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SHIPBUILDING SOLUTIONS

MANAGE SHIPBUILDING PROCESS WITH INTEGRATING PRODUCTION, DESIGN,


MATERIAL AND COST TO DEVELOP PROJECT PROFITABILITY

JUARI
IFS Business Consultant
Email: juari@ifssi.co.id
HP: +6281317838582

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TABLE OF CONTENT
● Project Based Solutions
● Shipbuilding Project Solutions
● Business Planning
● Sales Planning
Objective
● Estimate
● Building Planning
Integrated WBS Code
● Design Process
● Material Process Cost by Block
● Production Process
● Project Control Budget Type
● Project Conclusion
● Document Management Profitability

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PROJECT BASED SOLUTIONS (PBS)
WHY STANDARD MANUFACTURING IS THE WRONG CHOICE

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Manufacturing versus Project
MANUFACTURING PROJECT

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WHAT IS PROJECT BASED SOLUTIONS (PBS)?
A concept to provide businesses with the ability to manage…..

COST TIME RESOURCES CASH RISK

........in real time.


Enables full visibility and control of projects throughout the whole organization.
Allows companies to manage the future—not the past

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SUPPORTING EACH STAKEHOLDER
● In the organization

CASH

RESOURCES
COST
RISK
TIME

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COST
Manage cost throughout the whole organization

Control of Earned Value during all phases in the


project lifecycle

Actual cost of work performed (ACWP)


Budgeted cost of work performed (BCWP) Budgeted
cost of work scheduled (BCWS)

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TIME Great control of float of identified project tasks
and flexibility to manage the critical paths
Manage time—get it all done

Estimates and planning drive the setting of


deadlines for delivery of projects, and hence
the organization and customers assessments
of reliability to deliver in time

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RESOURCES
Having the right people, with the right skills Optimize staff utilization rates and align
and the proper tools, in the right quantity at projects with organizational objectives
the right time
Unlimited options for multidimensional
Supports real-time collaborative resource analysis and reporting
management that enables managing people,
processes and finances across multiple Recognize and resolve resource gaps and
projects and ad-hoc work over-utilization

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CASH
Cash management monitors your project related capital commitments and cash flows

Support budgeting and forecasting across different organizations, any currency, for multiple time
periods and for different purposes

Provides the most accurate information possible on incoming and outgoing payments

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MANAGING RISKS
Any project organization is subject to risk The 4 stages for efficient Risk Management:

Manage risks is characterized by inability to - Identification


decide what to do, when to do it, and whether - Quantification
enough has been done - Strategy
- Control and Follow up
A risk is a combination of constraint and
uncertainty which exists in all projects

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SHIPBUILDING SOLUTIONS
GENERAL OVERVIEW

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SHIPBUILDING COMPANY
BUSINESS PROCESS AND REQUIREMENT

Shipyard Management System


Design Tools

ERP System

Standard Design

Infrastructure

AVEVA’s Integrated Shipbuilding Strategy


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PROJECT BASED SOLUTIONS
FOR SHIPBUILDING COMPANY Delivery
Planning
Project
Executions Project
Business Planning
Control

Pre-project

After
Project

Project Planning

Project Closing
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BUSINESS PLANNING
GENERAL OVERVIEW
Inflow

•Business Target
•Facility Information
•Standard Make-span

Business Define
Strategic
Create Line Upgrade
Planning Plan
Chart Standard

Outflow

•Facility Plan (Ship Building Line Chart)


•Sales Target
•Man Power Plan & Outsourcing Plan
•Financing Plan

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BUSINESS PLANNING
EXAMPLE – LINE CHART
INDONESIA
ST
SHIP BUILDING LINE CHART No. 2/ R-6 / 29 Des 2017
2014

NO SHIP AT
2018
2014 2019
2015 2020
2016 2021
2017
US 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1

B GRAVING DOCK SEMARANG

L D
M000271 TANKER 17,500
1 Merchant
LTDW
Ship #1 #

95
S L D
M000272 TANKER 17,500 ,9
2 Merchant
LTDW
Ship #2 8
%
36
PKR - 1 (Assy Hall DKP & ,1 F K ASS'Y MOD 1 JOINT MODULE L D
1 Merchant Ship #3
Graving Dock Divisi KANIA) 6
%
5, F K L D
PKR - 2 (Assy
Merchant ShipHall
#4DKP & ASS'Y MOD 3 JOINT MODULE
2 07
Graving Dock Divisi KANIA)
%
CONTRACTUAL
EDC F K L D DELIVERY
3 Naval Ship#1 - 1
SSV Philipines Ta
ha
p CONTRACTUAL
Fa EDC
F K L D
DELIVERY
4 Naval Ship#2 - 2
SSV Philipines b

ST
2014 2015 2016 2017
NO SHIP AT
US 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1

D. KAPAL SELAM
Pr
os
1 KAPAL SELAM - 3 ASS & OUTFITT
es F FAB
T 18
BUSINESS PLANNING
EXAMPLE – MAN POWER PLANNING

2018 2019 2020

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SALES PLANNING
GENERAL OVERVIEW
Inflow

•Business Planning

Sales Marketing Business Business Business


Planning Campaign Lead Opportunity Activity

Outflow

• Opportunity (Prospect)
• Customer (Owner) Enquiry

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SALES PLANNING
EXAMPLE

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ESTIMATE
GENERAL OVERVIEW
Inflow

•Similarity Project, Performed Project Survey


•Case

Cost
Estimate Breakdown
Structure (CBS)
Budget Type
Estimation
Procedure
Budget Scope

Quotation Quotation Tender Contract

Outflow

•Estimated Budget (by Case)


•Final Quotation
•Contract

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ESTIMATE
COST BREAKDOWN STRUCTURE (CBS)

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ESTIMATE
COST BREAKDOWN STRUCTURE (CBS) VS WORK
BREAKDOWN STRUCTURE (WBS)

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ESTIMATE
BUDGET TYPE

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ESTIMATE
EXAMPLE

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BUILDING PLANNING
GENERAL OVERVIEW
Inflow

•Registered Project

Building Line Chart


Master Erection
Hull
Construction & Outfitting
Planning Schedule Network Pre-outfitting
Schedule
Schedule

Outflow

•Project Information: Line Chart (Key Event)


•Schedule: Master Schedule, Erection Network and Outfitting
•Design Master Schedule and Material Planning (Main Equipment)
•Planned Cost and Hours for Resource / Facility (Man Power Planning and Man Power Loading)

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BUILDING PLANNING
WORK BREAKDOWN STRUCTURE (WBS)

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BUILDING PLANNING
INTEGRATED WBS CODE

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BUILDING PLANNING
EXAMPLE

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DESIGN PROCESS
GENERAL OVERVIEW
Inflow

•Project Info (Key Event)


•Initial Design

Design DMS Basic Drawing


Production MPL (Material
Process Drawing Procured List)

Outflow

•Design Schedule based on Key Event or I.HOP


•Basic Drawing: GA, Key Plan and Yard Plan
•Production Drawing: Product Structure, Assembly Drawing, Assembly Part List, Nesting Info, Material List etc.
•Planned Cost & Hours for Material (MPL)
•Plan/Actual Cost & Hours for Engineering Resource

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DESIGN PROCESS
IFS PART HIERARCHY & DEFINITION FLOW
Tracking: Serial,
Lot/Batch, No Tracking

Part Catalog Type: Manufactured,


Type: Phantom, Purchased, Purchased (raw)
Make, Buy Subject to non-product
• Can be Phantom Part
Engineering Part Inventory Part • Starting point for other material Non-inventory Part

Engineering Structure Manufacturing Part Purchase Part Sales Part Service Part

Package Part
Copy Transfer

IFS Part
Project Structure Manufacturing Structure IFS Part Hierarchy

IFS Part Product


Realization
IFS Part to Product

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DESIGN PROCESS
EXAMPLE

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MATERIAL PROCESS
GENERAL OVERVIEW
Inflow

•Project Info (Key Event)


•Basic Design
•Material Procured List (MPL)

Supply Material
Planning (Main
Bulk Material
PR PO
Chain Equipment)
Planning

Outflow

•Material Planning
•Material Stock
•Plan / Actual Cost for Material
•Change Order

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MATERIAL PROCESS
INITIATE VS RUNNING
Initiate Project Running Project

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MATERIAL PROCESS
FROM DEMAND TO SUPPLY
MPL Demand Process Material Allocation Process Supply Request Process

Create Supply Purchase


Request Requisition

Transfer to
Release Product Approve Part Net Project
Project
Structure Definition Material
Inventory
Purchase Request for
Order Quotation

Review Material Run the Gross


Procured List Requirements
(MPL) Calculation (GRC)
Purchase
Purchase
Change
Order Receipt
Management

Purchasing
Inspection
Process
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MATERIAL PROCESS Material
Supply
EXAMPLE MPL Demand
Allocation
Process

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PRODUCTION PROCESS
GENERAL OVERVIEW
Inflow

•Manufacturing Schedule (Monthly, Weekly, Daily)


•Project Resource & Material Allocation

Testing &
Production Fabrication Assembly Erection Outfitting Sea Trial Delivery
(HAT/SAT)

Outflow

•Pieced Part
•Assembled Part
•Block, Grand Block & Module/Zone
•Change Order

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PRODUCTION PROCESS
PRODUCTION FLOW

Material
Material
Shop Order Transport to Job Card for
Requisition for
Preparation Production Production
Indirect Material
Warehouse

Off-cut Material Material Issue


Realize Finished Time Reporting
Return to Main from Production
Goods for Production
Warehouse Warehouse

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PRODUCTION PROCESS
PRODUCTION FLOW – MATERIAL HIGHLIGHT
Transport to Issue from Off-cut Material
Production Production Return to Main
Warehouse Warehouse Warehouse

Create
Review & Set as W/D/R Reserve Create &
Consolidate Receive Receive
Execute Review Off- Execute
Shop Order
Transport
Transported Built No for & Issue cut Material Transport
Transported
Material Material Quantity Off-cut Material Material
Task Task
Material

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PRODUCTION PROCESS
EXAMPLE

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PRODUCTION PROCESS
PRODUCTION FLOW FOR SUB-CONTRACTOR
Contractor Project
Company
Purchase
Order

Project
Temporary
Employee
Report time
Invoicing
Advice
Invoice
Match
Supplier Project
Invoice Transactions
Payment
PROJECT CONTROL
GENERAL OVERVIEW
Inflow

•Estimated Budget
•Initiated Budget
•Running Budget

Project Cost &


Hours
Revenue Budget
Control Progress
Progress Control

Outflow

•Performed Budget
•Earned Value (Actual Cost & Hours)
•S-Curve (Plan – Actual)

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PROJECT CONTROL Hours
Revenue
Cost
PROJECT PROGRESS Progress
Progress

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PROJECT CONTROL Budget
S-Curve
BUDGET CONTROL Spread
Control
Switch

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PROJECT CONCLUSION
GENERAL OVERVIEW
Inflow

•Progress Cost and Hours


•Ship Delivery

Project Complete
Warranty Finalize
& Close
Conclusion Project
Process Contract

Outflow

•Completed Project.
•Actual Cost/Revenue (Final)
•Project Profitability (Final)

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PROJECT CONCLUSION Close
Project
EXAMPLE Project
Profitability
Activity

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SUPPORTING PROCESS
DOCUMENT MANAGEMENT

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DOCUMENT MANAGEMENT
GENERAL OVERVIEW

Project
Document
Document
Package
Structure

Connect Doc.
Document
Package to
Required
Activity

Check-in & Attach


Release Document &
Document Release Part
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COPYRIGHT © 2015 INDUSTRIAL AND FINANCIAL SYSTEMS, IFS AB (PUBL). IFS AND ALL IFS PRODUCTS AND SERVICES NAMES ARE TRADEMARKS OF IFS. ALL
RIGHTS RESERVED. THIS DOCUMENT MAY CONTAIN STATEMENTS OF POSSIBLE FUTURE FUNCTIONALITY FOR IFS’S PRODUCTS AND TECHNOLOGY. SUCH
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