中韩造船的差距.ppt

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. 韩纳信息技术有限公司,2,Key Criteria : Comparison between China & Korea 主要数据：中国和韩国之间的比较,3,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,27,4,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,5,Chinese Shipyard 中国船厂,Korean Shipyard 韩国船厂,2. Angle storage condition 型材存放的条件,1. Disorganized, Not easy to find (Time) 散乱，不容易找（时间） 2. Heavily Corroded (Effect Quality) 严重锈蚀（影响质量） 3. Surface Preparation (Time / Paint / Labor + Energy) 表面处理（时间/油漆/劳动力+动能） 4. 浪费宝贵的钢材，角钢,Solution 解决措施 Use Angle Rack & Manage by number 使用角钢架并编号管理 First in / first out 先进先出 Require relevant information & Consulting 需要相关的信息和咨询,6,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）,7,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,8,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,9,Chinese Shipyard中国船厂,Korean Shipyard韩国船厂,6. Below Cutting Seat (Slag on Jig) 切割台的下面 （有渣滓）,1. Cutting defects 切割缺陷 2. Welding defects 焊接缺陷 3. Low Accuracy 准确度低 Time, $ etc 时间、金钱、等,Solution 解决措施 Clean everyday 10 minutes / Managerial issue 每天清洁 10分钟 / 管理事项,10,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,11,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,12,Chinese Shipyard 中国船厂,Korean Shipyard 韩国船厂,9. Steel : Small piece 钢材 小件,1. 由于缺少区域编号的控制，耗费太多的时间和增长设备的占用时间 2. 零件之间夹着方钢堆在一起，转运时发生划伤 3. Too much searching time 太多的查找时间 4. Drop off in piled efficiency for horizontal piece piled 堆放效率下降,Solution 解决措施 Area No.Control for Steel piece & Rack, Piece, Pallet control by block 对零件和存放零件的架子按位置编号进行控制，按分段对托盘进行控制 (Need of Consulting) 需要进行咨询,13,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,14,Chinese Shipyard 中国船厂,Korean Shipyard 韩国船厂,11. Assembly Shop & Allocation of Workforce 装配车间 劳动力的分配,1. Drop off in daily output for lack of assignment work volume 由于缺乏工作量的指定，每天的产出率下降 2. 在一个区域内挤满了工人且清洁状况很差，使每天的产出率下降 -Not control daily output by workers 不按照工人每天的产出率来进行控制,Solution 解决措施 Improving production efficiency for preliminary assignment work volume (Daily work volume : Worker, Group) 通过初步的指派工作量来提高生产效率（每日的工作量：每人、每组）,15,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,16,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,17,Chinese Shipyard 中国船厂,Korean Shipyard 韩国船厂,14. Angle Support & Pipe Poorly Leveled Block 角钢支撑和管子 分段找平很差,Heavy loss on MH & Working time during PE and outfitting installation due to heavy deformation of the Block that caused by under poor support 由于下面的支撑很差引起了分段的严重变形，从而，在总组和舾装阶段损失大量的工时和工作时间,Solution 解决措施 Recommend to use Hydro Pipe Supports 建议使用液压管支撑,18,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,19,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”,20,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,21,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,22,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,23,Chinese Shipyard 中国船厂,Korean Shipyard 韩国船厂,20. Relationship between Design and Pre-outfitting Practice 设计和预舾装的做法之间的关系,Loss time due to fairing and damage repair after painting due to outfitting work carried out after painting 由于在涂装之后进行舾装工作，火工矫正工作和油漆损坏修理工作损失了时间 2. Project delays due to outfitting works at dock and after launching 由于在坞内和水上进行舾装工作，使项目延期,Solution 解决措施 Recommend to move the Block after completion of the Outfitting works into Painting shop (Need to find Experts and set up the System) 建议在舾装工作完成之后将分段转运到涂装厂房。（要找专家并建立体系）,24,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,25,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,26,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30MM），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。,27,Chinese Shipyard 中国船厂,Korean Shipyard 韩国船厂,24. Block Painted without PE 没有总组的涂装分段,Excessive demand of man-power for repair of damaged coatings due to installation of the outfitting items 由于要对后续进行的舾装工作引起的涂层破坏进行修理，而需要超量的人力和工时。 2. Poor welding / painting quality 焊接/涂装的质量差,Solution 解决措施 Outfitting works at Block stage (nearly 100%) (Need Consultation) 在分段阶段舾装工作差不多100%结束（需要咨询/顾问）,28,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漆,29,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,30,Chinese Shipyard 中国船厂,Korean Shipyard 韩国船厂,28. Dock Stage : Scaffolding at Cargo Hold Inside 大坞阶段：在货舱内的脚手架,Loss of MH due to Scaffolding and its removal 打设和拆除脚手架损失了工时 2. Increased demand for the Cranes service 对吊车的配合作业需求量升高 3. Other processes are interrupted due to scaffoldings installed in Cargo holds 由于在货舱内打设脚手架，其它的作业受到中断,Solution 解决措施 Recommend to use special jig (Piece designed for Scaffolding) for ease of installation and removal of the staging at building docks 建议使用特殊的夹具（为脚手架设计的零件）来简化脚手架的打设和拆除。 ( Need of Consulting) 需要咨询/顾问,31,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,32,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!,33,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）,34,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,35,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,36,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）,37,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,38,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,39,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）,40,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,41,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,42,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