扫描中的SOS造船

Author: Thorsten Störig and Ralph Zimmermann, June 2016

Imagine putting together a jigsaw puzzle of more than 30 million pieces. The instructions say to group these pieces into about 80 individual blocks, which will weigh up to 800 tonnes. Those blocks must be precisely placed together, offering passengers a safe and pleasant journey aboard a tremendous cruise liner. Once planned, you have less than one year to construct, all the while meeting budget constraints and exceeding customer expectations in quality. Welcome to the world of cruise ship building.

At MEYER WERFT, we face these challenges on a daily basis. Building ships since 1795 in Papenburg, Germany, our company has seen the evolution of watercraft transportation from wooden ships to our latest release in April 2015 of the Royal Caribbean Anthem of the Seas. Measuring 350 metres long and 168,666 tonnes, the latest in our long line of luxury cruise ships is making waves in the industry for its sleek design.

No room for errors

“第一次正确”是德国造船厂Meyer Werft的所有员工的目标。一项学科中的小错误可能会对员工和物质费用产生重大影响，甚至可以延迟整个建筑过程，从而导致额外的费用。特别是，在码头大厅的短暂建筑期间，其长500米的干码头突出了每日挑战。通过使用其全容量并每年六个月的时间建造两艘船只，工作过程在不同阶段为两种类型的船提供服务。尽管一艘船的船体使用最终的钢块完成，但随后的水下零件的发动机室的建筑工程已经在进行。设计和生产中的复杂质量和高级计划程序可确保很少发生错误并迅速检测到错误。

如此复杂而多元化的过程的根源在于基于风险的方法，通过该方法，通过该方法分析并评估了单个容器零件和工作序列的潜在错误。但是，来自这些研究的行动不仅关注所谓的5R（正确的部分，正确的时间，正确的位置，正确的数量和正确的质量）。正确的信息是现代迅速造船的关键因素。构建图纸细节和众多标准文档的章节，即主题领域仅收到所需的独家内容，这会减少缺少树木森林的危害。

信息定制的工匠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.

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.

质量管理部门包括系统方法以及进行几何调查和定位的测量组。我们的小组由九种不同类型的工程师，五名技术人员，六名学员和学生学徒组成。我们在整个施工过程中进行所有测量工作。等离子火炬切割机的对齐只是第一个任务之一，绝对精度是铺设龙骨并制造块时必须的精度。最重要的是，还有许多其他特殊工作，例如确定船舶的总长度和协助研究项目。随着越来越多的船只被预制和附着在块中，我们需要毫无疑问地信任我们的测量。无论您是测量由多个凹形形状组成的复杂遮阳阴影，还是带有曲线和环的260个米的水滑行，零件的精确连接都是至关重要的。

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.

探索下一章：Versatile toolbox

故事：扫描中的SOS造船
Chapter 1: No rooms for errors
Chapter 2:Versatile toolbox
Chapter 3:前进3D激光扫描