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Accuracy Control

Principal

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1. Accuracy Control
Fundamental to achieve major improvements
Range

Average

Man-hours
per CGT

Japan (4 yards)

5.0 5.0

5.0

14 (1)

South Korea (2
yards)

4.5 4.5

4.5

23 (1.65)

Europe (4 yards)

2.5 4.5

3.8

30 (2.14)

US (15 yards)

2.0 4.0

3.0

45~75 (5)

Region

Source: NSRP Benchmark Report Summary -Dimensional and Quality


Control

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Accuracy Control Principal

The goal of accuracy control is to build in the accuracy at the


source, rather than inspect in.

It means to establish extensive standards and procedures,which


guarantee the accuracy of products in each process.

A self-check statistical process control system must be fully


implemented.

The final goal is to establish effective Neat-cut system. i.e NO


MARGIN/GREEN or EXTRAS.

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Steps to an Accuracy
Control System

Step by step approach:


1. Data collection and analysis.
2. Clear-up (fix) any causes of Deviation.
3. Establish standards and practices.
4. Training of supervisor and workforce.
5. Monitoring of result.
6. Refine above standards and practices.

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Neat-cut System
Cut parts without any excess materials on the edges.
Neat-cut system will minimize cost and delivery time
Save material cost for edge surplus.
Save man-hours for re-cut or trimming of edges at later
stage.
Squeeze cycle-time for erecting parts or assemblies. For
example, JSPL in Singapore takes 12 days for a full Cycle,
from Block Loading to Final VISUAL. Whereas, in Batamec,
the same cycle takes 3 mths on the average (based on
Historical Records).
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Steps to a Neat-cut System


1. Leave edge allowance (excess) after erection.
2. Trim edge allowance before erection.
3. Apply Neat-cut for parallel part of the vessel.
4. Apply Neat-cut for whole vessel.

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History of Accuracy Control


at a Japanese shipyard
1967~1971
Accuracy Control Project Team was organized by 5 people from
Production Engineering/ Fabrication/ Assembly process.
Data collection and analysis was started to establish a neat-cut
system in parallel part of the ship (flat panels).

1972~1977
Additional 4 people from shipwright trade were joined to Project
Team to apply neat-cut for curved part of the ship.
Accuracy control procedure was established.

1978~
Accuracy control task was gradually transferred to line organization
and Project Team were depressed to 3 people.
In 1986, neat cut system was fully applied for whole ship.All block
edges were neatly cut at plate and profile burning shop.
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Current Accuracy
Management
Task of Accuracy Control Team
Accuracy control plan.(Reference line/ Shrinkage factor/
planned excess etc,)
Data analysis and feed-back to planning

Task of Line Organization(Work shop)

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Maintenance of accuracy procedure.


Maintenance of machine.
Data collection (random sampling) and Monitoring
Education and Training

Important Tools
Reference system for measurement and alignment
(e.g.. Reference Line)
Statistical process control methods.
Monitoring(Check sheets) and Control Chart.
Standard procedure and Training manual.
Preventive Machine maintenance manual.
Shrinkage handling.

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What is Reference Line ?


A 3-dimensional Grid throughout the ship which
provides consistent datum lines for use in all
production stages (Frame Lines, Buttock lines &
Waterlines)
Advantage of using Reference Line

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More reliable datum than edges of steelwork


Easy to understand and use
Everyone uses same datum through whole process
Problem solving is easier and quicker

Usage of Reference Line

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At fabrication of subassembly and panel, this reference line is


used for setting internal members to the right position on the
main plate.
When some plates or panels are jointed together, this line is
used for checking the accuracy of dimension and square ness.
If a block is double-skinned or three-dimensional, this line is
also used for checking for any twist in the block
At construction,this line is used for setting the block at right
position by measuring the distance between two reference lines
across the joint, and checking the level of water line.

Usage of Reference Line

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Reference Line (continue)

Reference line should be selected to give at least one water


line/ buttock line/ frame line on each panel or block.
Required reference line and planned edge surplus should be
informed to design office early enough for preparing
manufacturing information (built into the Model).
All reference line on main panels should be marked and
protected up to completion of steel work. Punch marking or
masking is required to protect the reference line against blasting
and painting.
In a major panel, the reference line should be reversed to
opposite side of the panel at panel line or fabrication shop i.e
transfer the lines to the External Surface.
If misalignment occurs at any stage of construction, the
reference line should be modified and re-marked for the next
stage.

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Example of Reference Line

24.5W.L.
5.5B.L.
14.4W.L.
20B.L.
4.7W.L.
1.82W.L.

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27.9B.L.

15.7B.L.

0.3B.L.

Example of SPC
Correlation Analysis.
Histogram & Deviation Analysis.
Control Chart.
Etc,

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Data collection of Shrinkage

= shrinkage (mm)

(Welding Shrinkage)

= - 0.023t + 0.67

0.7
0.6
0.5
0.4
0.3
0.2
0.1
5

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10

15

t = plate thickness (mm)

20

Analysis of Deviation

mean
standard deviation

68.26%
95.44%
99.73%

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Monitoring (Control Chart)


UCL

x
LCL

UCL
R

R
Sample No.

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Maintenance of NC Burning
Machine

Daily

Height Sensor
Height of Burning torch
Verticality of Burning and Marking torch
Offset between Burning and Marking
torch

Weekly

Diagonal check of Marking

Monthly

Marking check by NC Test data


Backlash check of Rack and Pinion gear

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Example of Shrinkage factor


0.92mm/M

0.45mm/M

0.50mm/M
0.53mm/M

0.84mm/M
0.48mm/M
0.40mm/M

0.40mm/M

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0.80mm/M

0.77mm/M

Accuracy Target and Actual Result


Cutting and Marking

Flat bar cutting

01.0

Actual result
(mm)
Dimension: 0.020.86
Difference of diagonals: 3=0.97
Cutting dimension
plasma: - 0.061.11
gas
: - 0.040.84
laser : - 0.130.57
Marking dimension: 0.031.27
- 0.111.09

Profile cutting

01.0

- 0.311.21

Accuracy control Item


Skin plate cutting
NC Marking/Cutting

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Target
(mm)
Dimension: 01.0
Difference of diagonals: 3=1.0
Cutting dimension: 01.0
Marking Dimension: 01.1

Measuring : Skin plate cutting

Length ,Width, Diagonals


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All plates

Measuring : NC Marking/Cutting

Width, Marking
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5 samples / day / machine

Measuring : Flat bar cutting

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Length

10 samples / day

Accuracy Target and Actual Result


Sub-assembly
Accuracy control Item
Dimension of plate after
butt joint welding

Target
(mm)

Actual result
(mm)

01.5

- 0.211.50

01.0

- 0.371.69

Miss- alignment of stiffener

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Measuring : Plate length after


welding

Length
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5 samples / day

Misalignment of stiffener

misalignment of stiffener end


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5 samples / day / flow line

Accuracy Target and Actual Result


Assembly
Accuracy control
Item
Diagonal length after
Plate joint
Misalignment of
stiffeners
Twist of double skin

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Target
(mm)
< 3.0

Actual result
(mm)
2.19

03.0

Fore side:0.914.19
Aft side: 0.413.59

03.0

- 0.381.62

Diagonal length after plate joint

Diagonals
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All plates

Misalignment of Stiffeners

Difference between Skin plate and Internals


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All blocks

Refinement of shrinkage factor


Single Panel Process

Samples

Traditional
Estimated Shrinkage

Shrinkage Result

Breadth

104

0.24 mm/M

0.07 mm/M

Length

104

0.13 mm/M

0.03 mm/M

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