Technology capability of Indonesian medium-sized shipyards for ship production using Product-oriented Work Breakdown Structure method (case study on shipbuilding of Mini LNG vessel)

Figures & data

Table 1. Market potential for new shipbuilding in Indonesia

No	Type of Vessel	Size	Total
1	Mini LNG	1324–7809 M3	30
2	General Cargo	≤10.000 DWT	618
3	Bulk Carrier	≤70.000 DWT	21
4	Container	≤1.800 TEU’S	245
5	Oil Tanker	≤30.000 DWT	215
6	Ferry Ro-Ro (Roll on-Roll off)	≤6.000 GT	218
7	Tug Boat	≤3.000 HP	336
8	Supply Vessel	≤3.000 HP	31
		Total	1714

Sources: IPERINDO (2019) & BPPT (2021).

Table 2. Summary of state of the art: comparison of previous works with the current study

Authors	Model	Methods	Case study	Research contributions area within system level
				Production system	Firm system	Business system	Industry system
Sharif (1988)	(UNESCAP (1989)	Technometric	Steel industry		√	√	√
Wiratmadja and Setiawati (2011)	(UNESCAP (1989)	SEM-PLS	Rattan industry		√
Mirzapour Al-E-Hashem et al. (2018)	(UNESCAP (1989)	Technometric	Automotive		√
Antesty et al. (2020)	(UNESCAP (1989)	Technometric	Automotive		√
Aqidawati et al. (2022)	(UNESCAP (1989)	Technical & economic assessment	Electric motorcycle battery		√
This study	(UNESCAP (1989)	Technometric	Shipbuilding	√

Figure 1. Block method.

Figure 2. Modular method.

Figure 3. Basic businessprocesses in new shipbuilding.

Figure 4. Ship productionscenario based on PWBS model.

Figure 5. Research framework.

Figure 6. Detail shipbuilding business prosses based on PWBS.

Figure 7. Block and Modul Division for production of Mini LNG ship.

Table 3. Module’s weight of Mini LNG vessel 36 TEU’s

BLOCK/MODULAR WEIGHT (W)-Mini LNG Vessel 36 TEU’s
BLOCK/MODULAR		Module (M)-1	Module (M)-2	Module (M)-3	Module (M)-4	Module (M)-5	Module (M)-6
POSITION		FR −2~FR17(+)450	FR17(+)450 ~FR37(+)150	FR FR37(+)150~FR57(+)150	FR 57(+)150~FR77(+)150	FR 77(+)150~FR87	FR −2~FR17
REF FROM AP (m)		−1,200 ~ 10650	10,650 ~ 22350	22,350 ~ 34350	34,350 ~ 46350	46,350 ~ 52200	−1,200 ~ 10350
W (TON)	HC	53.514	91.480	74.196	89.408	8.610	17.852
	MO	25.553	7.768	0.213	0.216	0.017	0.000
	HO	22.358	3.112	12.042	2.015	7.713	33.800
	EO	0.937	0.000	0.000	0.000	0.052	1.242
	TOTAL	102.363	102.360	86.451	91.638	16.393	52.895

Table 4. Summary of case analysis on technology components contribution

Technology Components		Case (Shipyard)
		Shipyard A	Shipyard B	Shipyard C	Shipyard D
Technoware	Basic aspects in shipbuilding	Availability of design software and hardware to develop production drawings based on PWBS method and production facilities to execute them properly as planned. The level of technology used in production processes and technology used in quality control and testing techniques could determine the productivity level.
	Component Contribution	Block: 0.71 Modular: 0.56	Block: 0.65 Modular: 0.60	Block: 0.62 Modular: 0.53	Block: 0.59 Modular: 0.52
Humanware	Basic aspects of shipbuilding	Skills and knowledge capability of human resources in preparing design, drawings, and production engineering documents as needed, capability and creativity of production workforce to perform all planned drawings and documents properly.
	Component Contribution	Block: 0.75 Modular: 0.73	Block: 0.75 Modular: 0.75	Block: 0.71 Modular: 0.67	Block: 0.73 Modular: 0.69
Infoware	Basic aspects of shipbuilding	Availability of design and production integration scheme, block assembly and erection sequences, quality plan and inspection and test plan (ITP), complete build strategy, procurement schedule, master and detail schedules, and operating manuals.
	Component Contribution	Block: 0.83 Modular: 0.78	Block: 0.62 Modular: 0.57	Block: 0.81 Modular: 0.69	Block: 0.73 Modular: 0.69
Orgaware	Basic aspects of shipbuilding	The role and effectiveness of the management structure of the company and project organization chart, marketing effort, system operating procedures (SOP), quality management system (ISO 9001 series), and human resource management.
	Component Contribution	Block: 0.77 Modular: 0.75	Block: 0.71 Modular: 0.63	Block: 0.79 Modular: 0.74	Block: 0.75 Modular: 0.75
Technology Coefficient Contribution (TCC)		Block: 0.76 Modular: 0.70	Block: 0.68 Modular: 0.64	Block: 0.73 Modular: 0.65	Block: 0.70 Modular: 0.66

Figure 8. Example of block and modular assembly sequences on Mini LNG vessel.

Figure 9. TCC comparison of block (a) and module (b) construction before erection.

Figure 10. Technoware contribution.

Figure 11. Humanware contribution.

Figure 12. Infoware contribution.

Figure 13. Orgaware contribution.

Appendix A. An example instrument assessment for the design stage

No.	TECHNOWARE	Score						HUMANWARE	Score						INFORWARE	Score						ORGAWARE	Score
		Block			Modular				Block			Modular				Block			Modular				Block			Modular
	Hardware & software design facility and system integration							Manager, supervision/technician/engineer							Quality Manual, Build Strategy							Organization of engineering, design
1	Manual facilities are available	1	2	3	1	2	3	Having basic engineering drawing skills	1	2	3	1	2	3	General information shipbuilding is available	1	2	3	1	2	3	There are personnel/technicians assigned for engineering design work.	1	2	3	1	2	3
2	Powered facilities and CAD software with limited specifications are available	2	3	4	2	3	4	Able to carry out standard and routine design features using computer-aided design	2	3	4	2	3	4	Basic descriptions, including equipment and process shipbuilding, are available	2	3	4	2	3	4	Engineering design works are assigned in non-permanent groups/teams with multi-tasks	2	3	4	2	3	4
3	A CAD software and hardware facilities for general purpose are available	3	4	5	3	4	5	Able to operate advanced features of computer-aided design	3	4	5	3	4	5	Standard operating procedures, equipment set-up details, and work instructions are available	3	4	5	3	4	5	Engineering design works are assigned in permanent groups/teams with the specific task	3	4	5	3	4	5
4	CAD software and hardware facilities for special purposes are available	4	5	6	4	5	6	Able to produce a standard design computer-aided design and engineering	4	5	6	4	5	6	Build strategy documents for shipbuilding are available	4	5	6	4	5	6	Engineering design works are assigned to the permanent department	4	5	6	4	5	6
5	Automatic hardware and software design and engineering facilities are available.	5	6	7	5	6	7	Able to adapt/modify existing designs	5	6	7	5	6	7	Build strategy document of shipbuilding including assembly and block erection sequence, and O/F installation are available	5	6	7	5	6	7	Engineering design works are assigned at the production system level	5	6	7	5	6	7
6	Advanced computer hardware and software design engineering facilities are available. A notable example is CAD/CAM	6	7	8	6	7	8	Able to work under non-standard and non-routine decisions with a low physical effort to obtain an improvement	6	7	8	6	7	8	Build strategy document of shipbuilding including assembly and block/module erection sequence, O/F on-unit, on-block, on-board, and on-quay, are available	6	7	8	6	7	8	Engineering design works are assigned at the manufacturing system level	6	7	8	6	7	8
7	An integrated system engineering design and facilities are available	7	8	9	7	8	9	Able to work under non-standard and non-routine decisions with a low physical effort to obtain an innovation	7	8	9	7	8	9	Build strategy document of shipbuilding including assembly and block/module erection sequence, O/F on-unit, on-block, on-board, on-quay, and inspection and testing plan (ITP) are available	6	7	8	6	7	8	Engineering design works are assigned in enterprise system/firm level	6	7	8	6	7	8

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