Comparison-of-the-Shipbuilding-Business--Korea--Ch.ppt

Click to edit Master title style,Click to edit Master text styles,Second level,Third level,Fourth level,Fifth level,*,Comparison of the Shipbuilding Business Korea/China,韩国造船和中国造船之间的比较,HANA Information Technology Co.,Ltd.,1,Key Criteria:Comparison between China&Korea,主要数据：中国和韩国之间的比较,管理,Material,物资,预,算管理（,靠数据）,責任所在,(,清晰，,組織明確,),問題,/,改善意識,解決方案積極摸索,总是以生产为导向,预,算管理,）,(,通过估计）,責任所在,(,不清晰、,集團管理,),問題,/,改善意識,國營企業,文化,设计,质量设计,:,施工过程工序信息,物资和物流,与计划挂钩,以生产为导向,总工作单元,按阶段预舾装,来自于基本设计,成本有效性的设计,图纸是,:,仅仅基本信息,不及时,基本的产品设计,没有,生产率的概念,高度保守,（,不能成本有效）,Production,生产,多项行为,与设计构成一个小组,生产过程革新,按工时进行控制,计划与行动挂钩,作业过程之间,部门之间,共享信息,由,CIMS,支持,取决于,个人的领导,传统的过程,按量来控制,自上而下的行动,只有当命令下达时,复杂的机构,（,容易找借口）,信息不共享,抱怨设计,采购条件,容易控制（供货商）,较短的介入时间,丰富的基础设施,管理系统,开放招标,按预算控制,（,即时评审）,由,CIMS,支持,依赖于供应商,卖方的市场,（,钢板、主机，等）,选择面窄,(,小的/特殊的项目）,对交货控制较差,缺乏信息,管理,:,没有体系,韩国,中国,2,No.,Subject,比较事项,No.,Subject,比较事项,Block Painted without PE,没有总组的涂装分段,24,Team meeting room,会议室,Painting at Block Joint Area,在分段缝区域进行涂装,23,Notice for Safety,安全告示板,46,在分段/总组阶段超量的脚手架,22,Team News-Bulletin Board,项目的信息 看板,45,在总组现场，长时间的延期,21,Steel outfitting Storage Condition,铁舾件存放的状况,44,预舾装的做法 与设计的关系（,FPSO）,20,Warehouse,仓库,43,Engine Room Bottom Block,机舱底部分段,19,在分段阶段/总组阶段没有舾装的机舱,42,涂装和分段 对水泥墩而言发生了什么变化,18,在总组阶段没有舾装的大型分段,41,Scrap&Rubbish,废料&垃圾,17,甲板室/楼子施工使用的脚手架,40,Stand-by Areas,备用场地,16,法兰表面没有保护而喷油,39,Welding Machine in Hull Shop,船体车间的焊接机器,15,Pipe Unit without Support,没有支撑的管子单元,38,角钢支撑和管子 分段找平很差,14,没有设备和舾装的单元,37,Concrete and Wooden Blocks,水泥和木头的垫块/墩,13,Pipe Pieces at Dock Stage,在坞内合拢阶段的管段/件,36,Pipe Protection&Pallet s,管子保护和托盘,12,Machinery&Equipment Protection,机械/设备的保护,35,装配车间 劳动力的分配,11,Cabling at Hull Stage,在合拢阶段的电缆工事,34,Steel Plate Leftover,钢材 余料,10,Burn Damage and Cost,烧损和成本,33,Steel Small Pieces,钢材 小件,9,坞内：在合拢阶段而不是在总组阶段安装,32,Steel Material at Cutting Shop,在切割车间的钢材,8,坞内：机舱内部的危机,31,Workshop Floor,车间的内部场地,7,在艉部区域超量的脚手架,30,切割台的下面（有渣滓）,6,Scaffolding to Install Rudder,安装舵使用的脚手架,29,数控切割机，切割的状况,5,大坞阶段：在货舱内的脚手架,28,Steel Plate Condition,钢板的状况,4,大坞阶段：舱内腐蚀,表面处理和车间底漆车间,3,FPSO,外板上的烧损,26,Angle Storage Condition,型材存放的条件,2,25,Steel Plate Storage,钢板的存放,1,Comparison between,Chinese&Korean Shipyard,中国船厂与韩国船厂之间的比较,27,3,Chinese Shipyard,中国船厂,Korean Shipyard,韩国船厂,1.Steel plates storage condition,钢板存放状况,1.,钢板没有适当存放,-Difficult Surface preparation,表面处理困难,-,与车间底漆的附着力有问题,-Steel Plate cutting quality,钢板的切割质量,2.,钢板：要花长时间方能挑选出来,(Busy Crane)（,造成吊车的紧张）,Solution,解决措施,Steel Plate stored by production schedule,钢板按生产计划进行存放,适当地进行存放（按技术规格书要求）,Require relevant information&,Consulting,需要相关的信息/咨询,4,Chinese Shipyard,中国船厂,Korean Shipyard,韩国船厂,3.Surface Preparation&Shop Priming Shop,表面处理和车间底漆车间,1.Contamination at shop-priming line,预处理线被污染,2.Damage Facility&equipment,损伤了设备,3.Effect Quality&Productivity(Heavy dust),影响质量和生产率（灰砂严重）,4.Safety path invisible,看不到安全通道,Solution,解决措施,Clean workshop,清洁车间,Floor Coating(Secure safety path),地面涂装（保证安全通道）,Managerial issue(justify with Data),管理事项（照数据资料来评判）,6,Chinese Shipyard,中国船厂,Korean Shipyard,韩国船厂,4.Steel Plate Condition,钢板的状况,1.Steel plates are Mixed,Disorganized,钢板混合在一起，散乱,2.Cannot identify,不能识别（钢件的余料/废料/,BOM,件）,3.No temporary stop(stand-by)location,没有临时的备用位置,浪费时间和,$,Solution,解决措施,指定钢材的备用位置/场地,Designated area for specific project,piece type etc,特定的项目、零件类别等有指定的存放区域,Save time and$,improve Safety and productivity,节省时间和金钱，改善安全状况和生产效率,Need information/data,需要数据和资料,7,Chinese Shipyard,中国船厂,Korean Shipyard,韩国船厂,5.N/C Machine:Cutting Condition,数控切割机：切割的状况,1.Cutting Notch must be grinded,切割口必须打磨,2.Waste Time,$,Material,浪费时间、金钱、材料,3.Quality problem(Welding),质量问题（焊接）,4.Defects on painting,造成涂装的缺陷,5.Low accuracy,准确度低,6.Etc,等,Solution,解决措施,Adjusting N/C Machine,调整数控切割机,8,Chinese Shipyard,中国船厂,Korean Shipyard,韩国船厂,7.Workshop floor,车间的内部场地,1.Low efficiency in using space,低效率使用空间,2.Safety issue,安全问题/事项,3.Badly Effect Transportation,严重影响转运,4.Low productivity,生产效率低,All related with$,所有都与金钱有关,Solution,解决措施,Floor Coating,对地面进行涂装,material well organized,材料有序管理存放,Save$,Improve quality&Productivity,节省金钱、改善质量和生产效率,But,Need information/data,但是，需要信息和数据资料,10,Chinese Shipyard,中国船厂,Korean Shipyard,韩国船厂,8.Steel material at Cutting Shop,在切割车间的钢材,1.Scratch on plates,板上有划伤,2.Difficult to identify Pieces,识别零件困难,3.Long-time to find right piece(for each block),花很长的时间来找到正确的零件（对应于每个分段）,All related with$,所有都与金钱有关,Solution,解决措施,Steel store by Block,按分段存放钢材,Use Rack/Pallet,使用架子/托盘,Save$,Improve quality&Productivity,节省金钱、改善质量和生产效率,But,Need information/data,但是，需要信息和数据资料,11,Chinese Shipyard,中国船厂,Korean Shipyard,韩国船厂,10.Steel Plate:Leftover,钢材 余料,1.Increasing material cost because of letting scrap,由于有废料剩下，增加了材料成本,Solution,解决措施,-Expanding scrap control,using Lug,bracket,Piece,对废料进行控制，用作吊鼻、肘板、和小零件等,-Set-up scrap control rule,建立废料控制规定,(Need of Consulting),需要进行咨询,13,Chinese Shipyard,中国船厂,Korean Shipyard,韩国船厂,12.Pipe Protection&Pallets,管子保护和托盘,1.Because of bad Pipe Masking,由于管子覆盖很差，,-Pipe material Paint Damage,管子的油漆损坏,(Re-coating),（重新涂装）,-,增强了在设备操作阶段的损坏的担心,2.Not using Pallet,不使用托盘,-Re-Painting for Pipe Paint Damage,对管子的油漆损坏重新进行涂装,Solution,解决措施,Pipe Masking&Pallet Control,管子要进行覆盖保护，并使用托盘,(Need of Consulting),需要进行咨询,15,Chinese Shipyard,中国船厂,Korean Shipyard,韩国船厂,13.Concrete&Wooden Blocks,水泥和木头的垫块/墩,1.Excessive waiting time and delay of the Block transportation,超量的等待时间和分段转运的延迟,-Preparation of Jig&folk lift,夹具和叉车的准备,-Block Level work,分段的找平工作,-,根据分段的线型重新安排托架,Solution,解决措施,Recommend to use trestle for Block transportation,Concrete Block at Dock stage,建议使用托架来完成分段转运，水泥墩在大坞阶段使用,16,Chinese Shipyard,中国船厂,Korean Shipyard,韩国船厂,15.Welding Machine in Hull Shop,船体车间的焊接机器,1.Occupy work space due to poor arrangement of welding machine,由于焊接机器的布置很差，占用了工作空间,2.Potential injury due to unsafe arrangement of welding cable,由于焊接电缆的不安全布置，增多了发生潜在伤亡的机会,Solution,解决措施,Allocate welding machines in pre-fixed,“box type”storage,将电焊机放置在预制的“盒形”的存储箱中,18,Chinese Shipyard,中国船厂,Korean Shipyard,韩国船厂,16.Stand-by Areas,备用场地,Occupy spaces with steel pieces scattered around whole working areas and interrupt other process,钢材零件散乱在整个工作区域内，因而占用了场地，并扰乱其它作业施工,Lost-time due to piece searching,由于要寻找零件，而损失时间,Solution,解决措施,Designate“waiting area”in workshops,在车间内指定“等待区域”,19,Chinese Shipyard,中国船厂,Korean Shipyard,韩国船厂,17.Scrap&Rubbish,废料&垃圾,Waste time for sorting craps for“recyclable scrap”and Rubbish,etc.(insufficient scrap baskets),分拣出废料做再循环利用和垃圾、等，浪费时间（废料框不够充分）,Solution,解决措施,Scraps and Rubbishes(Combustible and incombustible)are separately collected upon the time they are generated,废料和垃圾（可燃烧的和不可燃烧的）在被产生之时就要开始单独进行收集,20,Chinese Shipyard,中国船厂,Korean Shipyard,韩国船厂,18.Paint&Block What Happened with Concrete Block,涂装和分段 对水泥墩块而言发生了什么变化,由于分段和木头（水泥）墩单独移动转运，从而损失了时间。同时，由于频繁转运的分段和木头墩，造成了大量的油漆损坏而必须重新涂装（分段频繁转运是为了提高涂装厂房的利用率）,Solution,解决措施,Recommend to use“Trestle”for block transport hence the Blocks and Trestles(as supports)are moved at same time Less damage,save times and Paint materials,建议使用托架来完成分段的转运，这样一来，分段和托架就是同时移动-减少了油漆损坏，节省了时间，节省了涂装材料,21,Chinese Shipyard,中国船厂,Korean Shipyard,韩国船厂,机舱分段在正转位置（分段总组和安装设备之后，设备防护，涂装）,19.Engine Room Bottom Block,机舱底部分段,Time loss due to Twice(2 times)turn-over,由于两次翻身，损失了时间,2.M/H loss for firing damage after painting,由于涂装之后动火工作的烧损，损失了工时,3.M/H loss on Scaffolding,在脚手架上损失了工时,Solution,解决措施,Need Consultation,需要咨询/顾问,22,Chinese Shipyard,中国船厂,Korean Shipyard,韩国船厂,21.Long-time Delayed at PE Site,在总组现场，长时间的延期,1.,分段的等待周期使进度延期（大约45天）安装管子、安装电缆托架、安装风道、等,2.Low“working-area”efficiency,工作区域的利用率低,3.Low efficiency of trestle&supporters,托架&支撑的利用率低,Solution,解决措施,Increase pre-outfitting at Block Stage,(Need of Consultation),在分段阶段提高预舾装,24,Chinese Shipyard,中国船厂,Korean Shipyard,韩国船厂,22.Excessive Scaffolding at Block/PE Stage,在分段/总组阶段超量的脚手架,1.,对脚手架的打设和拆除需要特别高的工时,2.,相关部门（舾装）的工作因脚手架打设工作而必须中断,3.,脚手架由专门的队伍来打设，他们得不到适当的打设指导，最后，造成打设出的脚手架使用起来不方便的情况。,Solution,解决措施,Plan works“without”or“minimum”scaffoldings,(Need Consultation),做出工作的计划，达到“不用”或“最少用”脚手架的程度,25,Chinese Shipyard,中国船厂,Korean Shipyard,韩国船厂,23.Painting at Block Joint Area,在分段缝区域进行涂装,1.Waste time to remove contamination(paint film,dusts etc.)before start painting works,在喷涂开始前，浪费时间来消除污染（涂层、灰尘、等）,2.Unsatisfactory welding result(poor welding quality due to residue of foreign material),焊接的结果不令人满意（由于外界杂物介入，使焊接质量很差）,Solution,解决措施,Protect“Block-joint areas”before painting primer coating(approx.30 mm)and keep such width protected,Remove the tapes just before welding works for P.E are executed,在上底漆之前对分段缝区域进行保护（大概30,MM），,并一直维持这种保护，直到总组的焊接工作开始时才拆掉保护胶带、等。,26,Chinese Shipyard,中国船厂,Korean Shipyard,韩国船厂,26.Burn damage at side-shell,FPSO,外板上的烧损,对于吊鼻切除的部位，对于分段的合拢缝部位，因为没有任何保护而产生了严重的锈蚀，这样，接下来的油漆修复工作消耗大量的工时。,Solution,解决措施,Carry out“touch-up”with primer coatings immediately after grind-off welding lines,lug stain etc.,在焊缝打磨后、吊鼻切除部位打磨后立即涂上车间底漆,28,Chinese Shipyard,中国船厂,Korean Shipyard,韩国船厂,27.Dock Stage:Corrosion at Hold Inside,大坞阶段：舱内腐蚀,1.Heavy Ruston Cargo Hold bulkhead that cause waste of paint material and manpower due to repeated surface preparation and coating application,货舱的壁子锈蚀严重，从而，引起了油漆材料的浪费和人力的浪费，因为要重复进行表面准备和涂装施工,2.Cause delay of the projects,造成了项目的延期,Solution,解决措施,Minimize block exposure at open space,减少分段在开敞空间的暴露时间,（降低分段涂层间的间隔（分段阶段）和完整涂层间的间隔（合拢）,Need Experts consultation,需要专家的咨询/顾问,29,Chinese Shipyard,中国船厂,Korean Shipyard,韩国船厂,29.Scaffolding to Install Rudder,安装舵使用的脚手架,Excessively high demand of manpower for the Scaffolding(install&remove),打设和拆除脚手架需要极其高的人力,Solution,解决措施,Recommend to use special Jig for Rudder Installation,建议使用专门的工装来安装舵,31,Chinese Shipyard,中国船厂,Korean Shipyard,韩国船厂,30.Excessive Scaffolding at Stern Area,在艉部区域超量的脚手架,Excessively high demand of manpower for the Scaffolding(install&remove),打设和拆除脚手架对劳动力有极其高的需求,Solution,解决措施,Recommend special Jig,建议使用专门的工装架,Hello!,32,Chinese Shipyard,中国船厂,Korean Shipyard,韩国船厂,31.Dock:Crisis at Engine Room Inside,大坞：机舱内的危机,在机舱内的活儿没有得到组织，引起了主要设备的安装工作、舾装件的安装工作、和合拢焊接工作之间的中断,2.,人力工时的浪费（在大坞阶段进行舾装件的安装对工时的需求要比在分段阶段的需求高得多。,Delay of the project due to outfitting works,由于舾装工作使项目延期。,Solution,措施,Workload and Progress shall be managed by optimum work-flow and Stage,(Need Consultation),工作负荷和进度要通过优化的作业流和作业阶段来管理（需要顾问）,33,Chinese Shipyard,中国船厂,Korean Shipyard,韩国船厂,32.,大坞：在合拢阶段进行安装而不是在预合拢（总组）阶段安装,Man-hour,工时,Delays,延期,Crane request,对吊车起重的需求,Solution,解决措施,Finish work at PE stages,在预合拢（总组）阶段完成工作,Pipe Connection,Cabling and Pilot-run of the equipment etc.,管子连接，电缆和设备的碰头等,(Need of Consultation),需要顾问,34,Chinese Shipyard,中国船厂,Korean Shipyard,韩国船厂,33.Burn Damage and Cost,烧损和成本,Self-explanatory,不必解释了,Solution,解决措施,Minimize Fire work at Dock Stage,在坞内建造阶段减少动火作业,(Need Consultation),需要咨询/顾问,35,Chinese Shipyard,中国船厂,Korean Shipyard,韩国船厂,34.Cabling at Hull Stage,在合拢阶段的电缆工事,1.Excessively high man-hours,极其高的工时需求,2.Badly influence to other departments due to interruption,对其它部门产生严重影响,3.Cables damaged during fire work(of other department),其它部门的动火作业过程中损坏电缆,Solution,解决措施,Pre-install cables,connect power-line from on-shore facility from to turn on light at dock stage,预先安装电缆，接岸电直到在坞内为照明送电。,(Need Consultation)（,需要咨询/顾问）,36,Chinese Shipyard,中国船厂,Korean Shipyard,韩国船厂,35.Machinery and Equipment Protection,机械/设备的保护,Self-explanatory,不必解释了,Solution,解决措施,Proper protection must be made immediately after installation of machinery and equipment(also after trial run at PE stage),在机械设备安装之后，必须立即进行保护（在总组阶段的动车之后也要立即保护）,:Need Consultation,需要咨询/顾问,37,Chinese Shipyard,中国船厂,Korean Shipyard,韩国船厂,36.Pipe Pieces at Dock Stage,在坞内阶段的管段儿,Solution,解决措施,Module Unit to be installed at Block&P.E Stage,(Need Consultation),分段和总组阶段要安装单元（需要咨询/顾问）,1.Increased Painting work for damage repair,提高了对损坏的油漆的修理工作量,2.Man-hour,人力工时,3.Quality,质量,4.Delays,延期,38,Chinese Shipyard,中国船厂,Korean Shipyard,韩国船厂,37.Units without Equipment and Outfitting,没有设备和舾装的单元,1.Low working efficiency,工作效率低,2.Re-works after installation of the equipment&,related outfit material,在设备和相关的舾装材料安装之后，要重新施工,Solution,解决措施,Enlarge module unit and install them in Block&P.E Stage,将单元做大，并在分段&总组阶段安装,(Need Consultation),（,需要咨询/顾问）,39,Chinese Shipyard,中国船厂,Korean Shipyard,韩国船厂,38.Pipe Unit without Support,管子单元没有支撑,Solution,解决措施,Pipe Modules also be executed in Unit concepts,管子模块必须按单元的概念来完成,Same as above,与上面相同,Low efficiency,效率低,Reworks,重复劳动,40,Chinese Shipyard,中国船厂,Korean Shipyard,韩国船厂,39.Painting Pipe Flange without Masking,法兰表面没有保护而喷油,1.Paint work damaged at Pipe Flange,管子法兰处的油漆损坏,2.Potential trouble with operation of the equipment,对设备的日后运行带来潜在麻烦,Solution,解决措施,Flanges must be protected before Painting,法兰在涂装之前必须保护,41,Chinese Shipyard,中国船厂,Korean Shipyard,韩国船厂,-,所有的楼子/甲板室都靠安装脚手架来施工,40.Scaffolding for Deck House Works,楼子/甲板室施工使用的脚手架,1.Wasted M/H for Scaffolding(install&removal),脚手架的打设和拆除浪费了人力工时,2.Install scaffold according to P.E welding guide,Too much spent M/H for Installation of the Outfitting,painting,根据总组的焊接指导来打设脚手架，对舾装和涂装的工作要消耗太多的工时,Solution,解决措施,Use special Jig for Deck House,使用专用的工作台来进行楼子的施工,(Need of Consultation),需要咨询/顾问,42,Chinese Shipyard,中国船厂,Korean Shipyard,韩国船厂,-,艉部分段在坞内合拢,41.Supper Block without Outfitting at PE Stage,大型分段在总组阶段没有得到舾装,1.Delays due to too many erection blocks,由于太多的合拢分段而产生延期,2.Waste of Man-hours at Dock Stage,在坞内阶段浪费了人力工时,3.Increased demand for G-Crane due to increased number of erection Blocks,由于合拢的分段数量增多，对龙门吊的使用需求量从而加大,Solution,解决措施,Recommend Block P.E in P.E Stage,建议在总组阶段对分段进行总组,:Need of Consultation,需要咨询/顾问,43,Chinese Shipyard,中国船厂,Korean Shipyard,韩国船厂,-,在机舱分段的总组阶段没有安装设备和铁舾材料,42.Engine Room without Outfitting at Block/PE Stage,在分段/总组阶段，机舱没有得到舾装,1.Progress delayed for Equipment install,in Dock Stage,由于在坞内安装设备，因而进度延期,2.,由于在坞内阶段安装舾装件和设备，产生了大量的工时消耗,3.Low efficiency and more demand for Crane-service,效率低下，且对吊车的使用需求高,Solution,解决措施,Recommend install equipment&,outfitting material in module type pre-install at P.E,Stage,(Need Consultation),建议将设备和舾装材料做成单元，在总组阶段预先安装,44,Chinese Shipyard,中国船厂,Korean Shipyard,韩国船厂,-,仓库内的物资水平放置,43.Warehouse,仓库,1.Low efficiency,效率低下,2.Heavy M/H in handling material,对物资进行操作，大量消耗工时,Solution,解决措施,Adopt Racks and computer-integrated control system,in warehouse,在仓库内引进托架和计算机集成的控制系统,45,Chinese Shipyard,中国船厂,Korean Shipyard,韩国船厂,铁舾材料，,水平,放置在仓库内,44.Steel Outfitting Storage Condition,铁舾件的存放状态,1.Occupy large space,占用大量的空间,2.Damage,Badly influence quality of material,发生损坏，严重影响材料的质量,3.Excessive demand of M/H for receipt material,对接收的物资材料要花费极其多的人力工时,Solution,解决措施,Same as above,同上，引进计算机集成控制系统,46,Chinese Shipyard,中国船厂,Korean Shipyard,韩国船厂,45.,班组信息 看板上的信息和新闻在公司范围内得到了共享,46.,安全告示-与上面45相同（关于安全、健康、质量事项、工作内容、组织机构、等的交流）,47,Chinese Shipyard,中国船厂,Korean Shipyard,韩国船厂,47.Team Meeting Room:Directly influence quality of works,会议室：直接影响工作的质量,48,中国韩国造船量比较,49,韩国造船的发展,韩国的船厂在材料费上升、汇率升值等恶劣的经营条件下通过持续的投资及技术开发，迎来了造船业史无前例的大好形势。因以钢铁为中心的原材料价格急剧上升等影响收益锐减，但从长期发展的角度出发，不断加大投资及技术开发。以,LNG,船，大型，超大型集装箱船，,FPSO,为中心的高附加值船舶接单为重点（,04,年,LNG,船接单,44,艘）通过系列船提高生产效率（如,HDM04,年交船,36,艘，纯利,10,亿美圆）,着重进行能缩短工期的生产技术开发及工法研究 单元舾装、预舾装率最大化及分段最大化 增加外包甲板室、分段、舱口盖等,为达成生产目标，推进专业化及合作化 为确保经营的透明性及提高企业价值 扩大中小型船厂的新建 开发、应用平地建造方法 不断开展设定新目标、节减成本及改善等活动,韩国造船业从初期开始通过持续的技术投资和改善管理，克服了薄弱的技术和恶劣的条件，通过不断的改善活动和员工的积极努力，迎来了急速发展的今天，确定了在造船业的霸主地位。,50,韩国先进生产技术,51,单元组装,52,机舱单元组装,53,单元运输,54,机舱单元,55,超大分段,56,超大分段吊装,57,超大分段吊装,58,平地造船技术,59,