SOS shipbuilding on scans

Author: Thorsten Störig and Ralph Zimmermann, June 2016

想象一下，将超过3000万件的拼图拼图放在一起。这些说明说，将这些碎片分成约80个单独的块，重达800吨。这些街区必须精确地放在一起，为乘客提供巨大的巡航班轮的安全而愉快的旅程。一旦计划，您的构建不到一年，同时满足预算限制并超出了客户的质量期望。欢迎来到邮轮大楼的世界。

At MEYER WERFT, we face these challenges on a daily basis. Building ships since 1795 in Papenburg, Germany, our company has seen the evolution of watercraft transportation from wooden ships to our latest release in April 2015 of the Royal Caribbean Anthem of the Seas. Measuring 350 metres long and 168,666 tonnes, the latest in our long line of luxury cruise ships is making waves in the industry for its sleek design.

没有错误的空间

“第一次正确”是德国造船厂Meyer Werft的所有员工的目标。一项学科中的小错误可能会对员工和物质费用产生重大影响，甚至可以延迟整个建筑过程，从而导致额外的成本。特别是，在码头大厅的短暂建筑期间，其500米长的干船坞突出了每日挑战。通过使用其全容量并每年以六个月的间隔建造两艘船只，工作流程在不同阶段为两种类型的船提供服务。尽管一艘船的船体已完成最终的钢块，但随后的水下零件的机房的建筑工程已经在进行中。设计和生产中的复杂质量和高级计划程序可确保很少发生错误并迅速检测到。

The roots for such a complex and diversified process lie in a risk-based approach by which the single vessel parts and work sequences are analysed and assessed for potential errors. Actions coming from those studies, though, do not only focus on the so-called 5Rs (right piece, right time, right place, right quantity and right quality). The right information is a key factor in modern and expeditious shipbuilding. Structuring drawing details and the chapters of numerous standard documents in a way that subject areas only receive the exclusive content they need reduces the hazard of missing the forest for the trees.

为手工艺人定制的信息分发技术细节以及最佳实践程序以及如何避免昂贵的缺陷的知识。关于巨大船只内部无关的过程步骤，有关使用新工具，序列和可用的实时数据的每种改进的新闻是不可避免的。

The second pillar in effective quality management is tests and inspections in short cycles. Quality assurance is supposed to be set up at certain stages where the risk of an error is high. A fast detection avoids having to dismantle, fix and restore completed hotel areas and mechanical spaces of a cruise ship. More than 60,000 single checks within the production process, plus additional checks in the commissioning and delivery phase, ensure problems in late stages will be eliminated.

These tests are carried out by dedicated and qualified staff coming from the disciplines of steel construction, welding, material testing, pipe systems, plant engineering, commissioning, interior furnishing and, in particular, dimensional control. The need for short-cycled quality assurance by well-trained inspectors is especially depicted in the above exponential cost graph. As construction cost incurs multiples of 10 or even more during each subsequent step of the process, mistakes not caught by early detection can result in millions of over-budget costs and jeopardise production schedules.

To sum up results at dedicated process steps, quality gates are installed to review test progress and test results. Due to the fact that the owner operating the ship later on and the classification society take part in some of the inspections, the follow-up of remarks and customer satisfaction contribute to a successful ship project completion.

The Quality Management Department comprises the system approach as well as the Measurement Group, which conducts geometric surveys and positioning. Our group is made up of nine different types of engineers, five technicians, six trainees and student apprentices. We conduct all measurement works throughout the entire construction process. Alignment of the plasma torch cutting machines is just one of the first tasks, and absolute accuracy is a must when laying keels and fabricating the blocks. On top of this comes a host of other special jobs, such as determining the overall length of a ship and assisting in research projects. With more and more parts of a ship being prefabricated and attached in blocks, we need to be able to trust our measurements without doubt. Whether you’re measuring a complex sun shade composed of multiple concave shapes or a 260-metrelong waterslide with curves and loops, precise connection of the parts is critical.

If we fail to identify potential mistakes or to provide the correct measurements, the entire ship could be scrapped. It is no wonder, then, why we take our responsibilities so seriously.

Explore next chapter:多功能工具箱

Story: SOS shipbuilding on scans
Chapter 1: No rooms for errors
第2章：多功能工具箱
第3章：Advancing 3D laser scanning