1. SBRCD Project Operations Simulation

2. Simulation Description • This simulation activity requires two class periods • Students work in groups of 4 • Each session can be completed within one class period (55 min.) • Students learn about the various departments by building a paper container ship.

3. Operation Simulation Schedule Day 1: Shipyard Operations Day 2: Design Calculations

4. Day 1 Day 2

5. Material Flow Information Flow Production Layout Plasma Cutting Bending Machine Supplier Welding

6. Day 1: Activities • Instruction manual is provided to guide students in constructing the ship • Three departments are involved in this simulation (excluding the Supplier) Teacher serves as the Supplier • Plasma Cutting Shop cuts the plates • Plate Shop bends the plates to form hull modules • Welding & Final Assembly Shop assembles the ship modules

7. Starboard Stern Bow Port Bow : Front part of the ship Stern : Rear part of the ship Starboard : Right side of the ship Port : Left side of the ship Ship Terminology

8. Activity Involved in the Plasma Cutting Shop • Receives steel plates from the supplier • Cuts the plates along the solid line • Sends the parts to the Plate Shop • All the parts are numbered in the order in which they have to be sent to the next department.

9. Bow – Cut Part

10. Mid-Hull – Cut Part

11. Stern – Cut Part

12. Bulk Head – Cut Part

13. Bow Deck Plate – Cut Part Stern Deck Plate – Cut Part

14. Mid-Hull Deck Plate – Cut Part

15. Super Structure – Cut Part

16. Activity Involved in the Plate Shop • Receives steel plates from the Plasma cutting shop • Bends the parts along the dotted lines using the instructions given in the instruction sheet • Sends the parts to the welding shop

17. Bow – Bent Part Bow Deck Plate – Bent Part

18. Mid – Hull Deck Plate – Bent Part Mid – Hull – Bent Part

19. Bulk Head – Bent Part Stern – Bent Part

20. Super Structure – Bent Part Stern Deck Plate – Bent Part

21. Activity Involved in the Welding Shop • Receives steel plates from the Plate shop • Welds the plates along the length of the joints and then assembles the parts • All the parts are joined to build the final assembly

22. Welding and Final Assembly of Bow

23. Welding and Final Assembly of Mid-Hull

24. Welding and Final Assembly of Stern

25. Welding of Super Structure

26. Final Assembly of the Ship

27. Day – 2: Design Calculations In the first set of calculations the students are required: • To calculate the weight of the ship • To calculate the draft of the ship • To calculate the kinetic energy of the ship *The formulae and instructions for calculations are given to the students*

28. A t Q 1. Calculation of Weight of the Water Displaced by the ship Step 1: Area of the Plates Step 2: Volume = Area*thickness where A = Area and t = thickness Step 3: Total Weight = Weight of the ship + Weight of the containers • Weight of the ship = Sum of weight of each steel part • Weight of the containers(1500 TEU containers)(Weight of 1 TEU container=24 tons)

29. Q 2. Calculation of Draft of the Ship

30. Q 3. Calculation of Kinetic Energy of Ship KE = ½ * m * v2 We know, 1kg = 9.8 N 1 Ton = 9800 N Weight = m * g Therefore, m = weight/g where g = 9.8m/s2

31. Sample Student Worksheets

32. A1 A1=A3 A4 A4=A6 A2 A2 A5 A5 Area Calculations - Bow Area of Bow= A1+ A2+ A3+ A4+ A5+ A6 = __________sq. mm = ___________sq. m

33. Calculation of Weight of the Ship Hull Plate thickness: 5cm and Deck Plate thickness: 2.5cm

34. Calculation of Weight of Water Displaced by the Ship Sum of weight of each part = _____________ kg = __________ tons Weight of steel used is approximately 50% of the weight of ship Therefore, the weight of the Ship = ___________ tons Weight of 1 TEU container = 24 tons Weight of 1500 TEU containers = ________________ tons Therefore, weight of water displaced by the ship = Weight of the Ship + Weight of the Containers = ___________________ tons

35. Q 2. Calculation of Draft of the Ship - Sample For example: The draft for the corresponding weight of water displaced (shown by the arrow) is 17.5 m

36. Calculation of K.E of the Ship KE = ½ * m * v2 Cruising speed = 26 knots (1 knot = .514 m/s) V = ___________ m/s We know, 1kg = 9.8 N, 1 Ton = 9,800 N So, 48,684 tons = _____________ N Weight = m * g (g= 9.8 m/s) m = _______________ kg KE = _________________ J

37. Assessment Shipyard Operations Simulation will be assessed based on the following quality characteristics • Cutting on the solid lines • Cutting the corners and intersections properly • Gluing the joints properly • Hull alignment • Bends are straight and creased

38. Wrap-up • Make sure all the items are put back in the kit box while returning it to the teacher. • Please clean the working area.