Trans RINA, Vol 156, Part C1, Intl J Marine Design, Jan - Dec 2014
VESSEL FIT OUT COST REDUCTION USING DIGITAL TECHNOLOGY AND MODULARITY
J R J Morgan, KPM-Marine Ltd, UK (DOI No: 10.3940/rina.ijmd.2014.c1.30)
SUMMARY
Inspired by WW2 liberty ship design and air craft interiors Sea-Ka-No (meccano) has been designed and developed for fast fit using modular standard parts. Interiors meeting and exceeding all regulation. The stylish and functional habitation and bridge systems can be fitted in hours rather than weeks. The interior of a vessel can be changed to another use within a day giving the operator vessel flexibility. The design methodology accounts for asset adaptability and extended operating life , whilst taking into account the budget, quality and lean, regulation, primary and secondary function ,modularity and regulation and legislation.
industries giving significant reductions in weight and improvement in performance. The paper details real
applications showing significant reductions in build cost and time whilst increasing the functionality and safety. 1.
INTRODUCTION
Lessons from history. The practice of modularity and standardisation in vessel construction is nothing new. The first recorded example was during the first Punic Wars (260-241 BC) between Rome and Carthage. Up to this date the dominant naval power in the Mediterranean was Carthage with some 300-400 ships and a highly developed port complex. Rome was primarily a land based force description [1].
with no Navy of
The paper also details materials and techniques used in other life
techniques eventually allowed Rome to dominate the Mediterranean
The same process was undertaken during the second world war with the introduction of the Liberty ships to the point that 3 complete ships were being delivered a day. The speed of delivery was also aided by adopting new technologies such as welding rather than riveting. However there were technical issues with cracking and the welds but mainly due to the untrained workforce. The lesson from history is that by new thinking and techniques vessels can be constructed very quickly by standardisation. Both these historical examples have been made in volume which justified the effort. Yet the technology
interconnectivity the principle of Design
available today with CAD and CNC for
Manufacture (DFM) for a “batch size of one” still is totally achievable.
In 260 BC the romans managed to capture a
Carthaginian Quinquireme that had run aground intact. The roman senate
decided to commission the
construction of 100 of these vessels to create their own fleet. The delivery time for all 100 ships was two months, and the delivery of all 100 ships where amazingly delivered on time.
The reasons that the romans could build the ships so fast was that the Carthaginians had standardised all aspects of the vessels, and every part and joint was numbered so that vessel parts could be made away from the shipyard. By making individual parts that were modular the whole operation of shipbuilding could be de-skilled hence drawing upon a larger unskilled labour pool. The quality of the vessels suffered from not having seasoned timber, yet these could be repaired using standard parts. The adoption of these production
All of the techniques described in this paper draw upon practices that have been used in the Construction, Rail, and automotive industries for the last 30 years and in some instances longer. These practices have been used for cruise liner construction but eluded the small batch boat builder. This paper shows how the use of digital technology and basic manufacturing practice can be used successfully on small batch vessel production. The irony is that this practice is Knowledge based and not a cost
based activity, but can significantly increase
productivity and competitive advantage. A multi- industry study of companies that have instigated design [4, 5 & 6] for manufacture and assembly programmes has reduced production costs by 30% and in the marine industry for every £1 spent on upfront design results in a saving or £30 at production stage. This level of practice has eluded the marine industry and is 30 years behind most other industries.
2. UNDERSTANDING PRODUCT LIFE CYCLE AND DESIGN.
The understanding of product life cycle is fundamental to design for manufacture (DFM) of vessels or any
©2014: The Royal Institution of Naval Architects C-121
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