Develop

1
Develop Implement aWorld Class Manufacturing
Model for U.S. Commercial and Naval Ship
Production

• Steel Process Analysis - Task 4.1
• May 3, 2000
• Tim Schreiber
• Industrial Engineering
• NASSCO

2
Steel Process Analysis - Task 4.1Participants

• NASSCO
• Industrial Engineering
• Production Control
• Engineering
• Steel Production
• Electric Boat
• Newport News
• Bath Iron Works

3
Steel Process Analysis - Task 4.1Agenda

• Project phase 1 task flow
• Project phase 1 data requirements and flow
• Process analysis requirements and methodology
• Process analysis task flow
• Results
• Summary, Q A

4
World Class Manufacturing Model Phase 1 Task Flow

• Identify shipbuilding business opportunities
  (task 2)
• Determine business plan ship classes / designs
  (task 2)
• Select shipbuilding performance metrics (task 2)
• Benchmark world class build of world class ships
  (task 2)
• Define a generic greenfield shipyard to
  competitively build selected business plan ships
  (task 3)
• Analyze current NASSCO processes on current ship
  (task 4)
• Develop a computer simulation method to compare
  current NASSCO to world class facilities
  producing business plan ship designs and interim
  product structures (task 4)

5
World class performance metrics

• Labor statistics
• Efficiency
• Manning levels
• Labor cost
• Make or buy strategy
• Processes
• Purchased / ship
• Build durations
• Keel to launch
• Raw stock to delivery
• Process

• Throughput capacities
• CGT / annum
• Interim products / annum
• Weld meters / annum
• Inventory WIP
• Annual turns
• Annual WIP / delivered
• Facility utilization
• Annual CGT / square meter
• Annual CGT / facility
• Process in use

6
World Class Manufacturing Model Development
Variables

• Products
• Ship class / design 1
• Interim product breakdown A
• Interim product breakdown B
• Ship class / design 2
• Build schedule
• Baseline
• Business scenario 1, 2, etc.
• Facility
• Baseline
• Alternative 1, 2, etc.

• Process sequence and flow
• Baseline
• Alternative 1, 2, etc.
• Labor efficiency
• Baseline
• Alternative 1, 2, etc.
• Process manning
• Baseline
• Alternative 1, 2, etc.

7
World Class Manufacturing ModelProject Data Flow
Workforce 3
Workforce 2
Workforce 1
Method C
Method B
Manpower Allocation
Method A
Part Routing / Assembly Sequence Flow
World-Class Competitiveness Evaluation
Computer Simulation
8
Process Analysis SimulationTask 4 Data Flow
Class 3
Class 2
Level 3
Current NASSCO
Level 2
Workforce 3
Current NASSCO
Ship Design Interim Product Structure
Workforce 2
Current NASSCO
Method C
Technology and Labor Rates
Method B
Current NASSCO
Scenario C
Manpower Allocation
Scenario B
Part Routing / Assembly Sequence Flow
Current NASSCO
Product Mix and Build Rates
Facility ALT 3
Current NASSCO Competitiveness Evaluation
Facility ALT 2
Current NASSCO
Computer Simulation
Process Lanes and Layout
9
Process Analysis and Simulation Approach
Requirements

• Product design and manufacturing breakdown
  structure alternatives are easily substitutable
  plug-in modules
• Product mix and delivery rate scenarios plug-in
• Facility layout and process cell modules
  plug-in
• Part routings and process sequence and flow
  alternatives plug-in
• Technology levels and labor rates plug-in
• Manning levels and allocations plug-in

10
Process Analysis and Simulation Design Concepts

• Product model database extractions provide work
  content information
• Part routings determine interim product build
  locations
• Work packages are quantified as macro-tasks
• Assembly sequence and flow charts sequence
  macro-tasks within a process
• Labor rates are unique to each process /
  technology and product type macro-task
• Process durations are a function of work content,
  labor rate, and manning levels

11
Shipbuilding Labor Measurement Levels
12
Macro-task Work Package
Macro-task Weld longs to panel
Arc Time
Gang box meeting
Drag leads
Put on gloves
Get weld rods
Adjust welder
Fit longs
Weld frames
Paint pipe
13
Macro-task Characteristics

• Units of work containing desired activity and
  associated peripheral activities
• About 25 different macro-tasks in steel assembly
• When linked together they become processes
• Labor content is a function of labor rate and
  quantity of work performed
• Single trade
• Manning level constraints
• Macro-task duration is a function of work
  content, labor rate and manning level

14
Process Analysis and Simulation Design Concepts

• Product model database extractions provide work
  content information
• Part routings determine interim product build
  locations
• Work packages are quantified as macro-tasks
• Assembly sequence and flow charts sequence
  macro-tasks within a process
• Labor rates are unique to each process /
  technology and product type macro-task
• Process durations are a function of work content,
  labor rate, and manning levels

15
Task 4Production Process Analysis

• Task 4.1 - Analysis of current steel processes
• Task 4.2 - Simulation of current steel processes

16
Task 4.1 NASSCO Steel Process Analysis Flow

• 1. Determine focus processes
• 2. Design analysis of each process
• 3. Time study processes
• 4. Summarize labor content by macro-task
• 5. Extract / compile product work content
• 6. Document assembly sequence and flow
• 7. Calculate labor rates and manning constraints

17
Determine Focus Processes

• Steel yard
• Blast and prime
• SOC 1 - Fabrication
• Large plate
• Small plate
• Profile (shapes)
• Flatbar

• SOC 2 - Subassembly
• Minor assembly
• Subassembly line
• Major subassembly
• Box girder process lane
• Stanchion process lane
• MT beam process lane

• SOC 3 - Assembly
• Panel line
• Pin Jig assembly
• Flat table assembly
• Material handling

18
Design Analysis of Each Process

• Determine principal sub-processes
• Select representative products
• Design time study method
• Determine macro-tasks and study codes
• Schedule and allocate study resources

19
Time Study Processes

• Introduce observers to process
• Observe and record labor with start / stop times
  by task code
• 3 digit shorthand macro-task code system
• ( indicates labor trade, work performed, product
  type, and process variation )

20
Time Study Processes
21
Summarize Labor Content by Task

• Separate data sheets by process and interim
  product and sequence chronologically
• Enter time study data into Excel spreadsheets
• Run visual basic program to sum hours
• Output results

22

Summarize labor content by task
23
Extract / Compile Product Work Content

• Segregate product by observed interim product
  structure
• Access TRIBON product model database
• Extract products dimensions, components, weld
  lengths, etc
• Summarize product content metrics

24
Extract /CompileProduct WorkContent
25
Document Assembly Sequence and Flow

• Flowchart for each sub-process
• Sequence of macro-tasks
• Establishes predecessor relationships
• Series / parallel activities
• MS Project format

26
Document Assembly Sequence and Flow
27
Document Assembly Sequence and Flow
28
Calculate Labor Rates

• Labor summary and work content sheets collected
  for each interim product time studied
• Sheets grouped by build location and product type
• Rates developed for each macro-task
• Averages and ranges (process variability)
• Labor rates are a function of process and product
  characteristics
• Dimensions (weld length)
• Component quantities
• Tooling factor
• Labor hours per interim product

29
Calculate Labor Rates

• Ship Factory Transformation II developed equation
• Equation format AX BY CZ D task labor
  hours
• A Labor rate per length (hr. / mm)
• X Product characteristic length (weld mm)
• B Labor rate per part installed (hr. / part)
• Y Product characteristic - quantity of parts
  installed
• C Process / tooling factor (hr. / scaffold)
• Z Product characteristic - instances requiring
  scaffolds
• D Manhours per interim product

30
Calculate Labor Rates
31
Manning Constraints
32
Material Handling Rate Matrix
33
Flowchart and Rate Index
34
Flowchart and Rate Index
35
Product Work Content-Based Predictions of
Production Performance
Interim Product
Assembly Sequence
Labor Rate
Build
Data Set
Flow Chart
Sheets
Schedule
Product
Work
Work
Rate
Content
Formulae
36
Analysis of SOC 1-3 Steel Areas

• Questions and Discussion