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(TUGAS) Resume Shipyard Layout
(TUGAS) Resume Shipyard Layout
technology and to requirements for new types and larger sizes of ships. Changes in
the layout of shipyards were, in most cases, piecemeal. Many yards are a century
old and have been extended and revised with little opportunity for a complete
redesign commensurate with a total systems approach. The history of shipyard
layout can be divided into three distinct periods:(1) prior to World War II, (2)World
War II to 1960,and (3) from 1960to the present.The movement from the first to the
secondperiod coincides with the changeoverfrom riveting to welding in the late
1930s.The introduction of flow line techniqueswas primarily responsible for the
movementfrom the secondperiod to the third.
bulk carriers
oil, bulk, ore carriers (OBO)
roll-on/roll-offships(RO/RO)with complex ramps, doors, hatches, and
elevators, and high freeboard
barge carriers
cementand grain carriers equipped with specialized unloading
gascarriers (LNGILPG) which required highly advancedwelding systemsand
insulation
Shipyards specialized in one or more of these types of merchant ships in order to
attempt to gain a competitive edge in a specific ship building market.
Conventional Shipyard Layout in the 1960s and 1970s
Series production and further advances in modular construction, begun in the
postwar period, contributed to development of heavy-lift ground transport vehicles
and cranes. Cranes capable of lifts of 200 tons were fairly common, and some yards
were equipped with gantry cranes capable of lifting over 1,600 tons. Docks have
been built in several variations, including:
Graving docks are permanent structures totally excavated from existing land or built
up by dredgingand depositingmaterial (sand, rock, and concrete)alongthe
sidesofthe dock area (see Figure 5-11).End gates are either hinged or floating. The
former are hinged at the bottomandusually havea buoyantchamber at the top to
facilitate openingand closing. When a ship is beinglaunched,the dock is flooded and
the end gate is opened.The buoyant chamberis alsoflooded,enablingit to sink to the
bottom in the openposition to permit the vesselto float out of the dock.
Side-launch systems are particularly well suited where conventional stern-
launching shipways would bevery steepor where there is insufficient openwater for
stern launching (seeFigure 5-12). Side-launch ways have the advantage of the ship's
being level during erection .As in longitudinal shipways, vessels are built on
blocksand the weight shifted to groundways and sliding ways just prior to launch.
Plate Fitting: Plates are moved by rollers and chain conveyors to the fitting
station, where they are fitted together manually and tack welded.
Plate Welding: The panel is then conveyed to the seam butt-welding station
where adjustable copper backup bars are positioned according to the width of
the plates.
Marking and Cutting : Plate is marked and cut to size at this station. Marking
of panels is done after welding to allow for neat cutting (i.e.,to exact
dimensions)ofthe panel.
Egg-BoxAssemblies : In conjunction with the panel assembly,and along side
it, is another conveyor line where longitudinals and transverse frames are
positioned.
StiffenerSetting:The normal flow of panels is a straight line through the shop.
Stiffener and Egg Box: The stiffeners and egg-boxblock assemblies are
welded using gravity or automatic methods
Repair: Welding checks are made at the exit end of the shop, and any final
repairs are performed here.
Pipe suppliedby the digitally controlled cutter is conveyed to the assembly and
welding stage swhich are equipped with the following N/C controlled equipment:
AssemblyStage
(1) Piperobot
(2) Flangerobot
(3) Flangebolt hole detector
(4) Flangecheckingmachine
WeldingSystem
Process Lanes
Group technology ship building systems are based on the organization of
work into distinct problem areas,using a product-oriented work break down
structure. The shipyard facility should reflect this organization. The process
lane concept marries the work organization and the physical plant. The
process lane concept can be defined as "the categorization and separation of
similar types of work, and the subsequent development of work centers
specifically designed to efficiently performthat kind ofwork."
3.1 Physical Process Lanes
Figure 5-32 presents the layout of a U.S. shipyard that adopted a process
lane work organization. This existing shipyard was reorganized to apply this
concept. Six major block categories were chosen.
3.2.Process Lane Loading
The goal of uniform work flow, either actual or virtual, throughout the
shipyard should be sought at each work station. Process lane loading
involves attempts to achieve uniform work flow in as much of the
shipbuilding system as is possible.The practical approach to loading process
lanes therefore entails the establishment of a hierarchy