Marine Kit – 2

Ship Construction

Part is Yellow
or Grey
Part is Yellow
or Grey

Alok K. Verma 6/09 Lean Institute ODU 1

 Ship Construction Activity

• The activity includes two modules

• Students work in groups of 4
• Each module can be completed within one
class period (55 min.)
• Students build a clipper ship

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 Clipper Ship
BOW MID SHIP SECTION STERN

Part is Yellow
or Grey
Part is Yellow
or Grey

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 Clipper Ship Cargo Ship

Clipper Ship is a very fast multiple-masted sailing ship. Generally narrow for its length,
limited in its bulk freight carrying capacities, the clipper ships have a large relative sail area.
A Cargo Ship or freighter is any sort of ship or vessel that carries cargo, goods, and materials
from one port to another. Cargo ships are usually specially designed for the task, often being
equipped with cranes and other mechanisms to load and unload, and come in all sizes.
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Definitions:
Stern:
• The stern is the rear or aft part of a ship or boat.
• The stern area has always been the location near the steering apparatus,
and by extension became the domain of the ship's captain and other
officers

Bow:
•The bow is the forward part of the hull of a ship or boat.
•The bow is designed to reduce the resistance of the hull cutting
through water and should be tall enough to prevent water from easily
washing over the top of it.

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Construction Activity Schedule

• Day 1: Bill of Material / Cost Estimation

• Day 2: Construction of Ship

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 Day -1

Bill of Material / Cost Estimation

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 Bill of Materials / Cost Estimation
The teacher is the supplier & the students are the employees of
ABC Yards.

• A bill of materials form is provided and the students identify the

number and type of parts needed to build the ship
• Photographs of the ship and sub assemblies are provided to identify
and count the number of parts
• Students calculate the cost of building the ship
• The students buy the material from the teacher (Supplier)
• Students will be initially given $290,000 to buy the parts.
• If the parts are not purchased with Bill of Materials, they can be
purchased later at double the price.
• If parts are left over after final assembly, parts can be returned with a
20% restocking fee. (The team receives only 80% of cost of the part)
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Bill of Material & Cost Estimation Sample Form

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Bill of Material & Cost Estimation Sample Form

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 Day - 2

Construction of Ship

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 Construction of Ship
• After buying the material each team starts constructing the
ship.
• Handouts are provided to each team to construct the ship.
• If the parts are not purchased with Bill of Materials, they can
be purchased later at double the price.
• If parts are left over after final assembly, parts can be
returned with a 20% restocking fee. (The team receives only
80% of cost of the part)

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 Ship Mid Section - Right
Bow
Clipper Ship Stern

7 8 5
1

6
10

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or Grey
2
4
3
9
Part is Yellow
or Grey

Bow Sub Assembly 1 Bow Sub Assembly 2 Ship Mid Section - Left
Assembly Steps

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 1 Stern Sub Assembly
Exploded View TWO PARTS
135 Degrees Support-
16mm Bar- 32mm Bar- White
Black
Green
Assembled Part

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 2
Bow Sub Assembly
Exploded View
180 Degrees
90 Degrees Support –
dark Gray Granite
Section 1
Support-
Yellow
16 mm Bar
- Black Assembled Part

32mm Bar
- White

Hanging Clip - Black

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 90 degrees Support-
3 Exploded View Dark Gray Granite Bow Sub Assembly
52mm Bar
- Blue 180 Degrees
Section 2
Support- Yellow
Assembled Part

32mm Bar
-White

Hanging Clip
- Black

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 4 Exploded View
360 Degrees Joint
Ship Mid Section-Left
- Blue
187mm Bar –
Light Gray
Assembled Part

Flat Joint
- Brown

180 Degrees joint- Silver

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5 Exploded View Ship Mid Section-Right
180 Degrees Joint
- Silver

Assembled Part

135 Degrees
Flat Joint Support
- Green
- Brown

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6 Assembly of Bow
Bow with Sub Assembly Section 1
Front section of Bow

Part is Yellow
Part is Yellow or Grey
or Grey

Flat Joint - Black

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 7 Bow with Sub Assembly Section 2 Assembly of Bow
75 Degrees 187mm Bar
Light Gray Granite - Light Gray

85mm Bar-
Dark Gray or Yellow Flat Joint - Brown

16mm Bar
- Black

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 8
Final Assembly of
Ship Mid Section
Left & Right

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9 Final Assembly of Ship Mid Section & Bow

Part is Yellow
or Grey

Part is Yellow
or Grey

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10 Final Assembly of Ship Mid Section, Bow & Stern

Part is Yellow
or Grey
Part is Yellow
or Grey

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 Bow with Sub Bow with Sub Ship Mid Section Ship Mid Section - Right Stern Sub
Assembly 1 Assembly Section 2 Assembly
Bow
8 5
1
7

10

6
Part is Yellow
or Grey
2
3 4

9 Assembly of Ship
Ship Mid Mid Section, Bow &
Bow Sub Assembly 1 Bow Sub Assembly 2
Section - Stern
Assembly of Left
Ship Mid Section with Bow Assembly Steps

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 Part Names & Color List
75 Degrees Support
– Light Gray
Granite
Side View

180 Degrees Support

- Yellow
85 mm bar-
Dark Gray
Hanging Clip
- Black

90 Degrees Support 360 Degrees joint

Part is – Dark Gray Granite - Blue
Yellow or
Grey 16 mm Bar
- Black Flat Joint
- Brown
187mm Bar
– Light Gray 52 mm Bar
- Blue
135 Degrees Support
- Green

Top View

32 mm Bar
- White

180 Degrees Joint - Silver

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 Ship Construction Assessment
Ship construction will be assessed for following
five quality characteristics.

1. Least construction cost

2. No missing parts
3. Least time for construction
4. Correct part counts
5. No restocking fee

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 Wrap Up
• After completing the construction activity,
place the components back into their respective
zip lock bags.
• Each zip lock bag is marked with a label.
• Count all the parts and match with the number
on the label.
• Place all zip lock bags in the box.

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