SOS shipbuilding on scans

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，我们公司看到了从木船运输到我们2015年4月最新发行的《皇家加勒比海国歌》（Royal Caribbean Onthem of the Sean of the Sean）的最新发行的船只的发展。长350米长，长达168,666吨，我们长期的豪华巡航船最新的一件是在行业中的光滑设计中引起了轰动。

No room for errors

‘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.

Information customised for the craftspeople distributes technical details as well as best practice procedures and the knowledge of how to avoid costly defects. With regard to location-independent process steps inside the huge vessel, news about every single improvement on error reduction by using new tools, sequences and available real-time data are inevitable for efficiency.

有效质量管理的第二个支柱是短周期的测试和检查。应该在某些阶段设置质量保证，而错误的风险很高。快速检测避免了必须拆除，修复和恢复完整的酒店区域以及游轮的机械空间。生产过程中的60,000多次检查，以及在调试和交付阶段进行的其他检查，确保将消除晚期的问题。

这些测试是由来自钢结构，焊接，材料测试，管道系统，植物工程，调试，室内家具，尤其是尺寸控制的专门和合格的员工进行的。在上述指数成本图中尤其描绘了训练有素的检查员对短疗法的质量保证的需求。由于在此过程的每个步骤中，施工成本会产生10甚至更​​多的倍数，因此未被早期检测捕获的错误可能会导致数百万的预算成本并危害生产计划。

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.

如果我们无法确定潜在的错误或提供正确的测量结果，则可以取消整个船。那么，难怪为什么我们如此重视自己的责任。

Explore next chapter:多功能工具箱

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