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Extended Modularization ofExtended Modularization ofExtended Modularization ofExtended Modularization ofExtended Modularization ofExtended Modularization ofExtended Modularization ofExtended Modularization of
Ship Design & Build StrategyShip Design & Build StrategyShip Design & Build StrategyShip Design & Build StrategyShip Design & Build StrategyShip Design & Build StrategyShip Design & Build StrategyShip Design & Build Strategy
The National Shipbuilding Research Program
Shipbuilding Opportunities in Short Sea Shipping WorkshopOctober 21-23, 2008
Charleston, SC
Laurent DeschampsLaurent DeschampsLaurent DeschampsLaurent DeschampsLaurent DeschampsLaurent DeschampsLaurent DeschampsLaurent Deschamps
President, SPAR Associates, Inc.President, SPAR Associates, Inc.President, SPAR Associates, Inc.President, SPAR Associates, Inc.President, SPAR Associates, Inc.President, SPAR Associates, Inc.President, SPAR Associates, Inc.President, SPAR Associates, Inc.
Annapolis, MarylandAnnapolis, MarylandAnnapolis, MarylandAnnapolis, MarylandAnnapolis, MarylandAnnapolis, MarylandAnnapolis, MarylandAnnapolis, Maryland
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NearNearNearNearNearNearNearNear--------inininininininin--------time procurement schedulingtime procurement schedulingtime procurement schedulingtime procurement schedulingtime procurement schedulingtime procurement schedulingtime procurement schedulingtime procurement scheduling
Improved vendor relations & pricing agreementsImproved vendor relations & pricing agreementsImproved vendor relations & pricing agreementsImproved vendor relations & pricing agreementsImproved vendor relations & pricing agreementsImproved vendor relations & pricing agreementsImproved vendor relations & pricing agreementsImproved vendor relations & pricing agreements
Material work order kittingMaterial work order kittingMaterial work order kittingMaterial work order kittingMaterial work order kittingMaterial work order kittingMaterial work order kittingMaterial work order kitting Standardized material parts & componentsStandardized material parts & componentsStandardized material parts & componentsStandardized material parts & componentsStandardized material parts & componentsStandardized material parts & componentsStandardized material parts & componentsStandardized material parts & components
Material buffer storage nearer to worksitesMaterial buffer storage nearer to worksitesMaterial buffer storage nearer to worksitesMaterial buffer storage nearer to worksitesMaterial buffer storage nearer to worksitesMaterial buffer storage nearer to worksitesMaterial buffer storage nearer to worksitesMaterial buffer storage nearer to worksites
Improved Procurement &Improved Procurement &Improved Procurement &Improved Procurement &Improved Procurement &Improved Procurement &Improved Procurement &Improved Procurement &Material ControlMaterial ControlMaterial ControlMaterial ControlMaterial ControlMaterial ControlMaterial ControlMaterial Control
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Integrated design & engineering systemsIntegrated design & engineering systemsIntegrated design & engineering systemsIntegrated design & engineering systemsIntegrated design & engineering systemsIntegrated design & engineering systemsIntegrated design & engineering systemsIntegrated design & engineering systems Standardized (repeatable) components &Standardized (repeatable) components &Standardized (repeatable) components &Standardized (repeatable) components &Standardized (repeatable) components &Standardized (repeatable) components &Standardized (repeatable) components &Standardized (repeatable) components &
interim productsinterim productsinterim productsinterim productsinterim productsinterim productsinterim productsinterim products
Simplified ship & ship systems designsSimplified ship & ship systems designsSimplified ship & ship systems designsSimplified ship & ship systems designsSimplified ship & ship systems designsSimplified ship & ship systems designsSimplified ship & ship systems designsSimplified ship & ship systems designs
Improved Ship Designs &Improved Ship Designs &Improved Ship Designs &Improved Ship Designs &Improved Ship Designs &Improved Ship Designs &Improved Ship Designs &Improved Ship Designs &EngineeringEngineeringEngineeringEngineeringEngineeringEngineeringEngineeringEngineering
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Modules can be developed in aModules can be developed in aModules can be developed in aModules can be developed in aModules can be developed in aModules can be developed in aModules can be developed in aModules can be developed in awide variety of ways:wide variety of ways:wide variety of ways:wide variety of ways:wide variety of ways:wide variety of ways:wide variety of ways:wide variety of ways:
Outfit and equipment modules,Outfit and equipment modules,Outfit and equipment modules,Outfit and equipment modules,Outfit and equipment modules,Outfit and equipment modules,Outfit and equipment modules,Outfit and equipment modules,
Hull assembly blocks,Hull assembly blocks,Hull assembly blocks,Hull assembly blocks,Hull assembly blocks,Hull assembly blocks,Hull assembly blocks,Hull assembly blocks,
Outfitted hull blocks, andOutfitted hull blocks, andOutfitted hull blocks, andOutfitted hull blocks, andOutfitted hull blocks, andOutfitted hull blocks, andOutfitted hull blocks, andOutfitted hull blocks, and Outfitted panel assembliesOutfitted panel assembliesOutfitted panel assembliesOutfitted panel assembliesOutfitted panel assembliesOutfitted panel assembliesOutfitted panel assembliesOutfitted panel assemblies
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Typical Hull Modular BlocksTypical Hull Modular Blocks
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Accommodation ModuleAccommodation Module
Turbocharger Lube Oil ModuleTurbocharger Lube Oil Module
Alfa Laval ModuleAlfa Laval Module Lube Oil w/Pumps ModuleLube Oil w/Pumps Module Westfalia Separator ModuleWestfalia Separator Module
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Hydrophore ModuleHydrophore ModuleSewage Treatment ModuleSewage Treatment Module
Refrigeration Compressor ModuleRefrigeration Compressor Module
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Expanded application of ship modulesExpanded application of ship modules
have been successfully developed byhave been successfully developed by
various European shipbuilders (forvarious European shipbuilders (for
example, Thyssen Nordseewerke, Scheldeexample, Thyssen Nordseewerke, Schelde
Naval Shipbuilding, Blohm & VossNaval Shipbuilding, Blohm & VossGmbh, Abeking & Rasmussen).Gmbh, Abeking & Rasmussen).
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Modules provide more flexibility for a standardModules provide more flexibility for a standardModules provide more flexibility for a standardModules provide more flexibility for a standardModules provide more flexibility for a standardModules provide more flexibility for a standardModules provide more flexibility for a standardModules provide more flexibility for a standard
ship platformship platformship platformship platformship platformship platformship platformship platform
Modules allow more focus of purpose forModules allow more focus of purpose forModules allow more focus of purpose forModules allow more focus of purpose forModules allow more focus of purpose forModules allow more focus of purpose forModules allow more focus of purpose forModules allow more focus of purpose forspecific operating requirementsspecific operating requirementsspecific operating requirementsspecific operating requirementsspecific operating requirementsspecific operating requirementsspecific operating requirementsspecific operating requirements
Modules may minimize need for incorporatingModules may minimize need for incorporatingModules may minimize need for incorporatingModules may minimize need for incorporatingModules may minimize need for incorporatingModules may minimize need for incorporatingModules may minimize need for incorporatingModules may minimize need for incorporating
unnecessary systems.unnecessary systems.unnecessary systems.unnecessary systems.unnecessary systems.unnecessary systems.unnecessary systems.unnecessary systems.
Ship Operations BenefitsShip Operations BenefitsShip Operations BenefitsShip Operations BenefitsShip Operations BenefitsShip Operations BenefitsShip Operations BenefitsShip Operations Benefits
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AircraftAircraftAircraftAircraftAircraftAircraftAircraftAircraftF4 began modularization; F35 extensive useF4 began modularization; F35 extensive useF4 began modularization; F35 extensive useF4 began modularization; F35 extensive useF4 began modularization; F35 extensive useF4 began modularization; F35 extensive useF4 began modularization; F35 extensive useF4 began modularization; F35 extensive use
of modulesof modulesof modulesof modulesof modulesof modulesof modulesof modules
CarsCarsCarsCarsCarsCarsCarsCarsparts and components, often interchangeableparts and components, often interchangeableparts and components, often interchangeableparts and components, often interchangeableparts and components, often interchangeableparts and components, often interchangeableparts and components, often interchangeableparts and components, often interchangeablebetween different modelsbetween different modelsbetween different modelsbetween different modelsbetween different modelsbetween different modelsbetween different modelsbetween different models
Home appliancesHome appliancesHome appliancesHome appliancesHome appliancesHome appliancesHome appliancesHome appliancesparts and componentsparts and componentsparts and componentsparts and componentsparts and componentsparts and componentsparts and componentsparts and components
Other industries have long exploitedOther industries have long exploitedOther industries have long exploitedOther industries have long exploitedOther industries have long exploitedOther industries have long exploitedOther industries have long exploitedOther industries have long exploitedthe benefits of modularthe benefits of modularthe benefits of modularthe benefits of modularthe benefits of modularthe benefits of modularthe benefits of modularthe benefits of modular
construction:construction:construction:construction:construction:construction:construction:construction:
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Requires better than normal engineeringRequires better than normal engineeringRequires better than normal engineeringRequires better than normal engineeringRequires better than normal engineeringRequires better than normal engineeringRequires better than normal engineeringRequires better than normal engineering
Requires better than normal quality assuranceRequires better than normal quality assuranceRequires better than normal quality assuranceRequires better than normal quality assuranceRequires better than normal quality assuranceRequires better than normal quality assuranceRequires better than normal quality assuranceRequires better than normal quality assurance
Requires higher level of design standards to minimizeRequires higher level of design standards to minimizeRequires higher level of design standards to minimizeRequires higher level of design standards to minimizeRequires higher level of design standards to minimizeRequires higher level of design standards to minimizeRequires higher level of design standards to minimizeRequires higher level of design standards to minimize
interferences and disconnects.interferences and disconnects.interferences and disconnects.interferences and disconnects.interferences and disconnects.interferences and disconnects.interferences and disconnects.interferences and disconnects.
There are precautions that mustThere are precautions that mustThere are precautions that mustThere are precautions that mustThere are precautions that mustThere are precautions that mustThere are precautions that mustThere are precautions that mustbe taken in order to minimizebe taken in order to minimizebe taken in order to minimizebe taken in order to minimizebe taken in order to minimizebe taken in order to minimizebe taken in order to minimizebe taken in order to minimize
failures in applying modularfailures in applying modularfailures in applying modularfailures in applying modularfailures in applying modularfailures in applying modularfailures in applying modularfailures in applying modular
construction techniques:construction techniques:construction techniques:construction techniques:construction techniques:construction techniques:construction techniques:construction techniques:
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The cost estimates were producedThe cost estimates were producedThe cost estimates were producedThe cost estimates were producedThe cost estimates were producedThe cost estimates were producedThe cost estimates were producedThe cost estimates were produced
for a notionalfor a notionalfor a notionalfor a notionalfor a notionalfor a notionalfor a notionalfor a notional
HST140HST140HST140HST140HST140HST140HST140HST140--------5353535353535353 TrailershipTrailershipTrailershipTrailershipTrailershipTrailershipTrailershipTrailership
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The CCDoTT HST140The CCDoTT HST140--5353 TrailershipTrailership
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Material & equipment prices are escalated/deMaterial & equipment prices are escalated/deMaterial & equipment prices are escalated/deMaterial & equipment prices are escalated/deMaterial & equipment prices are escalated/deMaterial & equipment prices are escalated/deMaterial & equipment prices are escalated/deMaterial & equipment prices are escalated/de--------escalatedescalatedescalatedescalatedescalatedescalatedescalatedescalated
by type commodity. Escalation factors (graphic below),by type commodity. Escalation factors (graphic below),by type commodity. Escalation factors (graphic below),by type commodity. Escalation factors (graphic below),by type commodity. Escalation factors (graphic below),by type commodity. Escalation factors (graphic below),by type commodity. Escalation factors (graphic below),by type commodity. Escalation factors (graphic below),both historical and predicted, are obtained from U.S.both historical and predicted, are obtained from U.S.both historical and predicted, are obtained from U.S.both historical and predicted, are obtained from U.S.both historical and predicted, are obtained from U.S.both historical and predicted, are obtained from U.S.both historical and predicted, are obtained from U.S.both historical and predicted, are obtained from U.S.
Government and industryGovernment and industryGovernment and industryGovernment and industryGovernment and industryGovernment and industryGovernment and industryGovernment and industry--------recognized commercial andrecognized commercial andrecognized commercial andrecognized commercial andrecognized commercial andrecognized commercial andrecognized commercial andrecognized commercial and
foreign sources.foreign sources.foreign sources.foreign sources.foreign sources.foreign sources.foreign sources.foreign sources.
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Margin, Bonds & Insurance1000
Shipyard Services900
Technical Support800
Armament700
Outfit & Furnishings600
Auxiliary Systems500
Electronics & Navigation400
Electrical300
Propulsion200
Structures100
SWBS
Jigs, Cradles, & Templates, Tools & Instruments
Miscellaneous Material & Support
Contract Detail Design Package (Optional)Contingency Labor:
Contract Engineering Management
ILS, Spares & Load Items
Purchase Specs & Support
Production Planning & Scheduling
Production Engineering & Construction Drawings
Functional Design
Preliminary Design
Basic Research - Concept Design
NonNonNonNonNonNonNonNon--------Recurring CostsRecurring CostsRecurring CostsRecurring CostsRecurring CostsRecurring CostsRecurring CostsRecurring Costs Recurring CostsRecurring CostsRecurring CostsRecurring CostsRecurring CostsRecurring CostsRecurring CostsRecurring Costs
The cost model generates costThe cost model generates costThe cost model generates costThe cost model generates costThe cost model generates costThe cost model generates costThe cost model generates costThe cost model generates cost
estimates at approximately SWBSestimates at approximately SWBSestimates at approximately SWBSestimates at approximately SWBSestimates at approximately SWBSestimates at approximately SWBSestimates at approximately SWBSestimates at approximately SWBSlevel 3 detail and summarizes them aslevel 3 detail and summarizes them aslevel 3 detail and summarizes them aslevel 3 detail and summarizes them aslevel 3 detail and summarizes them aslevel 3 detail and summarizes them aslevel 3 detail and summarizes them aslevel 3 detail and summarizes them as
follows:follows:follows:follows:follows:follows:follows:follows:
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The cost model also producesThe cost model also producesThe cost model also producesThe cost model also producesThe cost model also producesThe cost model also producesThe cost model also producesThe cost model also produces
estimated average costs forestimated average costs forestimated average costs forestimated average costs forestimated average costs forestimated average costs forestimated average costs forestimated average costs formultiple ship constructionmultiple ship constructionmultiple ship constructionmultiple ship constructionmultiple ship constructionmultiple ship constructionmultiple ship constructionmultiple ship construction
programs developed withprograms developed withprograms developed withprograms developed withprograms developed withprograms developed withprograms developed withprograms developed with
expected learning factors.expected learning factors.expected learning factors.expected learning factors.expected learning factors.expected learning factors.expected learning factors.expected learning factors.
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Cost risk of applied CERsCost risk of applied CERsCost risk of applied CERsCost risk of applied CERsCost risk of applied CERsCost risk of applied CERsCost risk of applied CERsCost risk of applied CERs
ShipbuilderShipbuilderShipbuilderShipbuilderShipbuilderShipbuilderShipbuilderShipbuilders experience risks experience risks experience risks experience risks experience risks experience risks experience risks experience risk
Engineering performance riskEngineering performance riskEngineering performance riskEngineering performance riskEngineering performance riskEngineering performance riskEngineering performance riskEngineering performance risk Cost risk due to compressed productionCost risk due to compressed productionCost risk due to compressed productionCost risk due to compressed productionCost risk due to compressed productionCost risk due to compressed productionCost risk due to compressed productionCost risk due to compressed production
scheduleschedulescheduleschedulescheduleschedulescheduleschedule
Cost risk of rework due to immature detailCost risk of rework due to immature detailCost risk of rework due to immature detailCost risk of rework due to immature detailCost risk of rework due to immature detailCost risk of rework due to immature detailCost risk of rework due to immature detailCost risk of rework due to immature detail
engineering when overlapping with productionengineering when overlapping with productionengineering when overlapping with productionengineering when overlapping with productionengineering when overlapping with productionengineering when overlapping with productionengineering when overlapping with productionengineering when overlapping with production
Cost RiskCost RiskCost RiskCost RiskCost RiskCost RiskCost RiskCost Risk::::::::The models develop cost risk withinThe models develop cost risk withinThe models develop cost risk withinThe models develop cost risk withinThe models develop cost risk withinThe models develop cost risk withinThe models develop cost risk withinThe models develop cost risk within
several focus areasseveral focus areasseveral focus areasseveral focus areasseveral focus areasseveral focus areasseveral focus areasseveral focus areas
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Modular construction promotes costModular construction promotes costand schedule benefits from early stageand schedule benefits from early stage
construction.construction.
There are a number of rules of thumbThere are a number of rules of thumb
that have been applied to estimate thethat have been applied to estimate the
savings. Labor costs on board can besavings. Labor costs on board can be
33--5 times and higher than equivalent5 times and higher than equivalentwork done in the shop or on the platen.work done in the shop or on the platen.
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As modules become more and more standardized,As modules become more and more standardized,As modules become more and more standardized,As modules become more and more standardized,As modules become more and more standardized,As modules become more and more standardized,As modules become more and more standardized,As modules become more and more standardized,
still more cost and schedule benefits can bestill more cost and schedule benefits can bestill more cost and schedule benefits can bestill more cost and schedule benefits can bestill more cost and schedule benefits can bestill more cost and schedule benefits can bestill more cost and schedule benefits can bestill more cost and schedule benefits can begarnered as efficiency increases from repetitivegarnered as efficiency increases from repetitivegarnered as efficiency increases from repetitivegarnered as efficiency increases from repetitivegarnered as efficiency increases from repetitivegarnered as efficiency increases from repetitivegarnered as efficiency increases from repetitivegarnered as efficiency increases from repetitive
manufacturing.manufacturing.manufacturing.manufacturing.manufacturing.manufacturing.manufacturing.manufacturing.
Use of standard modules also can reduce the costUse of standard modules also can reduce the costUse of standard modules also can reduce the costUse of standard modules also can reduce the costUse of standard modules also can reduce the costUse of standard modules also can reduce the costUse of standard modules also can reduce the costUse of standard modules also can reduce the cost
and schedule of nonand schedule of nonand schedule of nonand schedule of nonand schedule of nonand schedule of nonand schedule of nonand schedule of non--------recurring ship design andrecurring ship design andrecurring ship design andrecurring ship design andrecurring ship design andrecurring ship design andrecurring ship design andrecurring ship design and
engineering.engineering.engineering.engineering.engineering.engineering.engineering.engineering.
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% Total Onboard On Block On Unit
Work Type Modularized Factor Factor Factor
Piping - OMS 85.00% 1.000 0.530 0.280
HVAC - Rectangual Duct 85.00% 1.000 0.800 0.400
HVAC - Spiral Duct 85.00% 1.000 0.650 0.325HVAC - Fans 85.00% 1.000 0.650 0.325
HVAC - Air Handlers 85.00% 1.000 0.800 0.400
HVAC - Spools 85.00% 1.000 0.650 0.325
HVAC - Fire Dampers 85.00% 1.000 0.750 0.375
Electric Cable (Local) 85.00% 1.000 0.500 0.200
Auxiliaries - IMS 85.00% 1.000 0.650 0.325
Piping - IMS 85.00% 1.000 0.800 0.400
Cable Trays - IMS 85.00% 1.000 0.800 0.400
Staging - IMS 85.00% 1.000 0.800 0.400
Exhaust Casing - IMS 95.00% 1.000 0.500 0.500Casing Vent Trunk 95.00% 1.000 0.500 0.500
Foundations 100.00% 1.000 0.830 0.390
Seats - IMS 100.00% 1.000 0.750 0.375
Paint - Excluding Block Paint 85.00% 1.000 0.690 0.170
Paint - Block Paint 40.00% 1.000 0.800
Paint - Unit Paint 20.00% 1.000 0.500
Propulsion Machinery 90.0% 1.000 0.700
Outfit Machinery 90.0% 1.000 0.500 0.250
Electronics 85.00% 1.000 0.300
Outfit Equipment 85.00% 0.300
Armament 85.00% 0.300
Structures 85.00% variable variable
Cable, Machinery Spaces 80.00% 0.50
Cable, Accommodations Spaces 80.00% 0.50
Cable, Superstructure 80.00% 0.50
Cable, Exterior Decks 50.00% 0.85
% Total Modularization =% Total Modularization =% Total Modularization =% Total Modularization = Estimated Maximum Percentage of Work that can be Modularizedbeyond conventional methods.
Onboard Factor =Onboard Factor =Onboard Factor =Onboard Factor = Maximum Labor Cost at Onboard Stage of Construction
On Block Factor =On Block Factor =On Block Factor =On Block Factor = Percentage Labor Cost for On-Block Work Relative to Onboard Cost
On Unit Factor =On Unit Factor =On Unit Factor =On Unit Factor = Percentage Labor Cost for On-Unit Work Relative to Onboard Cost
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Estimated Reduced Labor Hours from Extended Modularization
98.0%
73.0%
47.7%
40.5%44.6%
56.9%
0.0%
71.4%
66.9%
77.2%
0%
20%
40%
60%
80%
100%
120%
100 200 300 400 500 600 700 800 900 1000 TOTAL
SWBS Group
PercentageofCo
nventionalLaborH
ours
(IncludesMo
duleManufacture)
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Estimated Reduced Labor Hours from Extended Modularization
2.0%
27.0%
52.3%
59.5%
55.4%
43.1%
0.0%
28.6%
33.1%
22.8%
0%
10%
20%
30%
40%
50%
60%
70%
100 200 300 400 500 600 700 800 900 1000 TOTAL
SWBS Group
P
ercentSavingsofC
onventionalLaborHours
(IncludesMo
duleManufacture)
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Breakdown of Modular Labor versus Remaining Production Work(Conventional Hull Block Construction Labor Included as "Other")
1.3%
63.0
%
33.1
%
25.5
%
29.6
%
20.5
%
0.0%
0.0% 10
.0%
96.7
%
10.0
%
14.6
%
15.0
%15.0
%
36.4
%
71.4
%
66.9
%67.2
%
0%
20%
40%
60%
80%
100%
120%
100 200 300 400 500 600 700 800 900 1000 TOTAL
Labor
Cost
SWBS Group
PercentageofConventionalLabo
rCost
Other Production
Modular Production
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Reduced Labor Cost Risk
33.1% 34.2%
58.7%
41.1%
74.0%
45.6%
0%
10%
20%
30%
40%
50%
60%
70%
80%
Co
nstru
ctio
nCo
stEstim
ateRi
sk:
Prod
uctio
n/Eng
inee
ringOv
erla
pRew
orkRi
sk:
Ship
yard
Exp
erienc
eRisk:
E
ngin
eerin
gPe
rform
ance
Risk:
P
rodu
ctio
nSche
dule
CostR
isk:
TotalE
stim
ated
CostR
isk:
Type Labor Cost Risk
P
ercentSavingsove
rLaborCostRisk
ofConventionalBuild
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Extending ship design and buildExtending ship design and buildExtending ship design and buildExtending ship design and buildExtending ship design and buildExtending ship design and buildExtending ship design and buildExtending ship design and build
strategies that advance the use ofstrategies that advance the use ofstrategies that advance the use ofstrategies that advance the use ofstrategies that advance the use ofstrategies that advance the use ofstrategies that advance the use ofstrategies that advance the use of
standard modules can reducestandard modules can reducestandard modules can reducestandard modules can reducestandard modules can reducestandard modules can reducestandard modules can reducestandard modules can reducedesign and construction costs,design and construction costs,design and construction costs,design and construction costs,design and construction costs,design and construction costs,design and construction costs,design and construction costs,
shorten delivery times, and benefitshorten delivery times, and benefitshorten delivery times, and benefitshorten delivery times, and benefitshorten delivery times, and benefitshorten delivery times, and benefitshorten delivery times, and benefitshorten delivery times, and benefitship operators with lowership operators with lowership operators with lowership operators with lowership operators with lowership operators with lowership operators with lowership operators with lower
maintenance and overhaul costs.maintenance and overhaul costs.maintenance and overhaul costs.maintenance and overhaul costs.maintenance and overhaul costs.maintenance and overhaul costs.maintenance and overhaul costs.maintenance and overhaul costs.
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35 Years Serving the Shipbuilding &35 Years Serving the Shipbuilding &Repair IndustryRepair Industry
PH 410.263.8593 FX 410.267.0503PH 410.263.8593 FX 410.267.0503
URL:URL: www.sparusa.comwww.sparusa.com Email:Email: INFO@sparusa.comINFO@sparusa.com