bluuebunny/crossref_metadata_2025 huggingface dataset:
Benefits of the National Shipbuilding Research Program to the Navy and the Industrial Base: Part 2—Industry Perspective
Authors: Brasher J. W.
Published: January 2021

The National Shipbuilding Research Program, a joint venture of the marine industry, the U.S. Maritime Administration and the U.S. Navy, is a mature and successful program. As a direct result of this program, major savings in ship acquisition costs have been realized. Today, participation and funding issues which could decimate the entire program are before the committee. If we are to continue to be successful in lowering ship acquisition costs and saving the taxpayer millions of dollars, these challenges must be overcome.
Discussion to Rinehart, Brasher, and Christensen: “Benefits of the National Shipbuilding Research Program to the Navy and the Industrial Base”
Authors: Nelson Perry W.
Published: January 2021

The authors of this most important paper are to be commended on their excellent presentation of a most important topic. The paper carefully identifies areas where research and development have resulted in improved productivity and reduced costs. The incentives to such development are the greatest when they result in the user gaining a competitive edge. In the case of the shipbuilding industry, the Navy's effort to acquire a 600-ship navy has provided such an incentive. As has been pointed out in the paper, the industry has responded with an impressive number of improvements.
Simulation for Shipyard Performance Analysis
Authors: Hatley John F.
Published: January 2021

Shipyard management operations require a continuous balance between ongoing vessel repairs and scheduling, while maintaining the best possible service levels in response to owners' needs and high rates of facility utilization. To maintain this desirable equilibrium between service demands and plant capacity, operations needs to monitor daily work loads and to develop a larger planning horizon. Simulation is presented in this paper as a tool employed to gain an overall operations perspective by analyzing, from a macroview, the utilization rates for shipyard facilities and attendant service levels provided to ship owners. The effects of market shifts or facility orientation are investigated in five "what if?" scenarios and analyzed by computer-based discrete simulation methods to predict how demand variations will be reflected in yard performance levels. The results show that simulation is a valuable information source for management during the planning and operation of a ship repair facility, providing a concise look at overall operations and focusing on bottlenecks affecting shipyard performance.
The Benefits of a Modified-Chemistry, High-Strength, Low-Alloy Steel
Authors: West John C.
Published: January 2021

Steels with 50 ksi and up yield points usually acquire their strength from some form of heat treatment. Most of these steels, 11/2 in. thick and up, must be welded using sustained preheat and controlled interpass temperatures, plus controlled welding heat input of approximately 50 to 60 kJ/in. These two items can add as much as 50 percent to the cost of submerged-arc welding, and increases of up to 30 percent are common for manual welding when compared with lower-strength steels previously used. To reduce costs, a quenched and precipitation-hardened steel, ASTM A710 Grade A Class 3, with a high degree of weldability, was tested. This steel, which can be welded without sustained preheat and almost unlimited heat input, has been extensively tested in thicknesses from 21/4 through 6 in. Although this steel costs more than the usual quenched-and-tempered plates at these strength levels, reductions of 40 to 75 percent in welding labor costs are probable. In addition, sizeable material savings should be realized when these items are used in place of HY-80 and HY-100.
Interim Products and Concepts of Their Management
Authors: Bartlett Francis G.
Published: January 2021

This paper discusses the progress leading to the development of interim products and proposes their division into four different types of increasing complexity. Database records prepared for each interim product and their material kits are introduced for use in a management system to direct the movement of materials through work stations and to record all administrative data needed to ensure that the vessel will be built within estimates of labor and materials and within the contracted time. In addition, the records of materials, of material kits and of simple interim products are searched and sorted, using database programming, to find items having similar repetitive work processes. Those aforementioned items having these characteristics are collected into groups for their manufacture in specially equipped work stations of a ship's production system. The commercial shipbuilding practices forming the basis for the majority of available references have favored the paper's emphasis on merchant ship construction. Most of the ideas presented can be readily applied to naval shipbuilding.
Unit Work Guide for Zone Outfitting in Repair and Overhaul
Authors: Kjerulf Shel
Published: January 2021

This paper compliments one previously published to describe Puget Sound Naval Shipyard (PSNS) progress in substituting zone for system logic for alteration, overhaul, and repair of U.S. Navy ships. More specifically, progress is tracked through development of a different way of grouping information to facilitate zone by stage implementation of work [1].2 The zone logic was extracted from a series of National Shipbuilding Research Program (NSRP) publications. Understanding by shipyard managers was enhanced by seminars followed by the July 26, 1983 presentation to the management luncheon by L. D. Chirillo, chairman of SNAME Ship Production Panel SP-2 and the program manager for the outfitting and production aids category of the NSRP. The NSRP publications particularly exploited are given in references [2–4].
The Effect of Welding Cables on Production Schedules and Costs: A Case Study
Authors: Agee Marvin H. , Jones Marilyn S. , Galgocy Chris B.
Published: January 2021

A detailed study of present welding cable production/repair operations was performed in an attempt to reduce the costs associated with production downtime due to defective manual arc welding cable resulting from copper inclusions in the cable and connectors. The paper discusses surveys used to obtain information from 14 commercial and naval shipyards concerning their present methods of manufacturing/repairing and management of manual arc welding cable sections. The results of the surveys and shipyard visits are summarized. The paper presents a detailed analysis of the various welding cable connectors used by the 14 shipyards responding to the survey. The connectors were evaluated from the standpoints of automation potential and economic life. In regard to cable manufacture/repair and procedures, and the welding support organization, general management practices observed in various shipyards visited are reported. A few general comments on methods engineering aspects of the procedures involved in the manufacture/repair of cable sections are given. While welding cable may seem to be a trivial part of the production process, the mismanagement of this area can have a significant impact on production schedules and costs.
The Streamlining of Navy Procurement Specifications
Authors: Piersall Charles H. , Sinche Charles J.
Published: January 2021

The Department of Defense has instigated a number of initiatives to reduce the time, risk, and costs associated with developing, producing and maintaining weapon systems. These initiatives are not standalone policies, but have definite interrelationships that need to be addressed and developed into a cohesive policy. This paper provides a brief discussion of some of these initiatives and how they have been implemented in various shipbuilding programs. The authors hope that some of their forecasts for future acquisition techniques will stimulate discussion and lead to the development of the cohesive acquisition policy that the Navy requires.
Competitive Bidding in the Shipbuilding Industry: Strategies and Decision Modeling
Authors: Friis Dag A.
Published: January 2021

Competitive bidding as experienced by the shipbuilding industry is examined. An overview is given of the analytical tools available for development of "optimal" bidding strategies. This is done by examining ways in which competitive bidding situations can be analyzed. The contract negotiation aspects as well as the sealed bid submission aspects are examined. A brief review of existing work in the area of sealed bid strategy modeling is given. A comparison with bidding conditions encountered in the construction industry is made to establish the degree to which the shipbuilding industry can use decision models developed specifically for construction contract bidding. Finally a Bayesian strategy decision model is developed. This model is designed to allow the shipbuilder to incorporate his own evaluation of all aspects of the tender. The evaluation can be based on analysis of competitor behavior in similar bidding situations, or it can be based on subjective evaluation of the present situation alone. The model is designed in such a way that features other than vessel price may be taken into consideration. These other features could include such factors as the shipyard's ability to meet the desired delivery time, the quality of its design, the standard of its workmanship, and the financing terms offered. The shipyard's performance in these areas is expressed relative to the performance of its competitors.
Minimum Inspection Costs in a Process Lane
Authors: Vickers P. W. , Perakis A. N.
Published: January 2021

A study was undertaken to explore methods for determining the minimum cost of inspection in a process lane. A literature review revealed dynamic programming could be effectively applied to determine minimum inspection and repair costs. It is shown that in a product-oriented work breakdown system, the level of inspection can be treated as an "all or none" decision. A program to determine inspection stations within a process lane is given.
IHI’s Experience of Technical Transfer and Some Considerations on Further Productivity Improvement in U.S. Shipyards
Authors: Sasaki Hiroshi
Published: January 2021

Ishikawajima-Harima Heavy Industries Co., Ltd. (IHI), a leading shipbuilder in Japan, has uniquely exported shipbuilding technology throughout the world for three decades. North American efforts, starting in the mid-1970's, were stimulated by the U.S. Government/industry National Shipbuilding Research Program (NSRP). The technology transfer, for which the U.S. Maritime Administration deserves much credit, has significantly modernized and improved U.S. shipbuilding systems with carryover into naval shipyard operations for overhaul of all types of warships. But, productivity levels achieved thus far in the United States, while impressive, are not nearly as great as those in Japan. This paper is based on analyses of the underlying differences of shipbuilding systems, technology, and practices between those in Japan and in the United States. It is hoped that descriptions of the state-of-the-art IHI technology will serve as guidance for further productivity improvements in the United States.
Implementation of Total Quality Management at Pearl Harbor Naval Shipyard
Authors: Damon Gerry A.
Published: January 2021

This paper discusses the strategy and methods used at Pearl Harbor Naval Shipyard to apply Dr. W. E. Deming's 14 management principles to the complex world of ship overhaul and repair. The purpose of Total Quality Management is to improve quality, and thereby reduce costs, and increase productivity, thus improving Pearl Harbor's competitive position in the market. A brief, general history of process control is given as well as a close examination of the current management and overall conditions at Pearl Harbor. The interdependent roles of top management, middle management, the union, and consultants are evaluated, and areas for improvement are examined.
Novel Techniques and Their Applications for Measuring Out-of-Plane Distortion of Welded Structures
Authors: Masubuchi Koichi , Luebke William H. , Itoh Hiroshi
Published: January 2021

Whether or not a certain-amount of planar distortion is critical, a point of consistency in the ship fabrication process is the need to accurately assess an existing degree of distortion in both local and global domains. At the Massachusetts Institute of Technology, three novel measurement devices have been developed as an adjunct to ongoing research. Distortion can now be evaluated either through laser interferometry, low-power laser beam triangulation, or direct surface contact. In addition to describing the operation and construction of the devices, this paper details their particular applications from a ship production/plate forming perspective.
The Use of Computer Simulation of Merged Variation to Predict Rework Levels on Ship's Hull Blocks
Authors: Storch R.L. , Giesy P.J.
Published: January 2021

In the modular construction of ships, significant productivity losses can occur during the erection stage, when the modules, or hull blocks, are joined together. Frequently, adjacent blocks do not fit together properly, and rework of one or both of the mating block interfaces is necessary to correct the problem. The specific cause of rework is the variation of plate edges at the block interface, which is itself a cumulative product of numerous manufacturing variations inherent in hull block construction. Variation in manufacturing is unavoidable, but not uncontrollable. The application of accuracy control techniques in shipbuilding has proven that a statistical analysis of variation makes possible an accurate prediction of its effects. This paper presents an examination of block interface variation, and the subsequent development of a computer simulation method of predicting rework levels on those blocks. The complex interaction of all the edges' random variations at the block interface gives rise to a unique rework probability distribution. This probability distribution is evaluated by means of the computer simulation program, which provides estimates of the average rework anticipated, the shape of the probability curve, and other parameters. Similar predictions are also available for cost and labor of required rework. In addition to predicting rework levels, the simulation program can be a useful tool for reducing those levels.
Implementation Plan for Flexible Automation in U.S. Shipyards
Authors: Whitney Daniel E. , De Fazio Thomas L. , Gustavson Richard E. , Nevins James L. , Stepien Thomas M.
Published: January 2021

This paper, commissioned by Panel SP-10 of the Ship Production Committee, surveys current design and automation practice in the shipbuilding industry and recommends a systematic approach to productivity improvement through flexible automation. Flexible automation in this context is not limited either to robots or to fabrication issues. It covers any equipment that can deal with a class of similar jobs. It can be applied to associated automation opportunities in design, production planning, outfit planning, measuring, data analysis, process improvement, and other areas that support fabrication, account for a large part of construction cost, and can benefit greatly from automation. New construction, overhaul, repair, and modernization can all benefit. Before one can effectively bring automation technology to bear, it is essential to gain increased understanding of planning and fabrication processes, and to rationalize design, fabrication, and outfitting. The best roadmap for accomplishing this lies in zone design/ construction and the concept of the interim product. Following this roadmap will encourage the necessary coupling between customer, designer, planner, and fabricator. An essential feature of enhanced productivity, and a requirement for automation, is rationalization of designs and processes. Even if there is little or no actual automation, this rationalization itself will save money and time, direct and indirect labor, initial work time, and rework time.
A Study of the Construction Planning and Manpower Schedules for Building the Multipurpose Mobilization Ship, PD214, in a Shipyard of the People's Republic of China
Authors: Bunch Howard M.
Published: January 2021

This paper presents the results of a study for building five PD214 ships in a shipyard of The People's Republic of China. The study was performed by the author in 1987 at the Zhenjiang Shipbuilding Institute, the People's Republic of China. A comparison of shipbuilding planning and resource expenditure estimates is made for building a series of identical ships in an advanced shipyard in the United States and in the People's Republic of China.
User’s Perspective of CAD/CAM Software
Authors: Shields R. V.
Published: January 2021

Great emphasis has been attached to the achievement of productivity and producibility benefits through the application of computer-aided design and computer-aided manufacturing (CAD/CAM) technologies. To ensure the achievement of these benefits, it is important that the end user have appropriate software and be able to use it to his advantage. The proper procurement, customization, installation, training, and implementation of software can play a significant role in the effectiveness of CAD/CAM.
Soviet Technique for Estimating Post-Welded Deflection: Case of Butt Welding
Authors: Birman V. , Latorre R.
Published: January 2021

The hulls of modern ships are almost entirely welded. This makes the prediction of post-welded deformations very important. The number of parameters involved in the process of welding is large, so the exact mathematical theory for prediction of deformations is unavailable. Some researchers have estimated the post-welded deflections based on empirical and semi-empirical equations. The growing literature on the study of postwelded deflections of hull plates enables the estimation of these deflections based on the plate geometry and the plate material. The limited number of critical parameters covered by these experiments makes it difficult to organize the data systematically. This has delayed the introduction of a framework for estimating the influence on the plate deflection from welding speed, current, number of passes, welding rod size and material, etc. The approach adopted in the U.S.S.R. was to develop an integrated framework to include the critical welding parameters. The main results from this approach were published in several books, with the main reference being a book by Kuzminov published in 1974. From the standpoint of ship production, it is useful to understand this Soviet approach as well as to give examples of its use. Therefore, this paper introduces the Soviet procedure for calculation of deflection due to butt welding, presents the graphical aids used in this procedure, and presents a worked example using this procedure for a butt welded plate.
Applications of Digital Transfer of Computer-Aided Design Data for Production Usage
Authors: Streiff M. A. , Cada D. G.
Published: January 2021

This paper addresses efforts to provide the capability to transfer data between computer-aided design (CAD) systems currently in use on the CG 47 contract. The paper discusses experience with the use of Initial Graphic Exchange Specification (IGES) and direct translators. The pros and cons of both approaches are addressed. The issue of transferring data between the two different hull-design and lofting systems in use in shipbuilding is explored.
Multiskilled, Self-Managing Work Teams in a Zone-Construction Environment
Authors: Stravinski Daniel J.
Published: January 2021

This report documents National Steel and Shipbuilding Company's (NASSCO's) efforts to develop self-managing, multiskilled work teams. The objective of this effort was to develop and test a new production work force organization corresponding to the technical requirements of product-oriented work breakdown structure, otherwise known as zone construction. NASSCO was awarded a grant from the Human Resource Innovation Panel (SP5) of the SNAME Ship Production Committee in order to explore the benefits of this type of work force organization.
Product Work Breakdown: The Challenge to Production and Design Engineers
Authors: Chirillo Louis
Published: January 2021

In response to a request from the Australian Department of Defense (Navy), a product work breakdown (zone logic) was reintroduced into Australia in the Spring of 1988 for the benefit of the consortiums which are competing for the $5(A) dollar ANZAC Frigate Program. At the same time, this brief paper advised Australian naval architects and shipyard managers at large of the improved quality that is inherent in the application of zone logic, particularly for warships, and of what is required of designers. Special note is made of the need for professional and decentralized production engineering upon which product-oriented designers are absolutely dependent throughout all phases of the design process. A surprise for most readers, including some in Australia, is reference to the technical cooperation agreement which resulted in product-oriented shipbuilding in an Australian shipyard "a decade before" the same logic revolution started in North American shipyards.
Zone-Oriented Drawings for Life-Cycle Management
Authors: Wilkins James R.
Published: January 2021

This paper presents the results of a study conducted to determine whether unit-oriented construction drawings, which are being developed and used by shipbuilders using modern zone-oriented, or modular, construction techniques, will satisfactorily substitute for system-oriented detailed arrangement drawings in the Navy's life-cycle maintenance management process. The study concluded that modular construction drawings will provide the necessary data in a more usable format, and thus are the preferred approach for the Navy's use. However, the study also identified several additionally needed features that are not now being provided in unit-oriented drawings, but which must be included in order to meet the needs of planning and maintenance activities during the operational life of a ship. A number of other observations about drawing use and maintenance are provided.
An Integrated CAD/CAM Network for Work Packaging Development and Database Management
Authors: O'Hare M. S. , Anderson M. J.
Published: January 2021

The Zone Logic Technology CAD/CAM and networked Database Management System is an integrated system of commercially available, off-the-shelf computer hardware and software products. These products have been carefully selected, tailored, and integrated to specifically satisfy and support the Philadelphia Naval Shipyard (PNSY) Zone Technology Program in support of work packaging development, computer-aided graphics and an on-line, real-time, distributive database management system. The process used in publishing this paper serves as a small example of some of the capabilities of the system at PNSY. The entire document, including graphics, was generated on the system. Scanners, CAD and PC systems were utilized to input, develop and convert the graphics files into appropriate formats for import into a technical publications software package. LAN interconnection capabilities provided the option of developing portions of this document on different systems and at different locations with the ability to access the appropriate files remotely.
Product Work Breakdown: An Essential Approach for Ship Overhauls
Authors: Chirillo L.D.
Published: January 2021

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
As-Rolled High-Strength Plate Grades for Navy Shipbuilding Applications
Authors: Speer J. G. , Hansen S. S.
Published: January 2021

As-rolled high-strength, low-alloy (HSLA) steel plates offer a number of benefits compared with heat-treated plates, and this paper discusses laboratory and production experiments which have been conducted to develop as-rolled grades for high-strength Navy shipbuilding applications (for example, HSLA-65 and HSLA-80). A low-carbon niobium/vanadium microalloyed steel is shown to offer favorable combinations of strength, toughness, and weldability. The results indicate that an as-rolled grade which meets the current HSLA-80 strength and impact requirements can be produced in thicknesses up to approximately 19 mm (3/1 in.); HSLA-65 plates can be produced up to about 51 mm (2 in.) thick. This grade is generally weldable without preheat using HY-80 consumables.
The Use of Computers in Establishing a Company-Wide Perspective Toward Advanced Ship Production
Authors: Stewart Eric W.
Published: January 2021

When introducing product-oriented work breakdown techniques as the means of defining work within a shipyard, it is worthwhile to consider the use of computers and how they may be utilized to improve the success of this task. This paper addresses experiences gained and reflects on the systems in place in some of the shipyards within the United Kingdom.
First-Time Integration of Product by Stage of Construction with Cost/Schedule Control Application
Authors: Reid Matthew , Dougherty John J.
Published: January 2021

There is nothing upon which shipbuilding managers and planning theorists are more solidly agreed than the need to optimize the integration of a steel hull with the maximum outfitting that can be achieved at a point in time that considers the facility, material, and available manpower—in other words, OPPORTUNITY. Now, couple this OPPORTUNITY with a doorway through which a manager can enter the whole domain of Cost Schedule Control (C/SC) objectives. Through these objectives the manager has access to a system capable of dealing with the multiple dimensions of organizational and product performance. This paper addresses the successful integration of Product by Stage of Construction (P/Sc) with the fundamental principles of C/SC and the specific requirement to provide meaningful performance data in managing a major military defense program on schedule and within cost.
Results from Use of an Integrated Schedule for Drawing Development and Equipment Procurement
Authors: Wilkins James R.
Published: January 2021

As part of an SP-4 project, a computer program was developed to produce integrated schedules for drawing development of drawings and equipment procurement. The program also can be used either to develop a schedule for the fabrication and assembly stages of the construction process or to receive data from an existing construction schedule. In either case, the construction data are used to ensure that drawings are produced and equipment is purchased in time to support production planning. The program uses a commonly available database program, is suitable for use on a minicomputer, and will allow a network of terminals to be used to enter data and obtain reports. This paper reports on the results of applying this scheduling program to a simulated shipbuilding program and highlights a number of significant results. The principal result was to clearly demonstrate that planning for the purchase of equipment must take into account the needs of the ship design process for data about the equipment being procured.
Harnessing Simulation for the Naval Shipyard
Authors: White Cynthia V.
Published: January 2021

The advantages of computer simulation as a tool to analyze and solve problems in a wide spectrum of industrial applications are presented. The basic methodology is described and its usefulness to the special circumstances of a naval shipyard is demonstrated by analogy to a delicatessen, the processes of which serve as a discrete-event model system. Several recent successful applications of computer simulation are cited and reference is made to appropriate microcomputer software programs.
A Design-Oriented Model of Plate Forming for Shipbuilding
Authors: Hardt David , Wright Andrew , Constantine Edward
Published: January 2021

Ship designers as well as product designers in general are most concerned with the function and form of the design, and typically cannot pay adequate attention to the manufacturing consequences of their design decisions. Much of this problem can be alleviated by providing the designer with new tools that allow easy, yet thorough exploration of material and process options as part of the design process. This paper presents a prototype of such a tool, aimed at providing process information about bending and rolling of plate. The model presented is derived from first principles of mechanics and can provide a plethora of information. However, the unique aspect of this work is the development and presentation of design-oriented information, such as optimization tradeoffs of process/material selection, and process control options ranging from purely manual to mechanized to fully automatic.
Information System Models—as a Tool for Shipyard Planning and Control
Authors: Odabasi A. Y. , Patterson D. R.
Published: January 2021

This paper proposes the use of information system models of production as a tool to achieve rationalization and integration goals and to create a learning organization. It is shown that through use of these models it is possible to identify cost-benefit ratios for various rationalization and modernization tasks, and to create an action plan for their implementation. The proposed production information model aims at reducing every job into its smallest elements in the form of processes and activities as well as rationalizing the subjective concepts of complexity, size, quality, etc. through the use of metrics. The paper also discusses the increasing reality variance of accounting systems and proposes the introduction of single-factor and total-factor productivity for correct evaluation of operating performances and of investment decisions. While the model is generic enough to cover all eventualities, its application to specific yards requires additional tailoring to reflect the effects of layout, facilities, organization and labor resources on the yard performance. The paper suggests that adoption of such models avoids subsystem optimization or importation of methods and techniques which might have been successful in some other operation and yet may not be appropriate in given circumstances.
Combining Welding Expert Systems with Welding Databases to Improve Shipbuilding Production
Authors: Vanderverldt Hans H. , Johnston Sterling , Jones Jerald E. , White Dawn , Cleveland B.
Published: January 2021

Construction of a large ship requires many thousands of feet of welding. Whenever the welding process can be streamlined or automated, tremendous cost savings can be obtained. The WELDEXCELL system is a WELDing EXpert manufacturing CELL that provides computerized technical support information, off-line weld planning, and an integrated welding robot/welding system/vision system controller. The first of two subsystems, the Welding Job Planner (WJP) accomplishes off-line intelligent weld planning for both automated and manual welding processes. The second subsystem, the Welding Job Controller (WJC) provides a fully integrated hardware control environment with associated software for combined control of a welding robot, welding equipment, and a robotic vision system. In the WELDEXCELL system, a series of expert systems and databases have been combined in a new type of computer software environment called a blackboard. There are as many as 19 separate components of the Welding Job Planner subsystem of WELDEXCELL which fall into five interrelated functional groups. WELDEXCELL will be used by design engineers, welding engineers, mechanical engineers, and nondestructive testing (NDT) engineers for both manual welding and to interface to automated and robotic welding systems and vision systems. WELDEXCELL also includes the control system hardware and software to provide off-line intelligent adaptive control of the welding process itself. The development of WELDEXCELL is a multi-year effort involving a partnership of government, industry, university research, and technology transfer. The project has already generated new concepts with potential for future spin-off benefits. The ultimate payback in productivity will be large for the American welding, fabrication, manufacturing, and construction industries.
Advanced Industrial Measurement Systems for Productive Shipbuilding
Authors: Horsmon Albert W. , Lupica Charles J
Published: January 2021

Modern shipbuilders have embraced the concept of modular construction and are realizing the gains in productivity associated with this method. Further gains in productivity are achieved if these modules are built and erected "neat," that is, without the traditional excess material normally trimmed at erection. Construction of "neat" hull blocks requires rigid control of accuracy throughout the production cycle. Interim products, from fabricated parts to erected hull blocks, must be measured to acceptable tolerances to prevent excessive rework. This paper analyzes viable types of advanced measurement techniques supporting the process requirements of "neat" modular construction. Documentation of costs and difficulties associated with each measurement technique selected are also analyzed. The first part of the paper is a general description and analysis of the systems. The second part describes actual demonstrations of three measurement systems and analyzes them in the shipbuilding environment: digital theodolites, automated photogrammetry, and an optical laser system.
Value Analysis Applied to the Optimum Division of a Large Graving Dock Using a Slave Caisson
Authors: Hyland H. L.
Published: January 2021

Many large, older but still useful graving docks are no longer within the optimum configuration for handling modern vessels and workload schedules. Some require an intermediate caisson to subdivide the dock into two separate work areas. Others already have an intermediate caisson, but the divisible lengths are inappropriate. Sometimes a lightweight caisson can be installed, or the expense accepted in constructing a full-size new caisson grove. However, often such expense in both downtime and money is prohibitive. This paper examines the cost effectiveness of utilizing the novel concept of a slave caisson to achieve the optimum division of a graving dock, at the minimum cost and disruption to the facility.
Shipyard Modeling—An Approach to a Comprehensive
Authors: Brodda Joachim
Published: January 2021

The application of computer integrated manufacturing (CIM) to one-of-a-kind heavy engineering industries is one of today's most challenging tasks for industry and information technology (IT) vendors. Because of the complexity of the shipbuilding process, as a typical representative of this kind of industry, available solutions are not yet satisfactory. Even the basic theory of current CIM systems does not fit many aspects of requirements for the shipbuilding industry. The application of CIM tools, which are based on ideas of line production and have a strict sequence for all tasks, has very often failed in the past, mainly because of a lack of flexibility. Therefore, basic work needs to be performed, starting with a detailed analysis of today's situation and leading to a careful development for the real requirements of tomorrow. This paper deals with the problems resulting from the exceptional nature of shipbuilding for the application of CIM elements. The approach chosen for modeling of the production process, illustrated by some examples from actual research and development (R + D) projects, is described. An evaluation of the benefit of structured shipyard modeling and a look at complementary R + D actions conclude the paper.
TQM for Survival
Authors: Adams Gary
Published: January 2021

Naval shipyards face a declining workload in the nineties and beyond. Survival is a key issue. Total quality management (TQM) is one of the keys to survival. Being the best performer by focusing on customers' ever-demanding needs is the bottom line. Portsmouth Naval Shipyard has developed a TQM effort that allows improved performance, clearer communication, and focus on customer demands. Portsmouth's TQM model requires committed leaders, involves training for everyone, and calls for the building of teams to break down the functional barriers. It includes teams making incremental improvements in all of their work processes and dramatic improvements in the vital few work processes. It also listens to the voice of the customer.
Cost-Effective Planning and Control
Authors: Bruce George J. , Reay Kenneth
Published: January 2021

Situations have frequently been encountered where It Is necessary to reestablish control of a shipbuilding contract when it has been lost. This has to be done quickly, and requires a combination of an effective planning and control system with a computer for data processing. Expediency dictates the use of readily available PCs and proprietary software. The approach adopted was found to be robust and effective, and has been used as a basis for development of more formal planning and control systems. These are now in use as the means of planning and implementing ship production.
Shipboard Aluminum/Steel Welded Transition Joints: Evaluations and Improvements
Authors: Gaines Ed , Banker John
Published: January 2021

Aluminum-to-steel explosion-welded transition joints are used to attach aluminum superstructures to steel hulls. Transition joint bond separation sometimes occurs during ship construction. Ingalls Shipbuilding conducted a long-term study to determine causes and corrective action for these separations. Aluminum/steel transition joints are manufactured by the explosion-bonding process and tested in accordance with MIL-J-24445. Traditional transition joints consist of alloyed aluminum bonded to mild steel with an interlayer of low-alloy aluminum. The study reviews transition joint manufacture and quality testing required by material specification, adequacy of design guidelines and production practices, and cost-effective methods for corrective action. Modifications in product design and testing, installation design and shipyard production practices can improve reliability. The most important result of this study was development of material with improved properties. This paper relates the study procedure, findings and recommendations so that transition joint separations can be avoided on future installations. This information is useful for designers and transition joint users
Large-Scale Processing Machinery for Fabrication of Composite Hulls and Superstructure
Authors: Raymer John F.
Published: January 2021

Large-scale mechanical systems for impregnating and positioning composite materials are now permitting efficient manufacturing of composite hulls up to 60 m (200 ft) and greater. Recreational, commercial, and military vessels fabricated from composite materials are gaining acceptance around the world; however, processing of thermosetting resins and fiber reinforcements in quantities exceeding 90 000 kg (200 000 lb) per unit presents a new set of challenges to production engineers responsible for maintaining quality control. Impregnation systems are currently being used at several mine-hunter production shipyards worldwide. Large-to-medium sized recreational yachts are also in production with impregnation systems. This paper reviews some past and current impregnator installations, the selection process used for choosing the systems, and production engineering factors.
The Importance of Considering Life-Cycle Maintenance and Modernization Costs in the Design of Navy Ships
Authors: Bankes F.W. , Spicknall M.H.
Published: January 2021

Experience with maintenance and modernization (M/M) of Navy ships has shown that life-cycle maintenance and modernization costs can significantly exceed initial acquisition costs, particularly for submarines and complex surface combatants, as shown in Fig. 1. The purpose of this paper is to draw increased attention to the influence that initial ship design has on the cost of maintenance and modernization of Navy ships, and to emphasize the need for greater consideration of these costs in Navy ship design. This paper presents several examples of actual design-related maintenance and modernization problems, along with possible design solutions, identified through a survey of U.S. naval shipyards. The paper also provides recommendations for increasing consideration of maintenance and modernization costs in Navy ship design through education, through the development of specific communication interfaces between design and maintenance and modernization production functions, and through research.
CAD/CAM in Phased Maintenance
Authors: Carr Bruce A. , Houlihan Thomas M. , Polini Michael A.
Published: January 2021

The authors' company is a medium-sized engineering company specializing in naval ship repair. The bulk of corporate work centers on the Phased Maintenance (PM) of three classes of ships. Typically, each PM contract covers three to five different ships per class scheduled for 90-day Availabilities at approximately one-year intervals over a period of five years. The type of work to be performed during each Phased Maintenance Availability (PMA) falls into one of two categories: ship alterations or ship repairs. The first group, ship alterations, is characterized by detailed, long-lead engineering and planning efforts, typically beginning 540 days prior to the vessels's arrival. The second group, ship repairs, makes up the other end of the spectrum with short lead times and compressed service details. The majority of repair items are identified 60 days prior to an Availability, while some are not determined until after the vessel has arrived in the shipyard. The engineering department that services PMA work is composed of three disciplines: structural, mechanical and electrical. The mechanical discipline is further subdivided into the areas of machinery and piping/HVAC. While the nature of PMA work within each discipline is peculiar to the application, the process is similar in each. Reference information is gathered and verified, technical analysis is provided where necessary, and detailed drawings are prepared and submitted for Navy approval prior to shipyard production. All drawings are developed using two-dimensional drafting techniques at various sites by teams of computer-aided design (CAD) input operators utilizing color graphic workstations on a multi-shift basis as required by the workload. Completed drawings are transferred to the engineering site over a network link, where additional workstations are available for engineers to check and correct them as necessary
The Path to U.S. Shipbuilding Excellence—Remaking the U.S. into a World-Class Competitive Shipbuilding Nation
Authors: Frankel Ernst G.
Published: January 2021

U.S. shipbuilding has a unique opportunity now to reenter and compete profitably in world commercial shipbuilding. World shipbuilding demand is expanding rapidly and U.S. costs of most factors or inputs of production are today comparable to those of major shipbuilding countries. A path for regaining a U.S. commercial shipbuilding competitiveness is described and formal steps suggested which will be necessary to remake the U.S. into a world class shipbuilding nation. Many of the proposed steps will be painful, but similar steps have been taken by other U.S. industries, such as manufacturers of automobiles, steel, construction, electronics, and appliances. They are deemed necessary if U.S. shipbuilding is to survive as a viable industry under conditions of declining defense budgets, consistent federal budget deficits, and increasing importance of trade to the U.S. economy.
Solving SARA Compliance with Computerized Hazardous Materials Tracking
Authors: Johnston Don , Schoenleber Dave
Published: January 2021

The advent of the Superfund Amendment and Reauthorization Act (SARA) Title III, or the Emergency Planning and Citizen Right-to-Know Act (EPCRA) has forced facilities to keep track of hazardous materials as never before. EPCRA contains five major reporting requirements, including planning notification, emergency release notification, Material Safety Data Sheet (MSDS) submission, chemical inventory reporting, and toxic chemical release reporting. The complexity and vastness of these requirements all but require a computerized system for hazardous material management. Peterson Builders, Inc., developed a computerized hazardous materials management system capable of meeting the requirements of EPCRA. After one year of operation, the system has proven successful. This paper discusses Peterson Builders' experience in implementing the system, system design, and future considerations for the system.
Modeling for Ship Design and Production
Authors: Wollert Juergen , Lehne Markus , Hirsch Bernd E.
Published: January 2021

The flexible operating and changing of the complex one-of-a-kind shipbuilding environment has to be based on adequate concepts and instruments to handle the related controlling, planning and implementation tasks. Product modeling defines the physical and application driven product-related information. It is of basic importance to support this environment, especially the concurrent engineering functions, during the whole product life cycle. Process modeling supports the implementation and operation of complex CIM (Computer Integrated Manufacturing) oriented processes. In this paper some modeling applications within European shipbuilding research and development projects will be highlighted from the viewpoint of an integrated product and process modeling approach. The following projects referenced: NEUTRABAS (Neutral Database for Complex Multifunctional Systems) explores a broad application field of product information for ship steel structure and outfitting systems; ROCOCO (Real Time Monitoring and Control of Construction Site Manufacturing) develops a CIM application and demonstrates this application within the pipe outfitting environment of a ship berth construction site; and MARIN-ABC (Marine Industry Applications of Broadband Communication) demonstrates new applications and services in the maritime transportation business based on future mobile satellite networks.
Intelligent Automated Welding for Shipyard Applications
Authors: Madden S. , Vanderveldt H. H. , Jones J.
Published: January 2021

Computer Aided Process Planning (CAPP) integrated with Computer Aided Design (CAD) and Computer Aided Manufacturing (CAM) will form the basis of engineering/planning systems of the future. These systems will have the capability to operate in a paperless environment and provide highly optimized process operation plans. The WELDEXCELL System is a prototype of such a system for welding in shipyards. The paper discusses three significant computer technology advances which have been in into the WELDEXCELL prototype. First is a computerized system for allowing multiple knowledge sources (expert systems, humans, data systems, etc.) to work together to solve a common problem (the weld plan). This system is called a "blackboard." The second is a methodology for the blackboard to communicate to the human user. This interface includes full interactive graphics fully integrated to CAD as well as data searches and automatic completion of routine engineering tasks. The third is artificial neural networks (ANS's), which are based on biological neural networks (such as the human brain) and which can do neural reasoning tasks about difficult problems. ANS's offer the opportunity to model highly complex multivariable and nonlinear processes (for example, welding) and provide a means for an engineer to quantitatively assess the process and its operation.