SOS shipbuilding on scans

Chapter 1: No room for errors

Author: Thorsten Störig and Ralph Zimmermann, June 2016

想象一下,将超过3000万件的拼图拼图放在一起。这些说明说,将这些碎片分成大约80个单独的块,重达800吨。这些街区必须精确地放在一起,为乘客提供了巨大的巡航班轮的安全而愉快的旅程。一旦计划,您的构建不到一年,同时满足预算限制并超出了客户的质量期望。欢迎来到邮轮大楼的世界。

在Meyer Werft,我们每天都面临这些挑战。自1795年以来,我们的公司自1795年在德国帕彭堡(Papenburg)开始,从木船运输到2015年4月的最新发行的船只的发展。尺寸为350米,长达168,666吨,我们的豪华巡航船长最新的一件是为其光滑的设计引起了行业的浪潮。

没有错误的空间

‘First time right’ is the target for all employees at the shipyard MEYER WERFT in Germany. Minor mistakes in one discipline can have a great effect on staff and material expenses and can even delay the entire building process resulting in additional costs. In particular, the short building period in the dock hall with its 500-meters-long dry dock highlights the daily challenges. By using its full capacity and building two vessels a year at intervals of six months, work processes serve two various types of ships in different stages. While the hull of one ship is completed with the final steel blocks, construction works in the engine room of the subsequent underwater part are already ongoing. Sophisticated quality and advanced planning procedures in design and production ensure that errors rarely occur and are detected promptly.

The roots for such a complex and diversified process lie in a risk-based approach by which the single vessel parts and work sequences are analysed and assessed for potential errors. Actions coming from those studies, though, do not only focus on the so-called 5Rs (right piece, right time, right place, right quantity and right quality). The right information is a key factor in modern and expeditious shipbuilding. Structuring drawing details and the chapters of numerous standard documents in a way that subject areas only receive the exclusive content they need reduces the hazard of missing the forest for the trees.

为手工艺人定制的信息分发了技术细节以及最佳实践程序以及如何避免昂贵的缺陷的知识。关于巨大船只内部无关的过程步骤,有关使用新工具,序列和可用的实时数据减少误差的新闻是不可避免的。

The second pillar in effective quality management is tests and inspections in short cycles. Quality assurance is supposed to be set up at certain stages where the risk of an error is high. A fast detection avoids having to dismantle, fix and restore completed hotel areas and mechanical spaces of a cruise ship. More than 60,000 single checks within the production process, plus additional checks in the commissioning and delivery phase, ensure problems in late stages will be eliminated.

这些测试是由专用和定性fied staff coming from the disciplines of steel construction, welding, material testing, pipe systems, plant engineering, commissioning, interior furnishing and, in particular, dimensional control. The need for short-cycled quality assurance by well-trained inspectors is especially depicted in the above exponential cost graph. As construction cost incurs multiples of 10 or even more during each subsequent step of the process, mistakes not caught by early detection can result in millions of over-budget costs and jeopardise production schedules.

To sum up results at dedicated process steps, quality gates are installed to review test progress and test results. Due to the fact that the owner operating the ship later on and the classification society take part in some of the inspections, the follow-up of remarks and customer satisfaction contribute to a successful ship project completion.

The Quality Management Department comprises the system approach as well as the Measurement Group, which conducts geometric surveys and positioning. Our group is made up of nine different types of engineers, five technicians, six trainees and student apprentices. We conduct all measurement works throughout the entire construction process. Alignment of the plasma torch cutting machines is just one of the first tasks, and absolute accuracy is a must when laying keels and fabricating the blocks. On top of this comes a host of other special jobs, such as determining the overall length of a ship and assisting in research projects. With more and more parts of a ship being prefabricated and attached in blocks, we need to be able to trust our measurements without doubt. Whether you’re measuring a complex sun shade composed of multiple concave shapes or a 260-metrelong waterslide with curves and loops, precise connection of the parts is critical.

If we fail to identify potential mistakes or to provide the correct measurements, the entire ship could be scrapped. It is no wonder, then, why we take our responsibilities so seriously.

Explore next chapter:多功能工具箱

Story: SOS shipbuilding on scans
Chapter 1: No rooms for errors
第2章:多功能工具箱
第3章:Advancing 3D laser scanning

Reporter 75 - June 2016

将自己的“记者75”作为PDF文件下载。

将自己的“记者75”作为PDF文件下载。

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