Marine Kit 1 Shipyard Operations A K Verma

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Marine Kit - 1 Shipyard Operations A. K. Verma 6/09 Lean Institute - ODU

Marine Kit - 1 Shipyard Operations A. K. Verma 6/09 Lean Institute - ODU 1

Shipyard Operations Description • This shipyard operations activity requires two class periods • Students

Shipyard Operations Description • This shipyard operations activity requires two class periods • Students work in groups of 4 • Each session can be completed within one class period (55 min. ) • Students learn about the various departments by building a paper container ship. A. K. Verma 6/09 Lean Institute - ODU 2

Shipyard Operation Schedule Day 1: Shipyard Operations Day 2: Design Calculations A. K. Verma

Shipyard Operation Schedule Day 1: Shipyard Operations Day 2: Design Calculations A. K. Verma 6/09 Lean Institute - ODU 3

Day 1 Time Topic 00: 00 Introduction to Shipyard Operation Activity by the teacher

Day 1 Time Topic 00: 00 Introduction to Shipyard Operation Activity by the teacher – 10 Min. 00: 10 – 00: 55 Simulation Activity – 45 Min. Day 2 Time Topic 00: 00 Introduction to Shipyard Operation Activity – 15 Min. 00: 15 – 00: 55 Design Calculations – 40 Min. A. K. Verma 6/09 Lean Institute - ODU 4

Production Layout There are three departments within our shipyard an external supplier Plasma Cutting

Production Layout There are three departments within our shipyard an external supplier Plasma Cutting Bending Machine Supplier Welding Material Flow Information Flow Our shipyard builds a container ship A. K. Verma 6/09 Lean Institute - ODU

Day 1: Activities • Instruction manual is provided to guide students in constructing the

Day 1: Activities • Instruction manual is provided to guide students in constructing the ship • Three departments are involved in this shipyard operation (excluding the Supplier) Teacher serves as the Supplier • Plasma Cutting Shop cuts the plates • Plate Shop bends the plates to form hull modules • Welding & Final Assembly Shop assembles the ship modules A. K. Verma 6/09 Lean Institute - ODU 6

Starboard Ship Terminology Stern Bow Port Bow : Front part of the ship Stern

Starboard Ship Terminology Stern Bow Port Bow : Front part of the ship Stern : Rear part of the ship Starboard : Right side of the ship Port : Left side of the ship A. K. Verma 6/09 Lean Institute - ODU 7

Ship Terminology Port Stern Bow Starboard A. K. Verma 6/09 Lean Institute - ODU

Ship Terminology Port Stern Bow Starboard A. K. Verma 6/09 Lean Institute - ODU 8

Activity Involved in the Plasma Cutting Shop • • Receives steel plates from the

Activity Involved in the Plasma Cutting Shop • • Receives steel plates from the supplier Cuts the plates along the solid line Sends the parts to the Plate Shop All the parts are numbered in the order in which they have to be sent to the next department. A. K. Verma 6/09 Lean Institute - ODU 9

Bow – Cut Part from Plasma Shop Cut along solid lines A. K. Verma

Bow – Cut Part from Plasma Shop Cut along solid lines A. K. Verma 6/09 Lean Institute - ODU 10

Mid-Hull – Cut Part Fold along dashed lines A. K. Verma 6/09 Lean Institute

Mid-Hull – Cut Part Fold along dashed lines A. K. Verma 6/09 Lean Institute - ODU 11

Stern – Cut Part Directions for folding Part Number A. K. Verma 6/09 Lean

Stern – Cut Part Directions for folding Part Number A. K. Verma 6/09 Lean Institute - ODU 12

Bulk Head – Cut Part A. K. Verma 6/09 Lean Institute - ODU 13

Bulk Head – Cut Part A. K. Verma 6/09 Lean Institute - ODU 13

Bow Deck Plate – Cut Part Stern Deck Plate – Cut Part A. K.

Bow Deck Plate – Cut Part Stern Deck Plate – Cut Part A. K. Verma 6/09 Lean Institute - ODU 14

Mid-Hull Deck Plate – Cut Part A. K. Verma 6/09 Lean Institute - ODU

Mid-Hull Deck Plate – Cut Part A. K. Verma 6/09 Lean Institute - ODU 15

Super Structure – Cut Part A. K. Verma 6/09 Lean Institute - ODU 16

Super Structure – Cut Part A. K. Verma 6/09 Lean Institute - ODU 16

Activity Involved in the Plate Shop • Receives steel plates from the Plasma cutting

Activity Involved in the Plate Shop • Receives steel plates from the Plasma cutting shop • Bends the parts along the dotted lines using the instructions given in the instruction sheet • Sends the parts to the welding shop A. K. Verma 6/09 Lean Institute - ODU 17

Bow – Bent Part Bow Deck Plate – Bent Part A. K. Verma 6/09

Bow – Bent Part Bow Deck Plate – Bent Part A. K. Verma 6/09 Lean Institute - ODU 18

Mid – Hull – Bent Part Mid – Hull Deck Plate – Bent Part

Mid – Hull – Bent Part Mid – Hull Deck Plate – Bent Part A. K. Verma 6/09 Lean Institute - ODU 19

Bulk Head – Bent Part Stern – Bent Part A. K. Verma 6/09 Lean

Bulk Head – Bent Part Stern – Bent Part A. K. Verma 6/09 Lean Institute - ODU 20

Stern Deck Plate – Bent Part Super Structure – Bent Part A. K. Verma

Stern Deck Plate – Bent Part Super Structure – Bent Part A. K. Verma 6/09 Lean Institute - ODU 21

Activity Involved in the Welding Shop • Receives bent plates from the Plate shop

Activity Involved in the Welding Shop • Receives bent plates from the Plate shop • Welds (gluing/taping) the plates along the length of the joints and then assembles the parts • All the parts are joined to build the final assembly A. K. Verma 6/09 Lean Institute - ODU 22

Welding and Final Assembly of Bow A. K. Verma 6/09 Lean Institute - ODU

Welding and Final Assembly of Bow A. K. Verma 6/09 Lean Institute - ODU 23

Welding and Final Assembly of Mid-Hull A. K. Verma 6/09 Lean Institute - ODU

Welding and Final Assembly of Mid-Hull A. K. Verma 6/09 Lean Institute - ODU 24

Welding and Final Assembly of Stern A. K. Verma 6/09 Lean Institute - ODU

Welding and Final Assembly of Stern A. K. Verma 6/09 Lean Institute - ODU 25

Welding of Super Structure A. K. Verma 6/09 Lean Institute - ODU 26

Welding of Super Structure A. K. Verma 6/09 Lean Institute - ODU 26

Final Assembly of the Ship A. K. Verma 6/09 Lean Institute - ODU 27

Final Assembly of the Ship A. K. Verma 6/09 Lean Institute - ODU 27

Day – 2: Design Calculations In the first set of calculations students are required

Day – 2: Design Calculations In the first set of calculations students are required to calculate: • Weight of the ship • Weight of displaced water • Draft of the ship and • Kinetic Energy of the ship * The formulae and instructions for calculations are given to the students * A. K. Verma 6/09 Lean Institute - ODU 28

Q 1. Calculation of Weight of the Water Displaced by the ship Weight of

Q 1. Calculation of Weight of the Water Displaced by the ship Weight of displaced water = Weight of loaded Ship = Weight of Ship+ Cargo Weight Step 1: Area of the Plates Step 2: Volume = Area*thickness where A = Area and t = thickness Step 3: Total Weight = Weight of the ship + Weight A of the containers • Weight of the ship = Sum of weight of each steel part • t Weight of the containers(1500 TEU containers) (Weight of 1 TEU container=24 tons) A. K. Verma 6/09 Lean Institute - ODU 29

Q 2. Calculation of Draft of the Ship 11. 83 10. 65 9. 47

Q 2. Calculation of Draft of the Ship 11. 83 10. 65 9. 47 8. 28 7. 1 5. 92 4. 73 3. 55 2. 36 00 60 0 00 50 0 00 40 0 00 30 0 00 20 0 00 0 13 12 11 10 9 8 7 6 5 4 3 2 1 0 0 Draft of the ship (m) Draft Calculation Chart Weight of Water Displaced(tons) A. K. Verma 6/09 Lean Institute - ODU 30

Q 3. Calculation of Kinetic Energy of Ship KE = ½ * m *

Q 3. Calculation of Kinetic Energy of Ship KE = ½ * m * v 2 We know, 1 kg = 9. 8 N 1 Ton = 9800 N Weight = m * g Therefore, m = weight/g where g = 9. 8 m/s 2 A. K. Verma 6/09 Lean Institute - ODU 31

Sample Student Worksheets A. K. Verma 6/09 Lean Institute - ODU 32

Sample Student Worksheets A. K. Verma 6/09 Lean Institute - ODU 32

Area Calculations - Bow A 1=A 3 A 4=A 6 A 2 A 5

Area Calculations - Bow A 1=A 3 A 4=A 6 A 2 A 5 Area of Bow= A 1+ A 2+ A 3+ A 4+ A 5+ A 6 = _____sq. mm = ______sq. m A. K. Verma 6/09 Lean Institute - ODU 33

Hull Plate thickness: 5 cm and Deck Plate thickness: 2. 5 cm Part Name

Hull Plate thickness: 5 cm and Deck Plate thickness: 2. 5 cm Part Name Area of paper boat (m 2) (1) Area of original ship (m 2) Thickness (m) (1 m=100 cm) (2) = (1) *(400)2 (3) Volume (m 3) (4)=(2)*(3) Weight of Each part (kg) (5)=(4)*density of steel (Density of steel=7800 kg/cu. m) Bow Bulk Head Bow Deck Plate Mid Hull Bulk Head Mid Hull Deck Plate Stern Bulk Head Stern Deck Plate Super Structure A. K. Verma 6/09 Lean Institute - ODU 34

Calculation’s of Weight of the Ship Part Name Area of paper boat (m 2)

Calculation’s of Weight of the Ship Part Name Area of paper boat (m 2) (1) Area of original ship (m 2) (2) = (1) * 400)2 Thickness (m) (1 m =100 cm) (3) Volume (m 3) (4)=(2)*(3) Weight of Each part (kg) (5)=(4)*density of steel (Density of steel=7800 kg/cu. m) Bow Bulk Head Bow Deck Plate Mid Hull Bulk Head Mid Hull Deck Plate Stern Bulk Head Stern Deck Plate Super Structure . 0212. 0031. 0082. 0327. 0063. 0153. 0169. 0031. 0071. 0092 3392 496 1312 5232 1008 2448 2704 496 1136 1472 . 050. 025. 050 169. 6 12. 4 32. 8 261. 6 25. 2 61. 2 135. 2 12. 4 28. 4 73. 6 1, 322, 880 96, 720 255, 840 2, 040, 480 196, 560 477, 360 1054, 560 96, 720 221, 520 574, 080 Total weight of the Steel Plates =6, 336, 720 kg A. K. Verma 6/09 Lean Institute - ODU

Calculation of Weight of Water Displaced by the Ship Sum of weight of each

Calculation of Weight of Water Displaced by the Ship Sum of weight of each part = _______ kg = _____ tons Weight of steel used is approximately 50% of the weight of ship Therefore, the weight of the Ship = ______ tons Weight of 1 TEU container = 24 tons Weight of 1500 TEU containers = ________ tons Therefore, weight of water displaced by the ship = Weight of the Ship + Weight of the Containers = __________ tons A. K. Verma 6/09 Lean Institute - ODU 36

Q 2. Calculation of Draft of the Ship - Sample 11. 83 10. 65

Q 2. Calculation of Draft of the Ship - Sample 11. 83 10. 65 9. 47 8. 28 7. 1 5. 92 4. 73 3. 55 2. 36 00 00 60 0 Weight of Water Displaced(tons) 50 0 00 40 0 00 30 0 20 0 10 0 00 13 12 11 10 9 8 7 6 5 4 3 2 1 0 0 Draft of the ship (m) Draft Calculation Chart For example: The draft for the corresponding weight of water displaced (shown by the arrow) is 4. 73 m A. K. Verma 6/09 Lean Institute - ODU 37

Calculation of K. E of the Ship KE = ½ * m * v

Calculation of K. E of the Ship KE = ½ * m * v 2 Cruising speed = 26 knots (1 knot =. 514 m/s) V = ______ m/s We know, 1 kg = 9. 8 N, 1 Ton = 9, 800 N So, 48, 684 tons = _______ N Weight = m * g (g= 9. 8 m/s) m = ________ kg KE = _________ J A. K. Verma 6/09 Lean Institute - ODU 38

Quality Assessment Shipyard Operations will be assessed based on the following quality characteristics •

Quality Assessment Shipyard Operations will be assessed based on the following quality characteristics • Cutting on the solid lines • Cutting the corners and intersections properly • Gluing the joints properly • Hull alignment • Bends are straight and creased A. K. Verma 6/09 Lean Institute - ODU 39

Wrap-up • Make sure all the items are put back in the kit box

Wrap-up • Make sure all the items are put back in the kit box and returned to the teacher. • Please clean the working area. A. K. Verma 6/09 Lean Institute - ODU 40