discuss the impact of competency in the Malaysian Marine Industry perspective focusing on shipbuilding

1. IMPACT OF COMPETENCY IN THE
MALAYSIAN , MARINE INDUSTRY
PERSPECTIVE –
FOCUS ON SHIPBUILDING
By
First Admiral Dato’ Ir Ahmad Murad b Omar (Retired),
FIEM, FIMarEST, MSNAME,
PEng, CEng, ASEAN Eng.
5 October 2016
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2. THE SPEAKER
First Admiral Dato’ Ir Ahmad Murad B Omar (Rtd)
BE (Mech) UTM. MSc EBM (Warwick), P Eng, C Eng, CMar Eng, FIEM, FIMarEST,MSNAME
(US), ASEAN Engineer
Vice President Institute or Marine Engineering Science & Technology
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3. …discuss the impact of competency in the Malaysian Marine
Industry perspective focusing on shipbuilding
Purpose
The purpose of this presentation is to…
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4. ► Introduction - Shipbuilding
► Related Competencies vs Work
Breakdown Structure (WBS)
► Impact
► Recommendation
Content
This proposal is structured as follows:
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5. ► Introduction
► Related Competencies vs Work
Breakdown Structure (WBS)
► Impact
► Recommendation
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6. RFQ
Issuance of
LOA
Design/detail
design
Fabrication
Installation -
outfitting
Commissioning Test/trials
Physical
handing
Over (PHO)
• Building Strategy
Introduction
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7. Phase 1
(RFQ & LOA)
Collboration agreement
Ident working
framework
Submission RFQ
Technical clarification
TPS development
Final deliberation on
technical & commercial
Identify & confirm final work
packages . Issuance oc contract
Phase 2
(Design)
Aveva marine capability
Basic design - DCNS
Determination of final
design protocol
Prelim Design
Detail Design
Develop production
drawings
Phase 3
(Fabrication)
Confirm Production
Engineering protocol (material
management)
Engage OEM for
fabrication transfer of
technology
Supply material
Participitative
engagement
production begins with
prototyping & prelim
certification
In process monitoring
Final production &
Certification
Phase 4
(install)
Master & understand
build sequence
Project planning,
coordination &
monitoring
Material & accessories
& ILS element verified
Outfitting by Zone
(Korean Best Practice)
Verification & Insp
Maintenance &
Protection
Phase 5 (Test
& Trials)
Compliance to
drawings approved
Insp dry survey
Insp final & punch list
clearance
Compartment closure
Insp
Compartment handing
over ensuring
conformity &
compliance
Verification ILS requirements
Make Ready for
Physical Handing Over
(PHO)
Phase 6
(PHO)
Preparation of final
handing over.
Insp certificate and
verification of punch
list clearance
Insp protocol sign off
agreement including
screening of ILS
elements
ILS elements -
documents, training,
onboard spares, base
spares, STTE etc
Certificate sign-off and
hand over
Determination of
Warranty framework
• Breakdown Work packages Build Strategy
Introduction
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8. MASTER SCHEDULE OF LCS 1
MASTER SCHEDULE
Introduction
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9. RFQ
Issuance of
LOA
Design/detail
design Fabrication
Installation -
outfitting
Commissioning Test/trials
Physical
handing Over
(PHO)
• Overview of Complete Shipbuilding Activity &
Competencies Required
• Estimators
• Engineers
• Naval Arch
• Financial
experts
• Design
engineers
• Draughtsman
• Naval Arch
• Material
engineers
• Skilled labor
• Project
engineers
• QA/QC
Engineers
• Project
Engineers
• Naval Arch
• Material
Supply chain
controller
• Skilled labor
force
• QA/QC
Engineers
• Project
Engineers
• Naval Arch
• Commissioning
engineers
• OEM
representative
• Skilled labor
force
Introduction
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10. ► Introduction
► Related Competencies vs Work
Breakdown Structure (WBS)
► Impact
► Recommendation
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11. Competencies vs Work Breakdown Structure
Through the phases of Build Strategy it is obvious that
there are different stages of construction that requires
sometimes similar skill sets and some other time differing
skill sets.
► Weak points identified:
 Production Planning & Production Engineering processes
 Supervisory, work coordination & work execution (Project
Management)
 Subcontractors’ organizational capabilities
skill sets and experience.
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12. Competencies vs Work Breakdown Structure
Ship Building module scope of work mainly cover
implementation of Shipyard production planning system on
all ship building projects
► Job Design - work breakdown & work packaging system
► Job Method - Detailed Work Procedure (DWP)
► Reality-based Planning - Interactive system between planning &
production (Zone Manager - Discipline Integrator)
► Job Instruction - Work Execution Program (WEP)
► Production Method - Integrated Hull, Outfitting & Painting (IHOP)
► Project Management - effective practical methodology / Task Force
meetings
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13. Competencies vs Work Breakdown Structure
- Skills sets required in Shipbuilding
Managers
Administrators
Designers/Engineers
Production Work force
Heavy Equipment Operators
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14. Competencies vs Work Breakdown Structure
- Skills sets required in Shipbuilding
Managers
Project Related
Project
Managers
Project
Planning
Financial
Cost &
Estimation
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15. Competencies vs Work Breakdown Structure
- Skills sets required in Shipbuilding
Administrators
Human
Resource
Personnel
Procurement
Purchasing
Supply
Chain
Material
Control
Facilities
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16. Competencies vs Work Breakdown Structure
- Skills sets required in Shipbuilding
Designer/Engineers
Planning
Work
Breakdown
Zone
Outfitting
Ship Design
Structural Construction
Detail Design
Drafting
Production
Drawing
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17. Competencies vs Work Breakdown Structure
- Skills sets required in Shipbuilding
Production
Production
Design*
Work
Breakdown
Zone
Outfitting
Production
Welding Piping Electrical HVAC Outfitting
QA & QC
Inspeectors NDT
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18. Competencies vs Work Breakdown Structure
- Skill sets required in Shipbuilding
Heavy Equipment
Operators
Machine MHEs
Cranage/Rigging
Goliath
Crane
Gantry
Mechanical
Handling Equip
Fork Lift Transporter Side Loader
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19. Competencies vs Work Breakdown Structure
- Flow Diagram of Ship Construction in a Typical Yard
SHIP 1 SHIP 2
SHIP 3
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20. Competencies vs Work Breakdown Structure
One of the better approach in completing a building
project on schedule would be to apply Korean best
practice. IHOP (Integrated Hull Outfitting & Painting)
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21. Competencies vs Work Breakdown Structure
- Adopting the Korean best practice produces tremendous results
- Achievement of jobs and work packages
- Lesser punch list
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22. ► Introduction
► Related Competencies vs Work
Breakdown Structure (WBS)
► Impact
► Recommendation
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23. Impact
- Impact of skill sets on overall shipbuilding
process
Management
•Project mgt failure
•HR planning failure
•Financial fail
Administrators
•Supply chain fail
•Material handling fail
•Facilities ineffective
Design
•Drawings late
•Drawings error
•Design production fail
Production
•Welding failure rework
•HVAC delay
•Electricalcable pulling
delay
•Piping delay
•Outfitting delay
Mechanical handling
Equipment
•ME not available on
time
•Defective
•Lifting delays
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24. Some Failures
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25. Masterpiece pipework
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26. Negative Impacts
Skill Set Negative Impact Final Result
Project Management Project delays Late delivery charges
Cost estimation Cost projection/estimation run-
out
Rectification & re-work cost
Human resource management Manpower utilization poor Manpower cost run-out
Procurement management Material delivery delay Impact on Gantt chart
scheduling. Project delay.
Facilities mgt Facilities defective Replacement cost and
outsourcing cost
Production design PMT fail to meet schedule Project delay. Cost increase
Drawing delays Impact on schedule Project delay
QA & QC failure Re-work and rectification cost Impact on schedule . liqudated
delay.
Non availability of heavy
machinery equipment
Cost increase for outsourcing Project cost increase.
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27. ► Introduction
► Related Competencies vs Work
Breakdown Structure (WBS)
► Impact
► Recommendation
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28. Recommendation
► Improve shipbuilding line production system:
 Indoor - steel fab / panel & block assy / block outfitting -
ensuring optimal building method, max use of yard
facilities & smooth production flow
 On-platform - module outfitting / block painting,
erection & joining / platform outfitting - ensuring
block/module completion, pallet management, erection-
fit up technic & use of IHOP schedule
 On-board - on-board painting / HAT / SAT - through zone
completion
 Project Management Teams – PMT competency to be
improved. Be mindful of ten Project Management
Knowledge areas.
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29. Recommendation
► Improve shipbuilding line production system:
 QA & QC – inspectors undertaking inspections such as
welding, electrical. Piping, HVAC and outfitting must be
qualified and trained.
 Human Resource Development – Interpersonal and skill
based training must be equally emphasized.
 Disciplinary – all work force must be aware of good
disciplinary abiding practice.
 Supply Chain & Material Handling – is essential to be
developed in order to circumvent delays and issuance of
wrong itms.
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30. Recommendation
► Improve shipbuilding line production system:
 Workshop Layout & Facilities Management - ensuring
max use of yard facilities & smooth production flow
 Streamline outfit parts manufacturing production
system –
 Steel Outfit Manufacture
 Pipe Spool Manufacture
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31. END
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Thank You