impact of competency in the malaysian , marine industry perspective – focus on shipbuilding

IMPACT OF COMPETENCY IN THE

MALAYSIAN , MARINE INDUSTRY

PERSPECTIVE –

FOCUS ON SHIPBUILDING

By

First Admiral Dato’ Ir Ahmad Murad b Omar (Retired),

FIEM, FIMarEST, MSNAME,

PEng, CEng, ASEAN Eng.

5 October 2016

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THE SPEAKER

First Admiral Dato’ Ir Ahmad Murad B Omar (Rtd)

BE (Mech) UTM. MSc EBM (Warwick), P Eng, C Eng, CMar Eng, FIEM, FIMarEST, MSNAME

(US), ASEAN Engineer

Vice President Institute or Marine Engineering Science & Technology

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…discuss the impact of competency in the Malaysian Marine

Industry perspective focusing on shipbuilding

Purpose

The purpose of this presentation is to…

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► Introduction - Shipbuilding

► Related Competencies vs Work

Breakdown Structure (WBS)

► Impact

► Recommendation

Content

This proposal is structured as follows:

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► Introduction



► Impact

► Recommendation

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RFQ Issuance of

LOA Design/detail

design Fabrication

Installation - outfitting

Commissioning Test/trials Physical handing

Over (PHO)

• Building Strategy

Introduction

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Phase 1 (RFQ & LOA)

Collboration agreement

Ident working framework

Submission RFQ

Technical clarification

TPS development

Final deliberation on technical & commercial

Identify & confirm final work packages . Issuance oc contract

Phase 2 (Design)

Aveva marine capability

Basic design - DCNS

Determination of final design protocol

Prelim Design

Detail Design

Develop production drawings

Phase 3 (Fabrication)

Confirm Production Engineering protocol (material

management)

Engage OEM for fabrication transfer of

technology

Supply material

Participitative engagement

production begins with prototyping & prelim

certification

In process monitoring

Final production & Certification

Phase 4 (install)

Master & understand build sequence

Project planning, coordination &

monitoring

Material & accessories & ILS element verified

Outfitting by Zone (Korean Best Practice)

Verification & Insp

Maintenance & Protection

Phase 5 (Test & Trials)

Compliance to drawings approved

Insp dry survey

Insp final & punch list clearance

Compartment closure Insp

Compartment handing over ensuring conformity & compliance

Verification ILS requirements

Make Ready for Physical Handing Over

(PHO)

Phase 6

(PHO)

Preparation of final handing over.

Insp certificate and verification of punch

list clearance

Insp protocol sign off agreement including

screening of ILS elements

ILS elements - documents, training, onboard spares, base

spares, STTE etc

Certificate sign-off and hand over

Determination of Warranty framework

• Breakdown Work packages Build Strategy

Introduction

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MASTER SCHEDULE OF LCS 1 MASTER SCHEDULE

Introduction

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RFQ Issuance of

LOA Design/detail

design Fabrication Installation -

outfitting Commissioning Test/trials

Physical handing Over

(PHO)

• Overview of Complete Shipbuilding Activity &

Competencies Required

• Estimators • Engineers • Naval Arch • Financial

experts

• Design engineers

• Draughtsman • Naval Arch • Material

engineers • Skilled labor

• Project engineers

• QA/QC Engineers

• Project Engineers

• Naval Arch • Material

Supply chain controller

• Skilled labor force

• QA/QC Engineers

• Project Engineers

• Naval Arch • Commissioning

engineers • OEM

representative • Skilled labor

force

Introduction

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► Introduction



► Impact

► Recommendation

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Competencies vs Work Breakdown Structure

Through the phases of Build Strategy it is obvious that

there are different stages of construction that requires

sometimes similar skill sets and some other time differing

skill sets.

► Weak points identified:

Production Planning & Production Engineering processes

Supervisory, work coordination & work execution (Project

Management)

Subcontractors’ organizational capabilities

skill sets and experience.

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Ship Building module scope of work mainly cover

implementation of Shipyard production planning system on

all ship building projects

► Job Design - work breakdown & work packaging system

► Job Method - Detailed Work Procedure (DWP)

► Reality-based Planning - Interactive system between planning &

production (Zone Manager - Discipline Integrator)

► Job Instruction - Work Execution Program (WEP)

► Production Method - Integrated Hull, Outfitting & Painting (IHOP)

► Project Management - effective practical methodology / Task Force

meetings

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- Skills sets required in Shipbuilding

Managers

Administrators

Designers/Engineers

Production Work force

Heavy Equipment Operators

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Managers

Project Related

Project Managers

Project Planning

Financial

Cost & Estimation

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Administrators

Human Resource

Personnel

Procurement

Purchasing Supply Chain

Material Control

Facilities

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Designer/Engineers

Planning

Work Breakdown

Zone Outfitting

Ship Design

Structural Construction

Detail Design

Drafting Production

Drawing

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Production

Production Design*

Work Breakdown

Zone Outfitting

Production

Welding Piping Electrical HVAC Outfitting

QA & QC

Inspeectors NDT

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- Skill sets required in Shipbuilding

Heavy Equipment

Operators

Machine MHEs

Cranage/Rigging

Goliath Crane

Gantry

Mechanical Handling Equip

Fork Lift Transporter Side Loader

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- Flow Diagram of Ship Construction in a Typical Yard

SHIP 1 SHIP 2

SHIP 3

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One of the better approach in completing a building

project on schedule would be to apply Korean best

practice. IHOP (Integrated Hull Outfitting & Painting)

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- Adopting the Korean best practice produces tremendous results

- Achievement of jobs and work packages

- Lesser punch list

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► Introduction



► Impact

► Recommendation

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Impact

- Impact of skill sets on overall shipbuilding

process

Management

•Project mgt failure

•HR planning failure

•Financial fail

Administrators

•Supply chain fail

•Material handling fail

•Facilities ineffective

Design

•Drawings late

•Drawings error

•Design production fail

Production

•Welding failure rework

•HVAC delay

•Electrical cable pulling delay

•Piping delay

•Outfitting delay

Mechanical handling Equipment

•ME not available on time

•Defective

•Lifting delays

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Some Failures

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Masterpiece pipework

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Negative Impacts Skill Set Negative Impact Final Result

Project Management Project delays Late delivery charges

Cost estimation Cost projection/estimation run-out

Rectification & re-work cost

Human resource management Manpower utilization poor Manpower cost run-out

Procurement management Material delivery delay Impact on Gantt chart scheduling. Project delay.

Facilities mgt Facilities defective Replacement cost and outsourcing cost

Production design PMT fail to meet schedule Project delay. Cost increase

Drawing delays Impact on schedule Project delay

QA & QC failure Re-work and rectification cost Impact on schedule . liqudated delay.

Non availability of heavy machinery equipment

Cost increase for outsourcing Project cost increase.

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► Introduction



► Impact

► Recommendation

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Recommendation

► Improve shipbuilding line production system:

Indoor - steel fab / panel & block assy / block outfitting - ensuring optimal building method, max use of yard facilities & smooth production flow

On-platform - module outfitting / block painting, erection & joining / platform outfitting - ensuring block/module completion, pallet management, erection-fit up technic & use of IHOP schedule

On-board - on-board painting / HAT / SAT - through zone completion

Project Management Teams – PMT competency to be improved. Be mindful of ten Project Management Knowledge areas.

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Recommendation


QA & QC – inspectors undertaking inspections such as welding, electrical. Piping, HVAC and outfitting must be qualified and trained.

Human Resource Development – Interpersonal and skill based training must be equally emphasized.

Disciplinary – all work force must be aware of good disciplinary abiding practice.

Supply Chain & Material Handling – is essential to be developed in order to circumvent delays and issuance of wrong itms.

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Recommendation


Workshop Layout & Facilities Management - ensuring max use of yard facilities & smooth production flow

Streamline outfit parts manufacturing production system –

Steel Outfit Manufacture

Pipe Spool Manufacture

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END

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Thank You