MATERI 2

ORGANISASI INDUSTRI
GALANGAN KAPAL

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Organisasi Industri Galangan

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 Shipbuilding Industry
An industry that produces products (ships, offshore
structures, floating plants etc) for customers
(private owners, companies, government, etc).
Shipbuilding Process
• Development of owner’s requirements
• Preliminary / concept design
• Contract design
• Bidding / contracting
• Detail design and planning
• Construction

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 Main shipbuilding tasks
Concept Design

Receive and review enquiries

Estimate cost Premilinary Design Plan Delivery

Negosiate contract
Finalise detailed Finalise building
design design

Prepare detailed Purchase Prepare detailed

product drawing materials build plans

Start construction
Monitor cost Monitor work Monitor materials
against estimate against plan delivery against plan

Reschedule product and program

Complete ship

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 Ship construction flow diagram
Steel stockyard Purchasing Design

Steel treatment
Production
Lofting
Steel preparation and drawing

P.P.C
Sub-assembly
Production
Engineering
Block assembly

Erection
Quality control
Launching

Outfitting / commisioning / trials

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 Basic sequence of Ship construction
• A preliminary lines plan and laid off to scale in lofting office
• Plates and section are brought into production shops from steel
stockyard and then, are straightened, shot blasted and primed in
the treatment line
• Rectangular plates are cut and the steel is also bent to fit the
ship’s contours
• The steel components are transported to be assembled and
welded together in the sub-assembly shop and facbricated into
major assembly or large block
• The large assemblies are erected on a building berth
• The ship is launched and towed after launch to a fitting out quay
• The ship goes to a dry dock for hull cleaning and painting
• The ship undergoes proving trial

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 Steelwork material flow diagram
Plate stockyard Stiffener stockyard

Plate treatment Stiffener treatment

Plate marking Stiffener marking

and cutting and cutting

Shaped unit Minor –assembly Plate/ stiffener panel

production production production

Shaped unit Unit built up from plate

built up panel and sub-assembly

Erection/ Berth

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 Shipyard organization
• Administration (payroll, accounting, labour, safety)
• Production (planning, scheduling and production control)
• Engineering (design, production engineering and information)
• Purchasing (raw materials, sub-contracted work and
competion)
• Quality assurance (vessel owner, regulatory agency and
class)
• Project management (progress, budget, schedules,
materials)

Trades
• Loftman, blaster, painter, burner, welder, labourer, crane
operator, machinist, electrician, carpenter, insulator and AC
equipment mechanics, pipe fitter, joiner, etc.

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 Typical Shipyard Facilities :
• A location and land for erecting a ship
• Piers for storing ships afloat
• Shops (steel marking, cutting, forming
shops, steel assembly shop, surface
preparation, coating shop, pipe shop, sheet
metal shop, machine shop, electrical shop)
• Storage, marshalling and out door work
areas
• Office and personnel support buildings

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 Definition of shipbuilding model :
It is based on the theory of production
applied to production run for predetermined
and fixed total output.

1- total output is fixed

at the time of contract signing
2- the times to start and complete
production are determined
3- the average production rate is
consequently determined

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 Function of shipbuilding model :
To analyze and explain cost over-run
in shipbuilding program, cost drivers and
how cost might be controlled using
better production management technique

Production function of shipbuilding :

- Defining a measure of output
- Time dependence of production cost
on resource utilization
- The effect on ship production cost
of changes in production rate

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 Production Output

- Percentage completion of the ship

- Components called work packages,
are estimated to require number of
manhours
- The work content of a ton of steel

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 Standard Production Function

Qt = Q (Kt, Lt, Et)

Where:
Qt = physical output rate
Lt = rate of use of labour at time t
Et = the efficiency effects of changes
to require output
Kt = rate of use of capital at time t

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 Qt = feet of pipe installed or tonnes of steel erected / day
or standard manhours / unit time

Lt = as quality adjusted labour, depends on

- ship sequence number
- number of workers
- time rate of changes in the number of worker
- length of the work day
- skill level
- experince level

Et = the effects of :
- incomplete or missing plan
- disruption of worker or support service
- worker morale

Rate of production is dependant on changes to the production

plan because of :
- Customer initiated changes to plans
- Estimation or scheduling errors by the builders

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 Character of Shipbuilding Model
- consists of many (n) discrete operations
or tasks
- the output of these tasks is an interim
product which is an input for
a subsequent product
- Output of construction processes are
work packages

- Total required output (q) =

sum of all required work packages

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 Progress on the ship construction
processes (Pi (t)) =

Number of packages completed at time (t), SMH

Number of required work packages, SMH

(percent physical completion)

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 Time after start fabrication
Average actual manhours
Average planned manhours
Average change to total required output
Average overtime hours

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 Experience curve effect

Ya = a / X b
Where:
Ya = the average cost of X unit produced
X = number of identical unit
a = the cost of first unit produced
b = an exponent that varies with the
complexity of the ship

The experience curve effect indicates that average cost of

all units produced decline at constant rate as function of
accumulated experiences
The experience curve benefit (Percentage of improvement)
has been found at 5-10 % ranges
The reasons underlying the experience curve such as learning,
specialization, investment, scale effect

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Organisasi Industri Galangan
Suatu Galangan Kapal, minimal mempunyai
fasilitas-fasilitas sebagai berikut:
1. Kantor
2. Fasilitas perancangan.
3. Gudang material.
4. Bengkel pelat dan pipa.
5. Bengkel mesin dan Listrik.
6. Tempat untuk pembangunan kapal.
7. Tempat untuk mereparasi kapal.
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Organisasi Industri Galangan
 Perletakan kantor, bengkel dan fasilitas-
fasilitas yang lain sangat tergantung kepada
bentuk tanah dimana galangan kapal
tersebut berada.
 Yang harus diperhatikan dalam penyusunan
letak bengkel ialah berusaha memudahkan
urutan rangkaian pekerjaan dan aliran
material.
 Harus diperhatikan pula posisi, kedalaman,
kondisi water front
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