UNIT-I

1. Explain about principles of design for production in ship building.

Ans: Production Design: The detailed specification of manufactured items parts and their
relationship to the whole procedure design needs to take into account how the item will
perform intended function in an efficient safe and reliable manner.
Principle of design for Production Ship building: Design to reduce production cost to a
minimum compatible to the requirements of the vessel to fulfil its operational functions with
acceptable reliability and efficiency.
Primary objectives:
 To produce a design which represents acceptable compromise between demands of
performance and production and where appropriate take into account the needs of
overall repair and maintenance
 To ensure that all design feature is comfortable with known characteristic of the
shipyard facilities
 To apply the individual design for production principle and procedures in so far as
they are relevant to particular vessel and the particulars shipyard where the vessel is to
be built
Co-ordinates the inter relationship between the making electrical outfitting works with
the structure work in order to create fully integrated design.

2. Explain in brief about welding edge preparation?

Ans: Edge preparation:
 Edge preparation is very important for welding (joining) thicker sheets and plates
heavy pipes and solid material.
 Size and shape of edge preparation or groove depends on what material is used and
joint design.
 Edge preparation is dependants on strength required or load bearing of the joint single
square groove will not penetrate full thickness of the joint but double v groove will
get full thickness
 Edge preparation consists of removing material along edges of metal surfaces. You
must prepare edges for welding when parts and assemblies require certain strength.
To achieve full welding penetration, you must cut the edges of the metal.
When to Bevel or Groove:
Bevelling or grooving is especially desirable for butt joints thicker than 5/8 in. bevelling is
sometimes used for material as thin as 1/4 in. where it can assist in tracking the weld seam
with knife edged wheel followers. In positioned tee joint or comer joint fillet welding where
complete root penetration is desired, the abutting member is generally bevelled if the depth of
fusion desired for each weld exceeds 3/8-in.

3. Explain in brief about structural design?

Ans: Structural design: The design of ship structure is the process of applying rules and
experience to integrate individual structural components into efficient and easily constructed
assemblies, modules, and hull. The design of a ships structure has a major influence on the
construction cost of the ship through the work content and the quantity of material. Many
ship structural designers use standard structural details which they may have borrowed from
other designers in another shipyard.
 For naval ship, they may simply copy the old BUSHIP standards, which are over 20
years old. Chances are that the decision to use a particular detail will be made without any
regard to producibility requirements for the shipyard involved.
Example: A Bulkhead may have Girder or stringer which will be grouped and pre-fabricated
& A shell may have Girder or stringer which will be grouped and pre-fabricated

4. Write a brief note design for welding in shipbuilding?

Ans: There is still a need for designers to be more aware of whether the Design for Build
concept is being actively followed. This has been highlighted when building vessels with a
significant proportion of thin plate in the structure. A basic principle in building these
structures is to minimise the heat going into the structure, as this tends to induce the
phenomenon of thin plate distortion. Consequently, the effects are seen as rework and
possibly build schedule impacts. One issue was the use of intermittent welding on non-
structural bulkheads the application of intermittent welding will reduce the amount of heat
going into the structure by about 50%. However, there appeared to have been non-structural
areas where this had not been applied, and also wet spaces where double continuous welding
had been carried out to remove the possibility of corrosion occurring in the unwelded spaces.
The wet spaces were subsequently produced using intermittent welding and a silicone sealant
in the area between the welds.
The role of designers in adopting a “design to reduce distortion” philosophy is also
significant in the overall scheme of this problem. In the places like double bottom margin
plate and shell plate in bilge strake region the connection is very typical where access will be
a big problem and has to be taken into consideration while designing the block. In skeg
region the access for welding will be a problem which the designer has to consider and give a
suitable design for construction of skeg of a ship In forward region of ship where we have the
bulbus bow of the and the flare region will have lot of structural members internally to take
heavy loads in the forward due to forces like panting, pounding, etc., So construction of the
forward block will be not similar to all other blocks due to its structural complexity where
welding of all member and shell plate and structural integrity to be considered by the
designer while designing.

5. Discuss in detail about quality control in shipyard?

Ans: Shipbuilding Quality Control (SQC):
 The main aim of Shipbuilding Quality Control (SQC) is to check and control the
different processes or procedures carry out in the manufacturing of a ship, as
shipbuilding demand an accurate, precise and accident free work, so that to minimize the
wastages of materials, instruments and tools
 QC put efforts to make possible efficient working by proper inspection of equipment’s,
tools, and various tests for materials, so that to use high quality of materials during
manufacturing.
Ship Repair Quality Control (SRQC):
 In the repair or replacement of parts or materials in a ship, QC tries to use high quality
materials, therefore reducing risk to a high percent.
Engineering Quality Control (EQC):
 The quality check for the all the steel works carried out in Shipyards are properly
checked and controlled in EQC.
 The different manufacturing works carried out consist of developing/manufacturing high
pressure vessels, rollers for sugarcane and cement industries, etc

UNIT-II
1. Explain about Theodolites used in shipbuilding industry?
Ans: Theodolites have been adapted from the field of surveying to be used as industrial
measuring tools. The theodolite is a rugged but (at a minimum) accurate instrument for
measuring horizontal and vertical angles (transits measure only horizontal angles). They are
usually set up in pairs and referenced one to the other. Aimed simultaneously at a single
target, the position of the target is determined by means of triangulation, the best modem
systems for industrial measurement employ electronic theodolites tied into a computer with
software to quickly compute the positions the instant both "guns" are set on the target
The operators must have reasonable visual access to the target along most of the
surface being measured. Theodolites can be moved and reset to cover different parts of a
difficult to cover target, but such a procedure increases measurement time. Items are usually
targeted so that both theodolites are positively aimed at the same point. Movement of heavy
machinery near the measurement site can upset theodolite calibration and should be
minimized.

2. Explain problems of accuracy with block construction process?

Ans: Assembly accuracy detection in the process of building ships, it has long been known
that in manufacturing components in accordance with design drawings, the dimensions of
these components may vary to an extent that adjustments have to be made during the
construction process to arrive at the vessel depicted in the design. These adjustments can
include a significant amount of re-work, including trimming of excess material, inserting
additional material, pulling, straightening and bending structure to suit alignment, and in
some cases discarding components which are too distorted to be reasonably utilized, The
setting of accuracy goals and the understanding of the actual accuracy attainable in various
manufacturing processes in the shipyard has been identified as a means of pre-determining
some of the aforementioned problems and to avoid them by adjustments during the
manufacturing process.
hull construction typically about 5 % of workhours are required for parts cutting, 50%
for sub-assembly and block-assembly, and 45% for hull erection. focused on statistical
accuracy control and line heating as means to reduce the work hours associated with the large
percentages. This ultimately led to the need provide shrinkage compensation both for flame
cutting and for subsequent welding operations. In contrast, shipyard managers elsewhere
focused on the least amount of work hours with N/Cutting and ultimately direct computer
control of cutting machines.

3. Briefly explain process planning in shipbuilding?

Ans: Process planning systematic determination methods by with product is to be
manufacture economically and on schedule function which established process on parameter
to be used convert a raw material finding between defect intermediate stages between
designing manufacture.
Process planning procedure:
 Preparation of working drawing so geometrical shape dimension tolerance surface
tension surface finish surface coating information or inspection identification material
specification
 Make or buy decision
 Process selection based on automation kind of work flow quality level, delivery agencies
etc
 Machine capacity and machine selection
 Selection of material fixtures auxiliary equipment’s
 Prepare document like operation and roots sheets.
Process planning procedure control: Shipbuilding process is
 Complex.
 Long cycle operation.
The most important objective in shipbuilding is maintained delivery schedule in few of above
point proper planning essential determine very sequence and inter related operations and
activities or derived construction.

4. Briefly explain interconnection between production design and process planning is

shipbuilding?
Ans: Production Design:
 Design information reinforce made internal for production process
 Design is made according material available limitation is suitability
 Structure design is given important
 Optimize initial of crane in short facilities
 Minimize material usage
 Good accessibility is use of transport storage
 Component easy to assemble and act
 Modification structure components design difficulty
 Bulbous made mini pies
 Hull design is optimizing
Process Planning:
 Product specification and quantity of work
 Available of raw material tools equipment’s personnel sequence production
 Standard time
 Machine on which process will be performed
 Process selection based on automatic kind of work flow quality level delivery agencies
etc
 Make or busy decision
 Prepare document like operation and root sheets
 Machine capacity and machine selection
 Schedule of the process.

5. Explain Flow process chart with sketch

Ans: A Flow process chart is a chart of all the activities involved in a process it is similar to
the operation process chart except that more details is been shown by including transportation
delays as well as operation, inspections and storages. Thus, this chart is been made (or)
mapping is been done for the identification of delays during production of a vessel and for
improvement of it by minimising time delays.
UNIT-III
1. Discus about Process
Planning.
Ans: Process planning is a
systematic determination of
methods by which product is to
be manufacture economically and
on schedule formation
manufacture economically and a
schedule formation which
establish process and process
parameter to be used covered the raw materials into finish product defined like intermediate
stages between designing and manufacturing
Main Information of process planning:
• Product specification and quantity of to be completed.
• Accessibility of raw materials tools equipment and personnel.
• Sequence of production.
• Standard time.
• Machine on which process will be perform.
• Schedule of the process.
Process Planning Procedure:
Preparation of working drawing showing geometrical shape dimension tolerance type
of surface formation surface coating information for inspection identification code materials
specification. Process selection based on level of automation kind of work flow quality level
delivery agencies etc. Machine capacity and machine selection of materials jig fixture
auxiliary equipment. Requires documents like operation and roll sheet

2. Explain Gant Chart with sketch

Ans: A Gantt chart is a horizontal bar chart developed as a production control tool in 1917 by
Henry L. Gantt, an American engineer and social scientist. Frequently used in project
management, a Gantt chart provides a graphical illustration of a schedule that helps to plan,
coordinate, and track specific tasks in Projects
A Gantt chart is constructed with a horizontal axis representing the total time span of
the project, broken down into increments
Horizontal bars of varying lengths represent the sequences, timing, and time span for
each task. As the project
progresses, secondary bars,
arrowheads, or darkened bars
may be added to indicate
completed tasks, or the
portions of tasks that have
been completed. A vertical
line is used to represent the
report date.

3. Briefly explain Procedure

control and system control of
production?
Ans: Production control is responsible for monitoring cost and schedule the while leak in
progress the production control origination is generally responsible for issuing man hour
budget to be used to control the ship building process relates actual work completed and
actual mon hours spent their data are covered by control group in order to monitor expended
man hour production progress and productivity and to feedback system oriented data for
estimation for ship building projects thus particular indene for monitoring expended man
hour progress and productivity are sufficient.
Man, hour Expensive
The character of man power index (man hours per unit time) is the same for the
various control group of work packages which apply to all work categories.
Production progress
 Production progress use different measures (weight, welding parameter, laid cable
length etc) per time factor it is sometime necessary to apply more than one index for each
group of work packages.
When compared to period schedules they are the basis for short term adjustment such
as shifting workers or using overtime when the shipyard organisation it is practical to
delegate such control to the part of delegates such control to the managers gets of parts
fabrication shop and assembly section.
Productivity indices
productivity indices utile both man hours expended and the measures used for
monitoring production process (Weight, Welding, parameters, cable length etc).Each of the
latter is usually an average based on the performance with the specific control group of work
packages any curve which appears above this efficiency indicates man hours expensive an
above average rate Productivity evaluation can be simplified by a productivity control group
(PCG) concept it eliminates consideration of specification man power control group and the
same indices to man power expensive progress and productivity apply within each
manufacturing level.

4. Explain Management cycle of a shipyard

Ans: Project definition-visualization the complete project a true structure. Vender pre-
Qualification -define and track process store result for future projects Design Approval-Make
visible approval comments in the building phase to assure vessel is built to connect design.
Building-important hull paint and outfitting. Delivery-documentation and structure
immediately. Operation-Expensive feedback to new project hull maintenance conversion.
System and zone oriented in management cycle indicates primary focus system or
zone of each phase in the cycle during planning okay transformation from system orientation
to zone orientation through execution and some testing to manner in which the work is
performed
1. Estimation
2. Planning
3. scheduling
4. Execution
5. Evaluation

5. Explain about maintenance of ships

Ans: Maintenance Work is Done Onboard a Ship Maintenance is one thing that keeps any
mechanical equipment or machinery going. Weather it is a small machine or a large structure,
efficient maintenance can help with prolonged life and favourable outcome. On a ship,
maintenance is one thing that keeps machinery up to date and is smooth running condition. In
this article we will learn as to how maintenance is being carried out on a ship.
In a ship’s engine room, where the maximum machines are located, engineers and crew
carry out the maintenance for safe and efficient operation. Each machine on board a ship
requires maintenance which has to be carried out at regular intervals of time. In the earlier
days, the number of crew members and engineers on a ship were large and so the
maintenance was carried out fast and easily. However, in the present scenario, the number of
crew members and engineers on the ship has reduced drastically. Many ships carry only 3-4
engineers on board a ship and even the time required to carry out maintenance on the ship has
reduced.  Maintenance requires manpower and time which may not be available all the time
as the number of crew members is less and the amount of machinery is more. It is for this
reason important to plan the maintenance of the machinery in advance so that the machinery
can be overhauled and maintained properly. Generally, second engineer is required to plan
the schedule of maintenance on a ship. Efficient planning and adequate usage of equipment’s
is the key to productive maintenance.

UNIT-IV
1. Explain methods of estimation of capacities of shipyards?
Ans: The method is based on highest shipbuilding output on reward which could base the an
estimation of shipbuilding capacity because the demand is very high almost all shipyard will
try produce maximum capacity because the demand is very high almost all shipyard will try
produce maximum capacity in this method would still be enough measure this methodology
considered to be reasonable demand for building of new ship is very high shipbuilding output
is closed to capacity all shipyard are expected to response to this high demand.
Shipyard is compensated on he both of gross tonnage for certain period of time in this
method on the basis of estimated gross tonnage the shipyard by increase the gross tonnage by
modifying is construction methods and by increasing its building dock capacity and
techniques.
Therefore, full modification capacity method solely depends upon capacity planning it
is the process of determining the production capacity needed by the organisation demand for
its products and the design capacity in accuracy and output.

2. Briefly explain strategies for modifying capacity?

Ans: Lead Strategy: Capacity planning is a strategic process whereby a company determines
what level of capacity it will need to satisfy the level of demand for its products or services
over a period of time. A lead strategy is aggressive and involves increasing capacity in mere
anticipation of an increase in demand.
Lag Strategy: A lag strategy is conservative and involves increasing capacity only when there
is an actual increase in demand. It may result in a loss of potential or current customers who
must go elsewhere if demand suddenly outpaces current capacity, and customers can't or
won't wait.

3. Briefly explain models for capacity planning under the special conditions of
shipbuilding?
Ans: Method for capacity planning used in ship building industry:
• Impact ability to meet future demands
• Affects operating costs
• Involves long term commitments
• Affects completeness
• Affects case of management
Factors involve:
Design capacity: maximum output rate devices capacity an operation process facility it is
designed for.
Effective capacity: Design capacity increase allowance sun as personal time maintenance and
scrap
Actual Output: Rate of output actually achieved cannot exceed effective capacity.
Objective:
• Amount of capacity needed
• Timing of changes
• Need of to maintain balance
• Extend of flexibility of facilities
Methods:
• Estimate future capacity requirements
• Evaluate existing capacity
 • Identify alternative
• Implement alternative chosen
• Monitor results.
4. Explain Yard-by-Yard aggregate method?
Ans: In this method maximum capacity of shipyard is compensated on he both of gross
tonnage for certain period of time. In this method on the basis of estimated gross tonnage the
shipyard by increase the gross tonnage by modifying is construction methods and by
increasing its building dock capacity and techniques. Therefore, full modification capacity
method solely depends upon capacity planning it is the process of determining the production
capacity needed by the organisation demand for its products and the design capacity in
accuracy and output.

5. Explain maximum capacity approach method?

Ans: The method is based on highest shipbuilding output on reward which could base the an
estimation of shipbuilding capacity because the demand is very high almost all shipyard will
try produce maximum capacity because the demand is very high almost all shipyard will try
produce maximum capacity in this method would still be enough measure this methodology
considered to be reasonable demand for building of new ship is very high shipbuilding output
is closed to capacity all shipyard are expected to response to this high demand. The
Advantage of the Method is it simplifying
UNIT-V
1. Explain production standards in several parts of the ship production?
Ans: The standard represents the consensus of the portion of the industry represented by the
organization that issues it. Standards are in accordance with established procedures for
certification, development, approval (ensuring consensus) and review of the standards
organization.
Conformation of a standard is done to ensure acceptability, compatibility,
interchangeability, identicality, or other aspects of commonality. Frequently the standard
contains tests to be used to determine that the conformation is within the specified tolerances.
While there are many reasons for using standards in many different applications, the ultimate
one is to save money.
Reference can be made to the type and level of a standard. type is the area of concern or
function of a standard and level can refer either to the portion of the ship being considered or
to the breadth of the organization developing the standard and its intended application. A
standard may be of one type or a combination of types.
There are advantages in applying different standards to different sized portions of the
ship.
SHIP LEVELS:
Module System
Unit Equipment
Panel Components
Plate or Shape Parts
Standards are utilized at levels ranging from the individual shipyard to the international
organization. Standards created at one level are often adopted at higher or lower levels.
2. Explain briefly about methods of man-hour estimation?
Ans: The estimation of labour man-hours for ship production is considered an important item
during the early stage of negotiation before signing the contract. With few information about
the ship during the preliminary design stage, it is necessary to apply a good prediction
method for estimating the ship production man-hours. In this paper, the previous works for
estimating the shipyard labour man-hours, based on hull steel and outfit weights as shipyard
output measure, are presented and their limitation is discussed. Add to that, the yardstick
productivity measure for shipbuilding yards, man-hours per compensated gross tonnage, is
presented. Based on this productivity measure, a method is proposed to predict the ship
production man-hours and its effectiveness is examined. In addition, the influence of any
improvements in ship production activities on the prediction approach is investigated.

3. What are the production documents required for ship Block production?
Ans: Production documentation for block construction are:
• Part list
• Profile list
• Nesting
• Material requirement
• Plate bending data
• Weight and centre of gravity
• WCOG
• Block Drawing
• Tape or NC Files.

4. Give a known shipyard layout?

Ans

5. Explain how Block division plan made and what parameters of block construction extracted
from block division plan
Requirements in generation of block division it is necessary to optimize both of the seam
position and the combination of the parts the concept of dimension optimization can be applied into
optimization of seam position which has already researched in the field of structure optimization
therefore the main problem to realize the optimization of block division is to develop the method it is
required to optimize not only erection block but also all the hierarchy from parts to ship.
The effectiveness to use the product model information in the evaluation has been proved in the
previous researches therefore it is desirable to achieve the evaluation using the product model by
integrating optimization engine and product model. The details which can be extracted from block
division plan are
[Link] no
2. Excess Detail for block
[Link] sequence
[Link] Position in the ship