Product Work Breakdown Structure (PWBS)

Product Work Breakdown Structure
(PWBS)
© A.Y.Odabaşı 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
Work Efficiency
WORK
x 100 %
WORK + WASTE
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 ?

15 % Breakdowns and stops
15 % Personal allowances
15 % Technical allowances
15 % Manual time
Utilization 40 % 40 % Machine time
Definitions
MACHINE TIME
Machine UTILIZATION =
TOTAL AVAILABLE TIME
USED MANHOURS
Personnel PRODUCTIVITY =
TOTAL QUANTITY
ALLOCATED MANHOURS
Project PERFORMANCE =
USED MANHOURS
Process Re-enginering
The goal: is to decrease the the amount of waste in any work process
Before After
Work Waste More work

A in the same
amount of time
Waste Work
Work Work Same amount

B of work
in much
Waste Waste 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 3h 25 min.
Process cycle time should be 1h 15 min.
• Reliability : Do outputs always meet customer approval?

Customer always wants zzzz
Customer usually gets z z
• Cost : Are process costs acceptable ?
Process costs $ 55 per output
Process should cost $ 36 per output
Production Flow - Shop Floor
Plate Plate
Cutting Forming
Curved Panel
Line
Profile
Forming
Steel Shotblasting &

Stockyard Priming
Web & Comp. Block

Line Construction
Profile Miscellaneous
Cutting Assemblies
Large Panel &

Double Bottom
Line
Small Panel
Line
Main Activities in Ship Construction - Functional Approach
Ship
Hull Form Hull Machinery Outfit ------

Structure
Shell Bulkheads Decks ------

Plating
Main Auxiliary ------

Machinery Machiney
Piping HVAC Mechanical Electrical ------
Frame Profile & ------

Body Plan Buttocks
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]
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
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]
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
Product Oriented Work Breakdown Structure - Requirements
Hull construction
Type of work Outfitting
Painting
Material
Resources Manpower
Facilities
Control of Product Structure (Zones)

Production Work Type (or system based)
Process Work Stage
Components of Integrated Hull, Outfitting and Painting (IHOP)
Product Work
Breakdown Structure
(PWBS)
Pipe Piece Family

Manufacturing
(PPFM)
Hull Block
Zone Outfitting Method Zone Painting Method
Construction Method
(ZOFM) (ZPTM)
(HBCM)
Integrated Hull, Outfitting and Painting (IHOP)
•The ship is dived and subdivided into blocks Blocks:

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

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

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

HMCM •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

ZOFM •Better and safer work conditions
•Easy supervision of work
•Reduced idle time
•Maximum amount of down hand or vertical plane paint work

ZPTM •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

PPFM 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
Complete hull is considered as a zone;

Hull fore, hull, aft hull, cargo hold, engine room, superstructure;
Erection work stage:erection, test
Post-block assembly stage;

Grand-block two or more block assemblies are joined
Joining to create a larger block;
work stage:joining, pre-erection
Main Work Flow
Block Block “BLOCK” = KEY ZONE
Assembly Assembly Flat, curved, superstructure blocks;
work stage:joining, assembly, back assembly
Semi-block Pre-block assembly stage;

Assembly assists to assemble
partial zones to main block
Assembled structural parts

Sub-block Sub-block (e.g. transverses, girders, floors)
Assembly Assembly work s.: assembly, back assy.
Part Part Part Part Built up sections

Assembly Assembly Assembly Assembly or stiffened brackets
work s.: assembly, bending
Part Part Part Part Part Part Part Part Produce non-subdividable
Fabrication Fabrication Fabrication Fabrication Fabrication Fabrication Fabrication Fabrication components&piece parts;
work stages: marking,
cuting & bending
Production Stages – Steel Hull
Parts Fabrication
Marking & cutting -

Marking NC Machine
Line Heating Press Bending
© A.Y.Odabaşı 2009 (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 Palletized sub-assemblies

a block assembly facility awaiting block assembly
Block Assembly
The first stage of flat-panel Block transportation with

block assembly heavy-lift transporters
Curved block assembly on Block assembly shop

an adjustable pin jigs with process lanes
Hull Erection
Pyramid erection system -

Keel laying - Past !! outfitted and painted blocks
Erection of machinery-space blocks Erection of stern block containing

rudder horn
Zone Outfitting Method (ZOFM) Manufacturing Levels
Testing of outfitted units

Operation
& Test
On-board Outfit work carried out on the hull of the ship

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

Outfitting are fitted to the structural blocks
defined by the HBCM
Main Work Flow
Semi-block Manufacturing level for
Assembly on-unit outfitting work
Manufacturing level for

Grand-Unit Grand-Unit on-unit outfitting work)
Assembly Joining
Unit Unit Unit Unit “UNIT” = KEY ZONE

Assembly Assembly Assembly Assembly Manufacturing level for
on-unit outfitting work
The work packages and

Component Component Component Component Component Component Component Component material requisition for
Procurement Procurement Procurement Procurement Procurement Procurement Procurement Procurement
component procurement
are grouped by zone & area
Outfit Components
100 foot diameter LNG sphere
Nuts & bolts
Ventilation ducts Cables; pre-cut, identified and palletized
On-Unit Outfitting
1) Tack welded supports for pipe unit 2) A pipe piece secured to supports
on a platen with U bolts
4) Completed pipe units

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

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

On-board outfitting pipes are in alignment
On-board outfitting On-board outfitting - traditional way
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.
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
Zone Painting Method (ZPTM) Manufacturing Levels
Final stage in the ZPTM;

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

Finish Finish (masts, cargo booms, hatch covers),
Under-coat Under-coat application of anti-corrosive paints
Paint Paint
Application of
Primer Unit anti-corrosive paints
Primer Primer Primer Assembly
Surface preparation
Shop Shop Shop and primer coating
Primer Primer Primer for plates and sections
Zone Painting
Priming of steel plate
An extensivelt outfitted and painted block
Pipe Piece Family Manufacturing Method (PPFM) Manufacturing Levels
Grouping of pipes according to

Palletizing the requirements for a specific pallet
(e.g. Hull, machinery, superstructure)
Pickling and coating

Coating of pipe assemblies
Checks for quality

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

Joining branch pipe sub-assembly
to produce pipe assembly
Flange and collar attachment

Pipe Piece Pipe Piece (excludes joining of main
Assembly Assembly and branch assemblies)
Pipe Pipe Pipe Marking, cutting and

Fabrication Fabrication Fabrication machining of pipes
Pipe Pipe Pipe Pipe Pipe Different arriving

Receiving Receiving Receiving Receiving Receiving materials are grouped
according to the
type of material
Pipe-Piece Family Manufacturing
PPFM Classification :
Straight
Pipe receiving area
PPFM Classification:
Unit assembled
Palletizing areas
PPFM Classification: Penetrations
Integrated Schedule for Hull Construction, Outfitting and Painting
Principle Event
Schedule
Integrated Hull Construction

Block Erection Block Assembly
Outfitting & Painting
Master Schedule Master Schedule
Master Schedule
On-board Outfitting On-unit Outfitting On-block Outfitting

Master Schedule Master Schedule Master Schedule
Monthly Schedule Monthly Schedule Monthly Schedule
Weekly Schedule Weekly Schedule Weekly Schedule
Hull Construction Progress
Producibility
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
Reduce labor cost by on its desired capabilities
reducing number of steps
to perform the task like size, speed, displacement,
payload, stability, strength etc.
Reduce the number of
piece parts varity
Incorporate
standardization
Increase repetitive jobs
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.
Building Progression: Keel Laying + days
PWBS - Erection Level
11
Landing the Block 13
Engine-room Tank-top blocks 15
PWBS - Erection Level Building Progression: Keel Laying + days
Blue sky outfitted control
19
console and diesel generators
Landing the Cant Block 22
Landing the grand block 22
24
Landing the main engine 24
Landing the aft superstructure
half
27
Finish paint application to the
28
undersides of hatch-covers
Aft half of superstructure being
fitted
29
Landing the aft half of
superstructure on board
29
PWBS - Operation and Test Level
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 Delivery
43
Start
workdays in
Fabrication
Keel Laying
building dock !!!

Product Work Breakdown Structure (PWBS)

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Product Work Breakdown Structure

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

• Efficiency :the degree of effectiveness as it applied to a process

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

• Reliability : the consistency of an output

• Rework : any unnecessary, repeated operational steps

• Work : actions that move a process forward or directly add value

• Work efficiency : a mathematical expression of how much work versus waste

What is AVAILABLE time ?

Utilization 40 % 40 % Machine time

Work Waste More work

Work Work Same amount

• Effectiveness : Do outputs meet customer requirements ?

• Reliability : Do outputs always meet customer approval?

Steel Shotblasting &

Web & Comp. Block

Large Panel &

Hull Form Hull Machinery Outfit ------

Shell Bulkheads Decks ------

Main Auxiliary ------

Piping HVAC Mechanical Electrical ------

Frame Profile & ------

A technique for manufacturing

•Reduction in engineering drawings

•PWBS provides indentation levels within production tree structure

Control of Product Structure (Zones)

Pipe Piece Family

•The ship is dived and subdivided into blocks Blocks:

•Works in conjunction with HBCM On-unit

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

•The ship is dived and subdivided into blocks

•Outfitting and installation work in closed & covered areas

•Maximum amount of down hand or vertical plane paint work

•Large variety pipe-piece parts with number of common elements can be

Complete hull is considered as a zone;

Post-block assembly stage;

Semi-block Pre-block assembly stage;

Assembled structural parts

Part Part Part Part Built up sections

Marking & cutting -

Line Heating Press Bending

Assembly of small sub-blocks

A completed sub-block being moved to Palletized sub-assemblies

The first stage of flat-panel Block transportation with

Curved block assembly on Block assembly shop

Pyramid erection system -

Erection of machinery-space blocks Erection of stern block containing

Testing of outfitted units

On-board Outfit work carried out on the hull of the ship

On-block On-unit and grand-unit outfitting assembly

Manufacturing level for

Unit Unit Unit Unit “UNIT” = KEY ZONE

The work packages and

100 foot diameter LNG sphere

Nuts & bolts

Ventilation ducts Cables; pre-cut, identified and palletized

4) Completed pipe units

Fitting out of electrical cable trays

View of outfitted block

Flanges for large & medium diameter

On-board outfitting On-board outfitting - traditional way

Outfit units which are dissimilar in arrangement and in

Unit : Standard Machinery Unit