Develop & Implement aWorld Class Manufacturing Model for U.S. Commercial and Naval Ship Production: Develop & Implement a World 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


Steel Process Analysis - Task 4.1Participants: Steel Process Analysis - Task 4.1 Participants NASSCO Industrial Engineering Production Control Engineering Steel Production Electric Boat Newport News Bath Iron Works


Steel Process Analysis - Task 4.1Agenda : Steel Process Analysis - Task 4.1 Agenda 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


World Class Manufacturing Model Phase 1 Task Flow: 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)


World class performance metrics: 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


World Class Manufacturing Model Development Variables: 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.


Slide7: Part Routing / Assembly Sequence & Flow Method A Method B Method C Manpower Allocation Workforce 2 Workforce 3 Workforce 1 Computer Simulation World-Class Competitiveness Evaluation World Class Manufacturing Model Project Data Flow


Slide8: Ship Design Interim Product Structure Current NASSCO Class 2 Class 3 Process Lanes and Layout Current NASSCO Facility ALT 2 Facility ALT 3 Product Mix and Build Rates Current NASSCO Scenario B Scenario C Part Routing / Assembly Sequence & Flow Current NASSCO Method B Method C Technology and Labor Rates Level 2 Level 3 Current NASSCO Manpower Allocation Workforce 2 Workforce 3 Current NASSCO Computer Simulation Current NASSCO Competitiveness Evaluation Process Analysis & Simulation Task 4 Data Flow


Process Analysis and Simulation Approach Requirements: 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”


Process Analysis and Simulation Design Concepts: 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


Shipbuilding Labor Measurement Levels: Shipbuilding Labor Measurement Levels


Macro-task Work Package: Fit longs Paint pipe Weld frames Macro-task Work Package Gang box meeting Adjust welder Put on gloves Get weld rods Drag leads Macro-task “Weld longs to panel” Arc Time


Macro-task Characteristics: 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


Process Analysis and Simulation Design Concepts: 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


Task 4Production Process Analysis: Task 4 Production Process Analysis Task 4.1 - Analysis of current steel processes Task 4.2 - Simulation of current steel processes


Task 4.1 NASSCO Steel Process Analysis Flow: 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


Determine Focus Processes: 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


Design Analysis of Each Process: 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


Time Study Processes: 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 )


Time Study Processes: Time Study Processes


Summarize Labor Content by Task: 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


Slide22: Summarize labor content by task


Extract / Compile Product Work Content: Extract / Compile Product Work Content Segregate product by observed interim product structure Access TRIBON product model database Extract product’s dimensions, components, weld lengths, etc Summarize product content metrics


Extract /CompileProduct WorkContent: Extract / Compile Product Work Content


Document Assembly Sequence and Flow: Document Assembly Sequence and Flow Flowchart for each sub-process Sequence of macro-tasks Establishes predecessor relationships Series / parallel activities MS Project format


Document Assembly Sequence and Flow: Document Assembly Sequence and Flow


Document Assembly Sequence and Flow: Document Assembly Sequence and Flow


Calculate Labor Rates: 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


Calculate Labor Rates: 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


Calculate Labor Rates: Calculate Labor Rates


Manning Constraints: Manning Constraints


Material Handling Rate Matrix: Material Handling Rate Matrix


Flowchart and Rate Index: Flowchart and Rate Index


Flowchart and Rate Index: Flow chart and Rate Index


Product Work Content-Based Predictions of Production Performance: Interim Product Data Set Product Work Content Assembly Sequence & Flow Chart Labor Rate Sheets Product Work Content-Based Predictions of Production Performance Work Rate Formulae Schedule Build


Analysis of SOC 1-3 Steel Areas: Analysis of SOC 1-3 Steel Areas Questions and Discussion