Professional Documents
Culture Documents
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
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Steps to an Accuracy
Control System
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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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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
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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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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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= 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
20
Analysis of Deviation
mean
standard deviation
68.26%
95.44%
99.73%
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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
Monthly
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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
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
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Target
(mm)
Dimension: 01.0
Difference of diagonals: 3=1.0
Cutting dimension: 01.0
Marking Dimension: 01.1
All plates
Measuring : NC Marking/Cutting
Width, Marking
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Length
10 samples / day
Target
(mm)
Actual result
(mm)
01.5
- 0.211.50
01.0
- 0.371.69
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Length
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5 samples / day
Misalignment of stiffener
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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
Diagonals
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All plates
Misalignment of Stiffeners
All blocks
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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