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Training Methods

Technology Management

What are the factors that affect productivity?

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19:42:27 8Operations of shearing and bending sheet

metals

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• BEGIN : Shipbuilding

• Dimensional Accuracy Control System for Shipbuilding and Marine

• Automated pipe bevel plasma cutting

• Pipe beveling with a cutting torch oxygen actelyne

• pipe bending machine

• SEAMLESS STEEL PIPE MANUFACTURING PROCESS

• Robotic Stiffener Profile Cutting Line -Highly Productive Profile Cutting for Shipbuilding Industry

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What are the differences between mechanised, automated and robotic welding?

The definitions of each term according to the British Standard BS 499:Part 1: 1991 are as follows:

• Mechanised welding - Welding in which the welding parameters are controlled mechanically or electronically and may be manually varied during welding to maintain the required welding position.

• Automatic welding - Welding in which all of the welding parameters are controlled. Manual adjustments may be made between welding operations but not during welding.

• Robotic welding - Automatic welding using a robot that can be pre-programmed to different welding paths and fabrication geometries.

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• Successful application of mechanised/automated systems can offer a number of advantages. These include – increased productivity,

– consistent weld quality,

– predictable welding production rates,

– reduced variable welding costs and

– lower part costs.

• Limitations include :– higher capital investment than for manual welding equipment,

– a need for more accurate part location and orientation, and

– more sophisticated arc movement and control devices.

• As such, production requirements must be large enough to justify the costs of equipment and installation, the maintenance of equipment and the training of operators/programmers for automated/robot equipment.

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• The extent to which automation should be employed is governed by several factors:

– Product quality• better process control,

• product improvement and

• scrap reduction are all possible.

– Production level• higher output and improved inventory turn-over may be the most significant advantages.

– Manpower• automation may allow the welder to work outside a hazardous environment, and

• it may be possible to use cheaper semi-skilled labour; however education and training of personnel will be required to make optimal use of an automated system.

– Investment• savings and costs resulting from an automated system must be identified, including

availability/cost of capital.

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• ship building process

• Wartsila in the Netherlands

• Ship Building SUNGDONG

• Hyundai Ship Building Video

• How its Made - Oil Tanker Ships

• Robotic Steel Beam Assembly | Specialist Machine Sales

• Intercut visar Kjellberg plasma

• Robot welding of micro panels for shipbuilding

• Hull Painting at Perama dry dock19:42:27 14

developing environment-friendly technologies

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This is called a ring pre-erection method because the bottom of a ship and the

upper part are assembled together in advance and loaded to reduce the working

period on skid rail or dock, which usually takes the largest cost and longest period

in the process of shipbuilding. In the case of a 170,000 tone-class bulk carrier. 28

loaded blocks and 13 days of loaded period can be reduced when this method is

used.

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This method complements shortcomings of dry dock where loading should be done

consecutively and maximizes the advantage of skid rail. Two or more loading points

are selected on a skid rail and parts of a ship are divided into groups according to the

points. When a block in a group is completed, loading can be done anywhere without

additional equipment. As a result, the construction period is dramatically reduced in the

on-land shipbuilding.

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LECTURES ON MARINE PRODUCTIONECONOMICS OF PRODUCTION

ExerciseFor one company the following data are available:1. Fixed costs $ 54,72. Variable costs for each output unit:

• Transportation = $ 11• Extra Labor = $ 5• Warehouse exp = $ 2• Insurance = $ 2• Utility bill contr. = $ 3• Marketing = $ 1

Variable cost to be multiplied by Factor F:

F= 1 - Units vFactor A x Units

Draw the relation amongst Fixed – Variable - Marginal CostWhat is the optimum Unit Production ????

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LECTURES ON MARINE PRODUCTIONECONOMICS OF PRODUCTION

ITEMS FIXED COST

FACTORA

VARIABLECOST

TOTAL COST

MARGINALCOST

AVERAGEFIXED COST

AVERAGE VARIABLE

COST

AVERAGETOTALCOST

01 1002 50.03 20.04 12.05 9.06 7.57 7.08 7.09 7.3

10 7.811 8.512 9.813 12.014 15.315 21.316 33.817 82.4

SOLUTION

Fixed costs $ 54,7

Variable costs $ 24,0 x F F= 1 - Units vFactor A x Units

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LECTURES ON MARINE PRODUCTIONECONOMICS OF PRODUCTION

ITEMS FIXED COST

FACTORA

VARIABLECOST

TOTAL COST

MARGINALCOST

AVERAGEFIXED COST

AVERAGE VARIABLE

COST

AVERAGETOTALCOST

0 54.7 0 551 54.7 100 24 78 24 54.7 23.8 78.52 54.7 50.0 47 102 23 27.4 23.5 50.93 54.7 20.0 68 123 21 18.2 22.8 41.04 54.7 12.0 88 143 20 13.7 22.0 35.75 54.7 9.0 107 161 19 10.9 21.3 32.36 54.7 7.5 125 180 18 9.1 20.8 29.97 54.7 7.0 144 199 19 7.8 20.6 28.48 54.7 7.0 165 219 21 6.8 20.6 27.49 54.7 7.3 186 241 22 6.1 20.7 26.8

10 54.7 7.8 209 264 23 5.5 20.9 26.411 54.7 8.5 233 288 24 5.0 21.2 26.112 54.7 9.8 259 313 26 4.6 21.6 26.113 54.7 12.0 286 341 27 4.2 22.0 26.214 54.7 15.3 314 369 28 3.9 22.4 26.315 54.7 21.3 343 398 29 3.6 22.9 26.516 54.7 33.8 373 427 29 3.4 23.3 26.717 54.7 82.4 403 458 30 3.2 23.7 26.9

SOLUTION

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LECTURES ON MARINE PRODUCTIONECONOMICS OF PRODUCTION

SOLUTION

0

20

40

60

80

100

120

0 2 4 6 8 10 12 14 16 18

VA

LUE

$

PRODUCED ITEMS

MARGINALCOST

AVERAGEFIXED COST

AVERAGEVARIABLE COST

AVERAGETOTALCOST

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LECTURES ON MARINE PRODUCTIONECONOMICS OF PRODUCTION

0

20

40

60

80

100

120

0 2 4 6 8 10 12 14 16 18

VA

LUE

$

PRODUCED ITEMS

MARGINALCOST

AVERAGEFIXED COST

AVERAGEVARIABLE COST

AVERAGETOTALCOST

OPTIMUM UNIT PRODUCTION

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LECTURES ON MARINE PRODUCTIONECONOMICS OF PRODUCTION

0

20

40

60

80

100

120

0 2 4 6 8 10 12 14 16 18

VA

LUE

$

PRODUCED ITEMS

MARGINALCOST

AVERAGEFIXED COST

AVERAGEVARIABLE COST

AVERAGETOTALCOST

FIXED COSTUSD

FROM TO

OPTIMUM UNIT

PRODUCTION

1 10 9

11 18 10

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28 49 12

50 70 13

71 78 14

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LECTURES ON MARINE PRODUCTIONECONOMICS OF PRODUCTION

THE LONG-RUN AVERAGE COST CURVE (SOMETIMES KNOWN AS THE PLANNING CURVE)

SAC = short-run average costLAC = long-run average cost

Ave

rage

co

st(u

nit

co

st)

Output rateQ1 Q2

A

SAC2

SAC3

LAC

SAC2 (Q1)

SAC1(Q1)

D

BC

Long run planning: Shipyard capacityΗ πρόβλεψη γίνεται για το μελλοντικό ρυθμό παραγωγής (Q), τον οποίο το ναυπηγείο θα

μπορούσε να επιτύχει.

Στη συνέχεια, οι επενδύσεις στην τεχνολογία και τη διαχείριση, γίνονται με τρόπο που το

ναυπηγείο μπορεί να λειτουργήσει σε ένα ανταγωνιστικό περιβάλλον βραχυχρόνιας

καμπύλης μέσου κόστους (SAC) .