPS shipyard has resulted some considerable improvements, such as: range of dimensional deviation at fabrication stage reduced from +5 mm to +2 mm after NC cutting machine was calibrated/repaired. The range of deviation at sub-assembly stage also reduced from +5 mm to +3 mm after most welders were trained and enforced them to follow welding preparations and procedures. These are also possible after establishing an accuracy working procedure, the use of single plate resource, better awareness of workers in quality and better working environment. At erection stage, most blocks can be erected without many reworks/ unnecessary works, However, zero margin at both sides of connected blocks have not been applied, since some related factors still can not be properly controlled. These factors consist of: uncontrolled sub-contractor’s workers, handling method of blocks, adequate of supporting constructions, inconsistent implementation of established working procedures, limitation of production resources, and the limitation of measuring tools. So far, 15-30 mm margin is given in one side of the blocks instead of 30-50 mm as previously applied. From the case study shows, the ranges of deviation at erection stage are mostly between -2 to +5 mm, Keywords: Shipbuilding, Block Construction, Accuracy Control, Margin, Erection Stage, Rework. 1) Presented at the Seminar of JSPS Maritime Transportation Program in Hiroshima-Japan, on 30* October 2003. 2) Research Staff of the Agency for the Assessment and Application of Technology. INTRODUCTION The only way to compete in the global market is to enhance the industry Capabilities to continuously improve productivity in terms of quality, cost, and “Study on Quality Management of Block Construction in ...7, (Buana Ma'ruf) “151delivery time. Dimensional accuracy is not really the concern of customer or - classification body as far as all interim and end products fulfill any quality acceptance standards, But it is obviously the concern of shipyard to reduce production costs through minimizing unnecessary works in erection stage. The block construction method is commonly used in modern shipbuilding, and the quality management of block construction is a key technology for efficient shipbuilding. This study is aimed at reducing the volume of unnecessary work at final block assembly stages, in order to reduce building period at the building berth. To reduce the volume of unnecessary works, accuracy control system has been implemented in major shipyards in Indonesia, including at PT DPS shipyard. Some efforts have been made such as training people and developing an accuracy control working standards by taking some blocks in the in parallel middle body of on-going projects as case study. However, these efforts had no considerable impacts on production performance and the block accuracy was still low level. The objectives of this particular research are: a. To identify dimensional errors occurred in cutting process using NC Gas Cutting Machine, and welding process using automatic welding machine (SAW) in sub-assembly/ assembly stages of entire shipbuilding process. b. To develop a proposed or an improved quality standard of accuracy control system, in order to get zero margin at the block erection stage. RESEARCH METHODOLOGY This particular research topic has been carried out during two years (year 2001- 2002) by using a series of case study of on-going shipbuilding projects at PT Dok dan Perkapalan Surabaya (Persero). The research steps and are as follows: 1/. Step 1: Data Collection, Dimensional data of parts, sub- assembly member, and hull blocks are.collected in accordance with the fabrication and assembly procedures; 2/. Step 2: Statistical Analysis, The collected data are analyzed statistically, and factor analysis or parametric study is carried out, determining the parameters which cause dimensional errors; 3/. . Step 3: Development of Quality Standard, In accordance with the above results, an accuracy control standard Is proposed or the current standard is modified and improved by execution and feedback. 152 Jumal Penetitian Enjiniring, Vol.9, No.2, Mel-Agustus, 2003, 151 ~462The flow of research activity as previously proposed as Figure 1. Preliminary Study + Basic concept of A/C System - Current yard condition Problem identification a Review of Yard Resources Literature Review a = Design and Production - Concept of A/C System = Standard & working practices - Related publications/journats Case Study ——P} - Fabrication stage a - Sub/ Assembly stage - Erection stage Computing And Analysis Development of Quality - Management and A/C Standards yp Quality Management and A/C Standards Figure 1. The Flow of Resesearch Activity RESULTS AND DISCUSSIONS This particular topic has been carried out since the end of 2000 through the comparison study of JSPS Program. During the year of 2000-2002, a series of case study have been carried out using current shipbuilding projects at DPS shipyard. The last research activity has been focused on data analysis, “Study on Quality Management of Block Construction in ...", (Buana Ma‘ruf) 153development of accuracy control ‘standards as a general guidance of shipbuilding industries in Indonesia leading to zero margin to minimize the volume of reworks at the erection stage. Year 2000 In the first year (2000), management cycle and responsibility of each related department were identified based on the basic concept of accuracy control system. Then, an accuracy contro! working procedure was developed and established within production functions, such as: engineering, production and quality control, Some preparation works were done before performing a case study, including preparation of check-sheets, measuring tools and establish a small team within the production functions. In this preliminary stage, case study was carried out in NC cutting process using collected data of Caraka Jaya project and navigation vessels built at DPS shipyard. Through these projects, dimensional deviations of numbers of samples from five different plate’s thickness (6, 7, 8, 9 and 10 mm) were tecorded. Data of welding process has not been recorded in this stage. From the case study shows that most dimensional deviations in cutting are within 0 to +3 mm, where the variance tends to decrease by increasing the plate thickness. Detail result and statistical analysis have been presented at the JSPS seminar in Hiroshima in November 2000, During the JSPS seminar in November 2000 in Hiroshima-Japan, we visited two middle-size shipyards (Koyo Dockyard and Kanda shipyard). The main purpose of the activity is to understand the present conditions and Operation of the shipyards, particularly the company practices in quality management of block construction. The results of the visits have been considered as a comparative reference for analyzing the practices of Indonesian shipyards. Koyo Dockyard for an example, this company has a well-established quality management system, and ISO 9001 certification (JISZ 9901) from JAB since 1999. By using accurate designs and consistent application of production Procedures as well as the established QC Procedure, the blocks are normally constructed without any margin in the block connecting zones. The measurements are maintained using reference lines about 100 mm from both sides, This reference line is then adopted in case study 2001. 154 Jurnal Penelitian Enjiniring, Vol.9; No.2 Mel-Agustus, 2003, 151 262Year 2001 ‘As reported by email to the JSPS in October 2001, a case study in Pontoon Project of floating dock Surabaya II had been carried out during its construction work in 2001. In this case study, research activity is not only limited in fabrication stage (plate cutting) but also in sub-assembly stage (welding process). At the beginning, the range of dimensional errors resulted from NC cutting machine was founded too high (+5 mm). Therefore, the machine was investigated and calibrated before collecting data in the normal operation. The sequences of work carried out in cutting process in 2001 are: 1, The NC cutting machine operation was investigated, such as: torch movement, rail alignment, moving parts, micro and macro calibrations. The torch movement was identified using different shapes of paper object. 2. Based on the investigation, some of machine parts were repaired, such as: control carriage and automatic puller of the NC control NCE 510, and its gear wheel of longitudinal and transversal drives. 3. By using the special sampling experiments, the collected data before and after machine repair were compared. The result shows, dimensional errors were smaller than before the machine was repaired/ well maintained. 4, Then, measurement data of fabricated parts were collected from the normal operation of the machine. . At sub-assembly/assembly stage, the case study was carried out was carried out in welding process. Submerged Arc Welding (SAW) is applied for joining flat panels of varied plate’s thickness (10, 11 and 13 mm). Dimensional deviations for joining plates are mostly varied from -3 mm to +1 mm. During the case study, the existing accuracy control standards are also reviewed and developed, including: accuracy control working procedures, imptementation approach, accuracy control plan, check sheet, data computing and anatysis. Level of worker's awareness on quality and dimensional accuracy during the case study may be also considered as another direct positive impact to shipyard’s productivity. Year 2002 As continuing activity of 2001, case study in 2002 is carried out in building process of three units of barge 300 ft (similar sizes) at DPS shipyard. The case study has been focused on cutting and welding processes. The plate thickness “Suxdy on Quality Management of Block Construction in ...", (Buana Ma'ruf) 155used in this project mostly consists of 8, 12 and 14 mm, then plate thickness 10 and 11 mm were taken from pontoon of floating dock Surabaya II being built in 2001. These plate materials were purchased from a single local manufacturer. Dimensional deviations in cutting vary with maximum range of +3 mm. Dimensional measurement of part fabrication Is made from side to side using calibrated roll-meter. The frequency of deviation for five different plate’s thickness is shown in Table 1. Table 1 Frequency of Dimensional Deviation for Cutting No. ] Thickness Range Deviation Frequency ] (mm) (nm) 3 [2] 4 [05] 0 [+s] 7 | 2 3 1 14 3to+3 [i fai |?|- faep3] 4 3 2 12 “3to+3 1{2|2/4f3 {ef of3 3 i 2tor2 | - | ifs fal - fa7t 4 [- 4 10 ow+2 |-|-|- [sl - [6 - 5 8 ~ost+os,- | -|- | sfs¥f2f-[- > Total Samples 273 14 | 10 [220] 6 [33 | 20 [9 From the above table, 69.4% of 317 total samples have zero deviation, 21.4% have positive deviation and 9.2% have negative deviation. Both positive and negative deviations occurred since part components tend to slightly move when they are in cutting process, particularly for small size components. Mean values vary from -0.06 to 0.40 mm, and Standard Deviations vary from 0.22 to 1.04 mm. In welding process, 388 samples lave been taken in sub-assembly stage. Dimensional deviations are measured every 1500 to 2000 mm from given reference lines (100 mm) on both components. The reference lines are given after tack welding between the two components. The frequency of dimensional deviation is shown in Table 2. 156 Jurnal Penelitian Enjiniring, Vol.9, No.2, Met-Agustus, 2003, 151-162Table 2 Frequency of Dimensional Deviation for Joint Plate/Welding to.) Oe oe Dimension of Frequency Thickness: Deviation (mm) (mm) 3 | 2 ]-1i) 0 1 2 3 [! 14 & 14 -3to + 3.0 | 1 [2 6 | 2 | 10 2 2 2) Gan ~2to+ 10 - [8 [2a] 54 | iz pre “3to+ 1.0 | 6 [aie [zl - 4 12812 -3t + 3.0 1 2 6 30 S 3 i 5 ad =3to+ 10 if 4 [Ria 6 - - 6 10 & 10 -3to+ LO 3[ 4 [By 3] 5 S - Total Samples i | 26 [ 82 | 207 | 54 5 3 From the above table, the results of dimensional deviation are within the range of +3 mm, consists of 53.3% in zer deviation, 16.0% in positive deviation and 30.7% in negative deviation. Mean Values vary from —0.52 to 0.13 mm, and Standard Deviations vary from 0.79 to 1,07 mm. These dimensional deviations are within the standard of JSQS 1979 (standard +4 mm, tolerance limit +6 mm), and the rule of ABS 1998 (standard +2.5 mm, tolerance limit +4 mm) for flat plate assembly. : At erection stage, there are two- factors must be maintained, namely: dimensional accuracy and positional accuracy of blocks. When two blocks are erected, dimensional accuracy is controlled using three. reference lines, namely: center line, water lines and frame lines. These lines must be clearly marked on before the blocks are fitted-up for erection. To maintain the length of the ship, the length of each block must be controlled at erection stage based on its design using frame line: as-reference tine, Water-line.and center tine are used to contro! the alignment of ship’s hutl: te Of te Some ring blocks of the last ship building project (middle body) at DPS shipyard have been selected in our case study this year, starting from_part fabrication up to block erection. The result of measurement, foreach connecting block as follows Table 3. : Boney “SREY en Ry Management of Block ConstructionTable 3 Dimensional Deviation and Gap in each block (bottom) for Erection a B c “|. 0 Beck | Face [ ARer GaP bere | Mer | cn Fore [aRer| °°? Prove Taner] S°? 45 [2 4 6 3 4 7 2 2 4 2 | 0 2 sé, 3 [i] 4 {[3f0f3f1])o0]1 12) 77 e7{,o]2 ],2,4f3f2f2f2f,of1T0T?1 7ef/ 2,3 ]sf2f2f4]fif2zys/itforlia 9/3 [0,3 ]/2]+4 f1afefa4)7i1f31a)2 sol 4 f]of4¢fsfifaf2zfyoey2)if,o0ft 10-11] 3 “1 2 4 a3 2 2 4 2 3 5 Table 4 Dimensional Deviation and Gap in each block (deck) for Erection A 8 Cc D Block Fre [alter | Gap | fore | Aer | °°? Prove] aner Gap a5{2f[4]{eéf{[1{[3]4{[2]/2]¢ sé6é{1{[2{3 {2 ]0f2 {21 {1)7~0 e7fo[2f2z[a][3}/2],2fefo 7ef2[2f4f3i{2ifsi)]3)a1)¢ eo {3 [0 | 3 [ ai}ifof2zf{fa4]3 ool 2fif3s{3f3fe6ef2zf{i]s3 tou 3 [+t | 2 2] a4{[24 [0 | 2] 2 Having considered the above result, provision of margin in one side of block connecting zone can be reduced to 10-15 mm instead of 15 to 30 mm as currently applied. But Engineering Department still has a doubt to provide smaller than that value or make zero margin blocks since a lot of uncontrolled factors and uncertainties during production, particularly in block assembly stage. From the second barge being built it self,,one block in aft peak position has dimensional error up to -30 mm, and another one even must be repaired because its high has more than 100 mm less. This is being investigated, but dimensional error in cutting process could be the main cause. A feedback sheet for this non-conformity was made to Engineering Department, including its preventive action required for the next ship building projects. 158 Jurnal Penelitian Erjiniring Vol9, No.2, Mel-Aguetus, 2003, 151 -162Development of Standards Based on pass experiences and the case studies, the accuracy control standards ‘as mentioned in the third research step, are also being reviewed and improved, including: implementation approach, management cycle of accuracy control system, working procedures, accuracy control plan, check sheet, feed-back sheet/ non-conformity report, data computing and analysis. These standards are basically developed according to common yard practices and standards in Indonesia. Therefore, these methods may be adopted or implemented as practical methods in any other major Indonesian. shipyards, particularly in maintaining dimensional accuracy in block construction. From the case studies, some improvements/ standards and production problems may be considered in design stage, such as: the use of reference lines for measuring points, identification of vital points each block, the use of margin in block connecting zones, production resources, position of eye plates for block handling, etc. Discussion Having assessed the result of case studies in entire ship building projects at DPS shipyard in 2000-2002, dimensional deviations occurred in fabrication and sub- assembly/ assembly stages are mostly within tolerance limits, and can be easily controlled because of the following reasons: * The ships being built are barges of 300 ft (similar sizes and mostly flat blocks), * Plate materials are coming from a single manufacturer and the best local one, * Production processes are mostly carried out using automatic cutting and welding machines, and they are well maintained, « Welders have better qualification, and working procedures are consistently implemented including working procedures as resulted from this case study. From our case study shows that potential errors are mostly occurred in assembly stage, since most of the works in this stage are still carried out manually and outside the shop (open space). So, degree of automation is primarily important for maintaining dimensional accuracy. In addition, block assemblies are mostly carried out by sub-contracting workers with under qualification levels. Limitation of facility (such as: crane to turn the blocks and “Study on Quality Management of Block Construction in ...", (Buana Ma‘ruf) 159Jig to maintain the shape of the blocks) and improper block handling also contribute to difficulties in join block. It is obviously from our experiences that there were some difficulties in clearly obtaining the causes when dimensional errors occurred in final block assemblies, as the result of the complexity of variables involved. To effectively implement the accuracy control system in the long run with continuous direct impacts to productivity improvement, a shipyard must consider a number of related factors, which may be influenced to its implementation. To provide zero margins in both connecting blocks, the shipyards have to consider as follows: * Focused on certain product ranges (type and size of ship), «Minimize variations of resources and standardization of production process, * — More automation in fabrication and assembly shops, * Sub-assembly and block assembly are carried out under covered shop, = Improve skill of manual workers through training program, « — Continuously improve accuracy control standards and working procedures. In a shipyard where variability of products and resources are limited and steady, implementation of accuracy control is certainly easier. For an example, variability of material used should be minimized by establishing a limited product ranges and selecting a permanent material vendors with a steady product quality. Type and variability of cutting and welding machines used should be also minimized, as well as the availability of supporting facilities (such as: crane and jig), high qualification of workers and constantly used of all working standards. The above factors have been taken as the main consideration at most Japanese shipyards, as concluded from our discussion at Koyo Dockyard and Kanda Shipyard. In addition, zero margins in Japanese shipyards is also supported by. climate condition and all covered shops. CONCLUSIONS A basic guidance/ standard of accuracy control system and quality management system related to dimensional control for block construction in Indonesia may be provided and proposed from this particular research. However, the developed standards need to be integrated with other production standards and 160 Jumial Penetitian Enjiniring, Voi.9, No. Mel-Agustus, 2003, 151-162yard practices, in order to have maximum benefits of its implementation. For effective implementation and continuous improvement, the basic concept of accuracy control system and the proposed standards must be socialized to all related departments within the shipyard through training program to middle and lower level managers. With regard to the above, the results of this study may be expanded to the activities which rely on management and technical approaches for effective implementation in the shipyards. A training module of accuracy control system may be prepared for middle and lower level managers. The training module may include: basic concept of accuracy control, accuracy contro! planning standard, executing standard, dimensional control and measurement technique, data collection and feed back, data computation and statistical analysis, as well as its implementation strategy. ACKNOWLEDGEMENT This research is carried out as a part of the JSPS-Asian Cooperation Program in Marine Transportation. This particular report is made by the support of the JSPS-Comparison Study Group, Board of Director of DPS shipyard, Director of Transportation Technology of the Agency for the Assessment and Application of technology, and the members of JSPS committee. Therefore, the author would like to thank to all participants mentioned above. Also, we would like to thank very much to Prof. Yasuhisa OKUMOTO, Prof. Yasumitsu TOMITA, Prof. Kunihiro HAMADA and Prof. Eiji SHINTAKU, for their valuable advice in JSPS- Comparison Study Group seminar in Jakarta on gh August 2002. 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